Service Manual

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Excavator
S/N B48411001 & Above

7320318enUS (06-18) (B) Printed in U.S.A. ©2018 Bobcat Company. All rights reserved.
T4-B
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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

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

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

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

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

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

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

HEATING, VENTILATION AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

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

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

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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.
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location.

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

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

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

the work lights. battery and cables.

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

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

function correctly and be in system.
good condition.

FW EXC-0617SM

1-7 E85 Service Manual

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

18. Inspect for loose or broken 22. Inspect the 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 E85 Service Manual

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

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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 E85 Service Manual

SAFETY INSTRUCTIONS (CONT’D)

The dealer and owner / operator review the

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

Cutting or drilling concrete containing sand or rock

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

Call Before You Dig

Dial 811 (USA Only)
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.).

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SI EXC1016 SM

1-10 E85 Service Manual

FIRE PREVENTION Hydraulic System

Check hydraulic tubes, hoses and fittings for damage

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

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

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

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

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.
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 E85 Service Manual

FIRE PREVENTION (CONT’D)

Welding And Grinding

Always clean the machine and attachment, disconnect

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

Have good ventilation when grinding or welding painted

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

Dust generated from repairing nonmetallic parts such as

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

Fire Extinguishers

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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 E85 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
operation.

Excavator Serial Number

Figure 1
1

1 P132001

The engine serial number (Item 1) [Figure 3] is located

on the side of the engine, below the alternator and next to
the oil fill cap.

NOTE: The rear counterweight may need to be

removed to see the serial number.
P132000

The excavator serial number plate (Item 1) is located on

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the frame of the machine in the location shown [Figure

1].

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 E85 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 of operator by
the dealer when the Bobcat excavator is delivered.

The delivery report must be reviewed and signed by the

owner or operator and the dealer.

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1-14 E85 Service Manual

EXCAVATOR IDENTIFICATION

2
26 24
4 16
3 26
1
15
17 23
5
14
6 18
10
12
13
7
22
8 20
11 21
9
25 19 20 25 NA13733
11 NA13734

ITEM DESCRIPTION ITEM DESCRIPTION

1 Operation & Maintenance Manual and Operator’s 16 CAB (ROPS / TOPS AND FOPS) [2]
Handbook
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2 Arm Cylinder 17 Rear Cover

3 Auxiliary Quick Couplers 18 Counterweight
4 Boom 19 Tracks
5 Arm 20 Tie Downs / Lift Points (Both Sides)
6 Bucket Cylinder 21 Track Frame
7 Bucket Link 22 Blade
8 Attachment Quick Coupler System (If Equipped) 23 Right Side Cover
9 Bucket [1] 24 Center Cover
10 Boom Cylinder 25 Step
11 Tie Downs 26 Mirrors
12 Blade Cylinders
13 Upperstructure
14 Control Levers (Joysticks)
15 Operator’s Seat with Seat Belt

[1] BUCKET - Several different buckets and other attachments are available from the Bobcat Excavator.
[2] ROPS, TOPS - (Roll-Over Protective Structure / Tip-Over Protective Structure) per ISO 12117-2 and ISO 12117. 
FOPS (Fall Object Protective Structure) per ISO 10262 - level 1

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SAFETY AND 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 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-5

OPERATOR CAB (ROPS / TOPS / FOPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
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Adjusting The Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Opening And Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

CENTER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing The Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

CAB FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Cleaning And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3

10-01 E85 Service Manual

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-4
Replacing The Fuel Tank Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-4
Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-5

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Checking And Adding Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing And Replacing The Hydraulic Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-2
Removing And Replacing The Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-3
Checking Swing Motor Gear Box Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-4
Removing And Replacing Swing Motor Gear Box Fluid . . . . . . . . . . . . . . . . . . . . . 10-130-4

LUBRICATING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

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PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Right Side Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Front Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

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

CONTROL CONSOLE LOCKOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

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

TOWING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

REMOTE START TOOL KIT - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-3

10-02 E85 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - 7217666 . . . . . . . . . . . . . . . . . . . . . 10-211-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211-1
Remote Start Tool (Service Tool) - 7022042 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211-2
Excavator Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211-3
Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-211-4
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10-03 E85 Service Manual

10-04
E85 Service Manual
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LIFTING AND BLOCKING THE EXCAVATOR Figure 10-10-1

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
P131422
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
correct function after adjustments, repairs or Figure 10-10-2
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807

WARNING
Put jackstands under the front axles and rear corners
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of the frame before running the engine for service. 1

Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
P131423

Raise one side of the machine (approximately 101,6 mm

[4 in]) using the boom and arm [Figure 10-10-1] and
[Figure 10-10-2].

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
weight is on the jackstands.

Repeat the procedure for the other side.

Stop the engine.

10-10-1 E85 Service Manual

10-10-2
E85 Service Manual
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LIFTING THE EXCAVATOR Figure 10-20-2

Procedure

Figure 10-20-1

1
1

P132088

Fasten four chains to the outer lift eyes on the track frame
(Item 1) [Figure 10-20-1] and [Figure 10-20-2] and to
2 the lifting fixture (Item 2) [Figure 10-20-1]. The lifting
fixture must extend over the sides of the cab to prevent
the chains from hitting the tracks.

NOTE: The lifting fixture must be at least 3658 mm (12

ft) wide so that the chains to not contact the
tracks when lifting.
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1 NA13729

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
AVOID INJURY OR DEATH
• Use chains and lifting equipment with sufficient
capacity for the weight of the excavator plus any
added attachments.
• Maintain center of gravity and balance when
lifting.
• Do not swing boom or upperstructure. Engage
the upperstructure slew lock.
• Never lift with operator on machine.
• Never lift with the blade angled (if equipped).
W-2580-0607

10-20-1 E85 Service Manual

10-20-2
E85 Service Manual
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OPERATOR CAB (ROPS / TOPS)

Description

The Bobcat excavator has an 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.

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 E85 Service Manual

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

Cab Door

Figure 10-30-1

P132006
1
When the door is in the open position, push down on the
P132004 latch (Item 1) [Figure 10-30-3] and close the door.

Figure 10-30-4
The cab door can be locked (Item 1) [Figure 10-30-1]
with the same key as the starter switch.

Figure 10-30-2
1

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P132007

1 2
From inside the cab, open the door using handle (Item 1)
P132005 [Figure 10-30-4].

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.

10-30-2 E85 Service Manual

OPERATOR CAB (ROPS / TOPS) (CONT’D) Figure 10-30-7

Front Window

Opening The Front Window

Figure 10-30-5

1 2

P128560

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

[Figure 10-30-7] (both sides) will close on the bracket in
the latched position.
P128559A
Pull down slightly on the window to make sure it is fully
latched.
Press the window latch button (Item 1) [Figure 10-30-5]
(both sides). Closing The Front Window

Figure 10-30-6 Use both window grab handles to support the window
while pressing the window latch button (Item 2) [Figure
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10-30-7] (both sides).

Use both window grab handles (Item 1) [Figure 10-30-6]

to pull the window down fully.

Press the top of the window in until the latch locks into
the latched position (both sides) [Figure 10-30-5].

Pull inward and upward slightly on the window to make

sure it is fully latched in the closed position.

P128563

Use both window grab handles (Item 1) [Figure 10-30-6]

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 E85 Service Manual

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

Front Wiper Figure 10-30-9

Figure 10-30-8

P132008

P128559A
The window washer reservoir (Item 1) [Figure 10-30-9] is
located under the right side cover.
The front window is equipped with a wiper (Item 1)
[Figure 10-30-8] and washer.

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10-30-4 E85 Service Manual

OPERATOR CAB (ROPS / TOPS) (CONT’D) Opening The Right Front Window

Right Side Windows Figure 10-30-12

Opening The Right Rear Window

Figure 10-30-10

P132090

Squeeze the latch (Item 1) [Figure 10-30-12].

P132089 Figure 10-30-13

Squeeze the latch (Item 1) [Figure 10-30-10].

Figure 10-30-11

1
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P132092

Pull the latch (Item 1) [Figure 10-30-13] back to open the

window to the desired position. Release the bottom latch
and snap the lock back in place.
P132091
Closing The Right Front Window

Pull the latch (Item 1) [Figure 10-30-11] forward to open Squeeze the latch (Item 1) [Figure 10-30-13] and push
the window to the desired position. Release the bottom the latch forward to close the window.
latch and snap the lock back in place.

Closing The Right Rear Window

Squeeze the latch (Item 1) [Figure 10-30-10] and push

the latch back to close the window.

10-30-5 E85 Service Manual

10-30-6
E85 Service Manual
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OPERATOR CAB (ROPS / TOPS / FOPS)

Description

The Bobcat excavator has an operator cab (ROPS /

TOPS and FOPS) as standard equipment to protect the
operator from rollover and falling objects if the excavator
is tipped over. The seat belt must be worn for rollover
protection.

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 E85 Service Manual

10-31-2
E85 Service Manual
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TRANSPORTING THE EXCAVATOR ON A TRAILER Fastening
Loading And Unloading
NOTE: There are multiple tie down locations on this
When transporting the machine, observe the rules, motor excavator. The locations are at the blade, at
vehicle laws, and vehicle limit ordinances. Use a the front track frame, and at the rear track
transport and towing vehicle of adequate length and frame (inside of track frame and outside of
capacity. track frame). Any combination of these tie
down locations is acceptable as long as the
Secure the parking brakes and block the wheels of the machine is tied down at a front location and at
transport vehicle. the rear location on both sides.
Align the ramps with the center of the transport vehicle.
Front Tie Down Locations
Secure the ramps to the truck bed and be sure ramp
angle does not exceed 15 degrees.
Figure 10-40-2
Use metal loading ramps with a slip resistant surface.

Use ramps that are the correct length and width and can
support the weight of the machine. 1

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.

Figure 10-40-1 P132063

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Figure 10-40-3

P132062A

P132064
Move the machine forward onto the transport vehicle
[Figure 10-40-1].

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

ramps.

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

vehicle.

Stop the engine and remove the key (if equipped).

Put blocks at the front and rear of the tracks.

10-40-1 E85 Service Manual

TRANSPORTING THE EXCAVATOR ON A TRAILER
(CONT’D)

Fastening (Cont’d) WARNING

Rear Tie Down Locations
AVOID SERIOUS INJURY OR DEATH
Figure 10-40-4 Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0807

P132074

Inside Rear Frame Tie-down Location

Figure 10-40-5

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1

1
P132065

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

[Figure 10-40-2] or the front sides of the track frame
(Item 1) [Figure 10-40-3].

Fasten chains to the rear insides of the track frame (Item

1) [Figure 10-40-4] or the rear outsides of the track
frame (Item 1) [Figure 10-40-5] to prevent it from moving
when going up or down slopes or during sudden stops.

Use chain binders to tighten the chains and then safely tie
the chain binder levers to prevent loosening.

Use chain binders to tighten the chains and then safely

tie the chain binder levers to prevent loosening.

10-40-2 E85 Service Manual

TAILGATE Adjusting The Latch

Opening And Closing Figure 10-50-2

WARNING
1
AVOID INJURY OR DEATH 2
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497 2

WARNING P132014

Keep the rear door closed when operating the

machine. Failure to do so could seriously injure a
The tailgate latch (Item 1) [Figure 10-50-2] can be
bystander.
adjusted by loosening the two bolts (Item 2), moving the
W-2020-1285
latch, and tightening the two bolts.

Figure 10-50-1 Close the tailgate before operating the excavator.

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P132013

To open the tailgate, press the button (Item 1) [Figure

10-50-1] and open the tailgate.

Push firmly to close the tailgate.

NOTE: The tailgate (Item 1) [Figure 10-50-1] can be

locked using the start key.

10-50-1 E85 Service Manual

10-50-2
E85 Service Manual
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RIGHT SIDE COVER

Opening And Closing

Figure 10-60-1

P132066

Open the tailgate to access the right side cover latch

(Item 1) [Figure 10-60-1].

Pull the latch handle (Item 1) [Figure 10-60-1] out until

the right side cover is unlatched.

Figure 10-60-2
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P132067

Two gas springs (Item 1) [Figure 10-60-2] will raise the

right side cover to the open position.

To close the right side cover, rotate the cover down until it
is in the fully closed position.

Check that it is securely latched in the closed position.

10-60-1 E85 Service Manual

10-60-2
E85 Service Manual
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CENTER COVER

Removal And Installation

Figure 10-61-1

1
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P132068

Remove the six bolts (Item 1) and remove the center

cover (Item 2) [Figure 10-61-1].

Installation

Position the cover (Item 2) [Figure 10-61-1] to the center

frame.

Install the six bolts (Item 1) [Figure 10-61-1] and tighten.

10-61-1 E85 Service Manual

10-61-2
E85 Service Manual
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SERVICE SCHEDULE

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

Every 10 Hours (Before Starting The Excavator)

• Engine Oil - Check level and add as needed.

• Engine Air Filters and Air System - Check the 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.
• 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.
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• Motion Alarm and Horn - Check for proper function.

• Operator Cab - Check the cab condition and mounting hardware.
• Operator Cab and HVAC Filters - Clean filters.
• Indicators and Lights - Check for correct operation of all indicators and lights.
• Safety Signs - Check for damaged signs (decals). Replace any signs that are damaged.
• Hydraulic Fluid - Check fluid level and add as needed.
• Fuel Filter - Drain water and sediment from filter.
• Swing Reduction Gearbox - Check fluid level and add as needed.
• Track Tension - Check tension and adjust as needed.
• Attachment Coupler - Check for damage or loose parts (if equipped).

First 50 Hours

• Engine Oil and Filter - Replace oil and filter.

• Alternator and Starter - Check connections.
• Fuel Filter - Replace filter.

Every 50 Hours

• Swing Bearing - Grease swing bearing. Service every 10 hours when operating in water.
• Blade, Boom Swing, Boom Swing Cylinder and Bucket Pivot Points - Grease all machinery pivot points.

See inside page of the back cover for symbols and identification.

10-70-1 E85 Service Manual

SERVICE SCHEDULE (CONT’D)

Maintenance Intervals (Cont’d)

Every 250 Hours Or Every 12 Months

• Battery - Check cables, connections, and electrolyte level; add distilled water as needed.
• Boom, Boom Cylinder, Arm, Arm Cylinder, Bucket Link, and Bucket Cylinder - Grease pivot points. Grease
clamp (if equipped).
• Travel Motors (Final Drive) - Check fluid level and add as needed.

Every 500 Hours Or Every 12 Months

• Engine Oil and Filter - Replace oil and filter.

• Fuel Filter - Replace filter.
• Cooling System - Clean debris from radiator, fuel cooler, hydraulic fluid cooler, air conditioning condenser (if
equipped).
• Hydraulic Filter, Pilot Filter and Hydraulic Reservoir Breather Cap - Replace the hydraulic filter, pilot filter and the
reservoir breather cap.
• Engine Air Filters and Air System - Check the display panel for service code. Service only when required. Check for
leaks and damaged components.
• Drive Belts - Alternator (Air Conditioning - If Equipped) - Check condition. Replace as needed.
• Swing Pinion - Grease swing pinion.
• HVAC - 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.

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• Swing Reduction Gear - Grease swing reduction gear.
• Swing Reduction Gearbox - Replace fluid.
• Fuel Tank Breather - Replace breather.
• Travel Motors (Final Drive) - Replace fluid.

Every 24 Months

• Coolant - Replace the coolant.

10-70-2 E85 Service Manual

AIR CLEANER SERVICE Outer Filter

See the SERVICE SCHEDULE for the correct service The air cleaner is located in the engine compartment.
interval. (See SERVICE SCHEDULE on Page 10-70-1.) Open the tailgate to access the air cleaner for service.
(See TAILGATE on Page 10-50-1.)
Replacing The Filter Elements
Figure 10-80-2
Figure 10-80-1

2 2

1 2
P113153
3
P132016
Replace the air filters only when necessary. The service
indicator (Item 1) will FLASH. Press the Information
button (Item 3) until the display screen shows the service To remove the air cleaner dust cap (Item 1) raise the
codes. Service code [M0117] (Air Filter Plugged) will three latches (Item 2) [Figure 10-80-2].
show in the display screen (Item 2) [Figure 10-80-1]
when air filter replacement is necessary. Remove and clean the dust cap (Item 1) [Figure 10-80-
2].
Replace the inner filter every second time the outer filter
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is replaced or as indicated.

10-80-1 E85 Service Manual

AIR CLEANER SERVICE (CONT’D) Inner Filter

Replacing The Filter Elements (Cont’d) Only replace the inner filter under the following
conditions:
Outer Filter (Cont’d)
• Replace the inner filter every second time the outer
Figure 10-80-3 filter is replaced.

• After the outer filter has been replaced, start the

engine and operate at full rpm. If service code
[M0117] (Air Filter Plugged) is still displayed in the
data display, replace the inner filter.

Open the right side cover to access the air cleaner for
service. (See RIGHT SIDE COVER on Page 10-60-1.)

To remove the air cleaner dust cap (Item 1) [Figure 10-

80-2], rotate the dust cap counterclockwise.
1
Remove the outer filter (Item 1) [Figure 10-80-3].

P132017 Figure 10-80-4

Pull the outer filter (Item 1) [Figure 10-80-3] from the air
cleaner housing.

Check the housing for damage.

Clean the housing and the seal surface. DO NOT use

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compressed air.

Install a new outer filter.

Install the dust cup (Item 1), and position the evacuator 1
(Item 3) [Figure 10-80-2] so that it is pointing down.
P132018
Fasten the three clamps (Item 2) [Figure 10-80-2] to
secure the dust cap.
Remove the inner filter (Item 1) [Figure 10-80-4].
Close the right side cover and the tailgate.
NOTE: Make sure all sealing surfaces are free of dirt
Check the air intake hose and the air cleaner housing for and debris.
damage. Make sure all connections are tight.
Install the new inner filter.

Install the outer filter and the dust cap.

Close the right side cover and the tailgate.

10-80-2 E85 Service Manual

CAB FILTERS Fresh Air Filter

Cleaning And Maintenance Figure 10-90-3

The recirculation filter and the fresh air filter must be

cleaned regularly. (See Cleaning And Maintenance on
Page 10-90-1.)
1
The recirculation filter is located to the right of the
operator seat and the fresh air filter is located under the
right side cover. 2

Recirculation Filter

Figure 10-90-1

P113022

The fresh air filter is located under the right side cover.
Open the right side cover. (See RIGHT SIDE COVER on
1 Page 10-60-1.)
Pull out on the tab (Item 1) and remove the cover (Item 2)
[Figure 10-90-3].
Figure 10-90-4

P128579
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The recirculation filter (Item 1) [Figure 10-90-1] is

located to the right of the operator’s seat.

Figure 10-90-2 1

P113023

Pull the filter (Item 1) [Figure 10-90-4] out of the housing.

Shake the filter or use low pressure air to clean the filter.
Do not use solvents. Replace the filter when very dirty or
damaged.
P128580
Installation: Position the filter (Item 1) [Figure 10-90-2]
into the housing and slowly push the filter in fully.
Pull up on the filter (Item 1) [Figure 10-90-2] until
removed from the housing. Place the bottom tabs of the filter cover (Item 2) into the
frame and push the top in until the tab (Item 1) [Figure
10-90-3] locks to the frame.
Shake the filter or use low pressure air to clean the filter.
Replace the filter when very dirty or if damaged. NOTE: Do not use a brush on the filter as it can push
debris into the filter. Gently tap the sides of
Installation: Position the bottom of the filter (Item 1) the filter and / or use low pressure
[Figure 10-90-2] into the housing and slowly push the compressed air from the back side of the filter
to remove debris. If the filter is damaged,
filter down fully. replace the filter.

10-90-1 E85 Service Manual

10-90-2
E85 Service Manual
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ENGINE COOLING SYSTEM Figure 10-100-2

Check the cooling system every day to prevent over-

heating, loss of performance or engine damage. (See 3
SERVICE SCHEDULE on Page 10-70-1.)

Cleaning

Open the tailgate and the right side cover. (See

TAILGATE on Page 10-50-1.) and (See RIGHT SIDE
COVER on Page 10-60-1.)

1 2
NOTE: Allow the cooling system and engine to cool
before servicing or cleaning the cooling
system.
P132029
Figure 10-100-1

Tilt the fuel cooler (Item 1), and / or the condenser (Item
2) (if equipped) from the radiator / charged air / oil cooler
2
(Item 3) [Figure 10-100-2]. Be careful not to damage
1 fins.

Use low air pressure or low water pressure to clean the

fuel cooler (Item 1), the condenser (Item 2) (if equipped),
and the radiator / charged air / oil cooler (Item 3) [Figure
10-100-2]. Be careful not to damage fins when cleaning.

Reposition the condenser (Item 2) (if equipped) and the

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fuel cooler (Item 1) [Figure 10-100-2] to the radiator / oil

cooler. Be careful not to damage fins.
P132028
Install and tighten the knob (Item 1 and 2) [Figure 10-
100-1].
Remove the knob (Item 1) from the fuel cooler and from
the air condition condenser (Item 2) [Figure 10-100-1] (if
equipped).

10-100-1 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

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

Too much antifreeze reduces cooling system

AVOID BURNS efficiency and may cause serious premature engine
Do not remove radiator cap when the engine is hot. damage.
You can be seriously burned.
W-2070-1203
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

WARNING concentrated coolant can cause serious premature
engine damage.
I-2124-0497
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

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

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Figure 10-100-3

P132030

Check the coolant level when the coolant is cold. Check

the coolant level in the coolant recovery tank (Item 1). It
must between the “MIN” level (Item 2) and the MAX” level
(Item 3) [Figure 10-100-3]. Add fluid as needed.

NOTE: The cooling system is factory filled with

propylene glycol (purple color). DO NOT mix
propylene glycol with ethylene glycol.

10-100-2 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 10-100-5

Removing And Replacing Coolant

See the SERVICE SCHEDULE for correct service 2

intervals. (See SERVICE SCHEDULE on Page 10-70-1.)

Stop the engine. Open the tailgate and the right side
cover. (See TAILGATE on Page 10-50-1.) and (See 1
RIGHT SIDE COVER on Page 10-60-1.)

WARNING
1
P132032
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned. The radiator and the engine block can be drained at the
W-2070-1203
engine oil cooler and at the heater shut-off valve.

Figure 10-100-4 Put a locking hose pinching plier (Item 1) on both sides of
the heater valve (Item 2) [Figure 10-100-5] or similar
tool. Disconnect the hose clamps from the heater valve.
Route the hoses out of the upperstructure, remove the
two locking hose pinching pliers and drain the coolant
into a container.
1
Figure 10-100-6
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P132031

When the engine is cool, loosen and remove the radiator

cap (Item 1) [Figure 10-100-4].
1

3
2
4
P132033

Pinch off the coolant hose attached to the engine oil

cooler using a locking hose pinching plier (Item 1)
[Figure 10-100-6] or similar tool.

Remove the hose clamp (Item 2) and disconnect the

hose (Item 3) from the engine oil cooler fitting (Item 4)
[Figure 10-100-6].

Quickly install the spare 0.75 in coolant hose onto the

engine oil cooler fitting.

Drain the coolant into a container.

10-100-3 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Mix new coolant in a separate container. (See Capacities
on Page SPEC-10-6.)
Removing And Replacing Coolant (Cont’d)
The correct mixture of coolant to provide a -37°C (-34°F)
Figure 10-100-7 freeze protection is 5 L propylene glycol mixed with 4,4 L
of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.

IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
4
Too much antifreeze reduces cooling system
1 efficiency and may cause serious premature engine
damage.
3
2
P132033
Too little antifreeze reduces the additives which
Remove the temporary drain hose from the engine oil protect the internal engine components; reduces the
cooler fitting when the coolant has drained. boiling point and freeze protection of the system.

Install the coolant hose (Item 1) onto the engine oil cooler Always add a premixed solution. Adding full strength
fitting (Item 2) and install the clamp (Item 3) [Figure 10- concentrated coolant can cause serious premature
100-7]. engine damage.
I-2124-0497

Remove the tool used to pinch off the coolant hose (Item

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4) [Figure 10-100-7]. Add premixed coolant, 47% water and 53% propylene
glycol to the radiator until the coolant level reaches the
Figure 10-100-8 top of the radiator.

2 Install the radiator cap (Item 1) [Figure 10-100-4].

Add premixed coolant; 47% water and 53% propylene

3
glycol to the recovery tank until it is at the cold fill mark
[Figure 10-100-3].
1 4
Run the engine until it is at operating temperature. Stop
the engine.

Add coolant to the recovery tank as needed.

Close the right side cover and the tailgate.

4
P132032

Install the two heater hoses (Item 1) onto the heater valve
(Item 2) with the two hose clamps (Item 3). Remove the
two tools used to pinch off the coolant hose (Item 4)
[Figure 10-100-8].

Recycle or dispose of used coolant in an environmentally

safe manner.

10-100-4 E85 Service Manual

FUEL SYSTEM Biodiesel Blend Fuel

Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
NOTE: Contact your local fuel supplier to receive
recommendations for your region. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
U.S. Standard (ASTM D975)
• Biodiesel blend fuel is an excellent medium for
Use only clean, high quality diesel fuel, Grade Number microbial growth and contamination that can cause
2-D or Grade Number 1-D. corrosion and plugging of fuel system components.

Ultra low sulfur diesel fuel must be used in this machine. • Use of biodiesel blend fuel may result in premature
Ultra low sulfur is defined as 15 mg/kg (15 ppm) sulfur failure of fuel system components, such as: plugged
maximum. fuel filters and deteriorated fuel lines.

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

Apply the following guidelines if biodiesel blend fuel is

NOTE: Biodiesel blend fuel may also be used in this
used:
machine. Biodiesel blend fuel must contain
no more than five percent biodiesel mixed
• Ensure the fuel tank is as full as possible at all times
with ultra low sulfur petroleum based diesel.
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to prevent moisture from collecting in the fuel tank.

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

10-110-1 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 10-110-1

Filling The Fuel Tank

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

P132070

WARNING The fuel cap uses the start key to unlock the fuel cap.

AVOID INJURY OR DEATH Remove the fuel fill cap (Item 1) [Figure 10-110-1].
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil. Use a clean, approved safety container to add fuel. Add
Failure to use care around combustibles can cause fuel only in an area that has a free movement of air and
explosion or fire. no flames or sparks. NO SMOKING!
W-2103-0508
Install and tighten the fuel fill cap.

Clean up any spilled fuel.

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See the SERVICE SCHEDULE for the service interval
when to remove water from or replace the fuel filter. (See
SERVICE SCHEDULE on Page 10-70-1.)

10-110-2 E85 Service Manual

FUEL SYSTEM (CONT’D) Replacing Elements

Fuel Filters Figure 10-110-3

Removing Water

See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.) 2

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

1
Open the right side cover. (See RIGHT SIDE COVER on
Page 10-60-1.)

Figure 10-110-2
P132021

Disconnect the electrical connector (Item 2) [Figure 10-

110-2].

Remove the clamp (Item 1) [Figure 10-110-3].

Remove the filter (Item 2) [Figure 10-110-3].

NOTE: Do NOT fill the new fuel filter element with fuel
at this time.
1
Put clean oil on the two new fuel filter element O-rings,
2 install the element, and tighten to 13,5 N•m (10 ft-lb)
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P132020
torque.

Reposition the filter assembly (Item 2) and install the

Loosen the drain (Item 1) [Figure 10-110-2] at the clamp (Item 1) [Figure 10-110-3].
bottom of the filter to remove trapped water from the filter.
Connect the electrical connector (Item 2) [Figure 10-
Securely tighten the drain. 110-2].

Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-110-4.)
WARNING Start the engine and allow to operate for one minute.

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
WARNING
explosion or fire.
W-2103-0508
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
Close the right side cover and the tailgate. 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

Stop the engine and check for leaks at the filter.

10-110-3 E85 Service Manual

FUEL SYSTEM (CONT’D) Replacing The Fuel Tank Breather

Removing Air From The Fuel System See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
After replacing the fuel filter or when the fuel tank has run
out of fuel, air must be removed from the fuel system Open the tailgate. (See TAILGATE on Page 10-50-1.)
before starting the engine.
Open the right side cover. (See RIGHT SIDE COVER on
Page 10-60-1.)

WARNING Figure 10-110-5

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 1
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807

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

Open the right side cover. (See RIGHT SIDE COVER on

Page 10-60-1.)

Figure 10-110-4
P132096

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1
Remove the fuel tank breather (Item 1) [Figure 10-110-5]
and replace.

P132022

Open the air vent plug (Item 1) [Figure 10-110-4] on the

fuel filter assembly three full turns.

Squeeze the hand pump (priming bulb) (Item 1) [Figure

10-110-7] until fuel flows from the air vent plug with no air
bubbles.

Close the air vent plug (Item 1) [Figure 10-110-4].

10-110-4 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 10-110-7

Draining The Fuel Tank

See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.)

Figure 10-110-6

P132023

Squeeze the hand pump (priming bulb) (Item 1) [Figure

10-110-7] to start the fuel siphoning from the fuel tank.

Drain the fuel into the container.

P132022
Reuse, recycle or dispose of fuel in an environmentally
Remove the hose (Item 1) [Figure 10-110-6] from the safe manner.
fuel filter. Route the hose to a container.
Reinstall the hose (Item 1) [Figure 10-110-6] after the
fuel is removed from fuel tank.
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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

10-110-5 E85 Service Manual

10-110-6
E85 Service Manual
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ENGINE LUBRICATION SYSTEM Engine Oil Chart

Checking And Adding Engine Oil Figure 10-120-2

ENGINE OIL
Check the engine oil after every 8 - 10 hours of operation RECOMMENDED SAE VISCOSITY NUMBER
and before starting the engine. (See SERVICE (LUBRICATION OILS FOR DIESEL ENGINE
SCHEDULE on Page 10-70-1.) CRANKCASE)

Figure 10-120-1

TEMPERATURE RANGE ANTICIPATED BEFORE

1 NEXT OIL CHANGE (DIESEL ENGINES MUST USE
API CLASSIFICATION CJ-4 OR BETTER)
[1] Bobcat Synthetic Oil – 5W-40

P132024 Bobcat engine oils are recommended for use in this

machine. If Bobcat engine oil is not available, use a good
quality engine oil that meets API Service Classification of
Open the tailgate. (See TAILGATE on Page 10-50-1.) CJ-4 or better [Figure 10-120-2].

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

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Keep the oil level between the marks on the dipstick.

WARNING
Use a good quality motor oil that meets the correct API
Service Classification. 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

10-120-1 E85 Service Manual

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-120-4

Removing And Replacing Oil And Filter

See the SERVICE SCHEDULE for the service interval for

replacing the engine oil and filter. (See SERVICE
SCHEDULE on Page 10-70-1.)

Run the engine until it is at operating temperature. Stop

the engine. 1

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

Figure 10-120-3 P132024

Remove the oil filter (Item 1) [Figure 10-120-4] and clean

the filter housing surface.

Use a genuine Bobcat replacement filter. Put clean oil on

the filter gasket. Install the filter and hand tighten.
Install and tighten the drain cap (Item 1) [Figure 10-120-
3].

1 Figure 10-120-5

P132025

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Place a container under the oil pan. Remove the drain
cap (Item 1) [Figure 10-120-3] from the elbow on the
bottom of the engine oil pan. 1

Recycle or dispose of used oil in an environmentally safe

manner.

P132026

Remove the fill cap (Item 1) [Figure 10-120-5].

Put oil in the engine. (See ENGINE LUBRICATION

SYSTEM on Page 10-120-1.)

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

Start the engine and let it run for several minutes.

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

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

dipstick.

10-120-2 E85 Service Manual

HYDRAULIC SYSTEM Figure 10-130-2

Checking And Adding Hydraulic Oil

Put the machine on a flat level surface.
Retract the arm and bucket cylinders, put the bucket on
the ground and lower the blade. Stop the engine.
Open the right side cover. (See RIGHT SIDE COVER on
Page 10-60-1.) 1
Figure 10-130-1

P132035
B

A Check the condition of the fill strainer screen (Item 1)

[Figure 10-130-2]. Clean or replace as necessary.

Be sure the screen is installed before adding fluid.

Add the correct fluid to the reservoir until it is visible in the

sight gauge. (See HYDRAULIC SYSTEM on Page 10-
130-1.)
2 Check the cap and clean as necessary. Replace the cap
if damaged.

Install the cap.

Close the right side cover and tailgate.

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Hydraulic / Hydrostatic Fluid Chart

B Figure 10-130-3
HYDRAULIC / HYDROSTATIC FLUID
1
A RECOMMENDED ISO VISCOSITY GRADE (VG)
P132082 AND VISCOSITY INDEX (VI)

Park the machine in the position shown [Figure 10-130-

1]. (The preferred method is to check the hydraulic oil
when it is cold.)
Check the hydraulic oil level, it must be visible in the sight
gauge (Item 1) [Figure 10-130-1]. The decal on the
hydraulic tank shows the correct fill level.
A - Correct Oil Level COLD (Preferred)
B - Correct Oil Level HOT (Optional)
Clean the surface around the reservoir cap and remove TEMPERATURE RANGE ANTICIPATED
the cap from the reservoir (Item 2) [Figure 10-130-1]. DURING MACHINE USE
[1] VG 100; Minimum VI 130
[2] VG 46; Minimum VI 150
WARNING [3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
AVOID INJURY OR DEATH Fluid (Unlike biodegradable fluids that are vegetable
Always clean up spilled fuel or oil. Keep heat, flames, based, Bobcat biodegradable fluid is formulated to
sparks or lighted tobacco away from fuel and oil. prevent oxidation and thermal breakdown at operating
Failure to use care around combustibles can cause temperatures.)
explosion or fire.
W-2103-0508

10-130-1 E85 Service Manual

HYDRAULIC SYSTEM (CONT’D) Case Drain Filter

Removing And Replacing The Hydraulic Filters See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)

The case drain filter is located in the right front side of the
WARNING upperstructure.

Open the tailgate and the right side cover. (See

AVOID INJURY OR DEATH
TAILGATE on Page 10-50-1.) and (See RIGHT SIDE
Always clean up spilled fuel or oil. Keep heat, flames,
COVER on Page 10-60-1.)
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
Figure 10-130-5
explosion or fire.
W-2103-0508

Hydraulic Filter

See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.)

Open the tailgate and the right side cover. (See

TAILGATE on Page 10-50-1.) and (See RIGHT SIDE 1
COVER on Page 10-60-1.)

Figure 10-130-4

P132037

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Remove the case drain filter (Item 1) [Figure 10-130-5].

Clean the housing where the filter gasket makes contact.

1 Put clean hydraulic fluid on the gasket. Install the new

filter and hand tighten only.

Recycle or dispose of the used hydraulic fluid in an

environmentally safe manner.

P132036

Remove the hydraulic filter (Item 1) [Figure 10-130-4].

Clean the housing where the filter gasket makes contact.

Put clean hydraulic fluid on the gasket. Install the new

filter and hand tighten only. Use a genuine Bobcat
replacement filter.

Recycle or dispose of the used hydraulic fluid in an

environmentally safe manner.

10-130-2 E85 Service Manual

HYDRAULIC SYSTEM (CONT’D) Figure 10-130-7

Removing And Replacing The Hydraulic Fluid

See the SERVICE SCHEDULE for the correct service

interval. (See SERVICE SCHEDULE on Page 10-70-1.) 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 P132039
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. 10-130-7] on the hydraulic pump. Tighten the plug after a
W-2072-0807
steady stream of hydraulic fluid, 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.
the ground. Stop the engine.
Open the tailgate and the right side cover. (See Figure 10-130-8
TAILGATE on Page 10-50-1.) and (See RIGHT SIDE
COVER on Page 10-60-1.)

Figure 10-130-6
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2 1

P132031

P132038
There is also a port (Item 1) [Figure 10-130-8] on the
hydraulic cooler for bleeding air. Install a diagnostic
Remove the hose clamp (Item 1). Disconnect the hose coupler and hose on this fitting and to allow air to be
(Item 2) and reposition the hose out the side of the bleed from the hydraulic system after the hydraulic fluid
upperstructure [Figure 10-130-6]. has been replaced. Remove the diagnostic coupler.

Drain the fluid into a container. Start the engine and operate the machine through the
hydraulic functions. Stop the engine. Check the fluid level
Recycle or dispose of the hydraulic fluid in an
and add as needed.
environmentally safe manner.
Reinstall the hose (Item 2) and the clamp (Item 1)
[Figure 10-130-6].

Add fluid to the reservoir. (See HYDRAULIC SYSTEM on

Page 10-130-1.)

10-130-3 E85 Service Manual

HYDRAULIC SYSTEM (CONT’D) Removing And Replacing Swing Motor Gear Box
Fluid
Checking Swing Motor Gear Box Fluid Level
Figure 10-130-10
Figure 10-130-9

2
2
1 1

P132084

P132083

Open the center cover to access the swing motor. (See

Open the tailgate and the right hand cover to access the CENTER COVER on Page 10-61-1.)
swing motor. (See TAILGATE on Page 10-50-1.) and
(See RIGHT SIDE COVER on Page 10-60-1.) The swing motor carrier drain plug (Item 1) [Figure 10-
130-10] is located on the side of the swing motor carrier.
The swing motor gear box (Item 1) has a dipstick (Item 2)
[Figure 10-130-9] for checking the swing motor gear box Place a oil containment mat (Item 2) [Figure 10-130-10]
oil level. in the upperstructure by the drain plug to collect the used

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fluid.
Keep the oil level between the marks on the dipstick.
Remove the plug (Item 1) [Figure 10-130-10] and drain
the swing motor carrier fluid onto the oil containment mat.

Reinstall the drain plug.

Recycle or dispose of the fluid in an environmentally safe

manner.

Remove the dipstick (Item 2) [Figure 10-130-9] and add

gear lube (80W-90) until it is at the correct mark on the
dipstick. (See REGULAR MAINTENANCE on Page 70-
20-1.) and (See Capacities on Page SPEC-10-6.)

10-130-4 E85 Service Manual

LUBRICATING THE EXCAVATOR Figure 10-140-2

Lubrication Locations

Lubricate the excavator as specified in the SERVICE 5

SCHEDULE for the best performance of the machine.
(See SERVICE SCHEDULE on Page 10-70-1.)

Always use a good quality lithium based multipurpose

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

Figure 10-140-1

5
4 2

2 6
P132044
3

5. Boom Swing Pivot (2) [Figure 10-140-2]

6. Boom Swing Cylinder Rod End (1) [Figure 10-140-2]

1 1
Figure 10-140-3
P132043
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Ref Description (# of Fittings)

1. Blade Cylinder Rod End (2) [Figure 10-140-1]

2. Blade Cylinder Base End (2) [Figure 10-140-1]

7
3. Blade Pivots (2) [Figure 10-140-1]

4. Boom Cylinder Base End (1) [Figure 10-140-1]

P132045

7. Boom Cylinder Rod End (1) [Figure 10-140-3]

10-140-1 E85 Service Manual

LUBRICATING THE EXCAVATOR (CONT’D) Figure 10-140-6

Lubrication Locations (Cont’d)

10
Figure 10-140-4

8
11 P132048

10. Arm Cylinder Rod End (1) [Figure 10-140-6]

P132047
11. Arm Pivot (1) [Figure 10-140-6]

8. Boom Pivot (1) [Figure 10-140-4] Figure 10-140-7

Figure 10-140-5
12

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9

P132049

P132046
12. Bucket Cylinder Base End (1) [Figure 10-140-7]

9. Arm Cylinder Base End (1) [Figure 10-140-5]

10-140-2 E85 Service Manual

LUBRICATING THE EXCAVATOR (CONT’D) Figure 10-140-9

Lubrication Locations (Cont’d)

Figure 10-140-8
18 19
17 20
13
15

16
14
P132000
15

Lubricate the following locations on the hydraulic

excavator EVERY 50 HOURS:

17. Swing Bearing (1) [Figure 10-140-9]

18. Swing Pinion (1) [Figure 10-140-9]. (Install 3 to 4

pumps of grease then rotate the upperstructure 90°.
P132050 Install 3 to 4 pumps of grease and again rotate the
upperstructure 90°. Repeat this until the slew pinion
has been greased at four positions.)
13. Bucket Cylinder Rod End (1) [Figure 10-140-8]
19. Swing Reduction Gear (1) [Figure 10-140-9]
14. Bucket Link Pin (2) [Figure 10-140-8]
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20. Swing Cylinder (base end) (1) [Figure 10-140-9]

15. Bucket Pivot (3) [Figure 10-140-8]

16. Hydraulic Clamp (2) [Figure 10-140-8] (If Equipped)

10-140-3 E85 Service Manual

10-140-4
E85 Service Manual
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PIVOT PINS

Inspection And Maintenance

Figure 10-150-1

2
2

3
1

1
3

2
1 3
P132051

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

position with a bolt (Item 2) and double nuts (Item 3)
[Figure 10-150-1] securing the pin.

The two nuts (Item 3) are used as jam nuts to hold the
bolt (Item 2) with out tightening the bolt (Item 2) to the pin
boss. After the nuts (Item 3) are tightened together, the
bolt (Item 2) [Figure 10-150-1] should be free to spin.
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10-150-1 E85 Service Manual

10-150-2
E85 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 SERVICE SCHEDULE on Page 10-70-1.)
Figure 10-160-1
Park the excavator on a level surface with plugs (Items 1
and 2) [Figure 10-160-1] positioned shown. Remove
both plugs and drain the lubricant into a container.

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
P132040

Install the bottom plug (Item 2) [Figure 10-160-1]. Add

Park the excavator on a level surface with the plugs lubricant (SAE 90W) through the plug hole until the lube
(Items 1 and 2) [Figure 10-160-1] positioned as shown. level is at the bottom edge of the hole. (See Capacities
on Page SPEC-10-6.)
Remove the plug (Item 1) [Figure 10-160-1]. The lube
level must be at the bottom edge of the hole. Install the plug (Item 1) [Figure 10-160-1].

Add lubricant (SAE 90W) through the hole (Item 1)

[Figure 10-160-1] if the lube level is low.
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10-160-1 E85 Service Manual

10-160-2
E85 Service Manual
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EMERGENCY EXIT Front Window

The door, the right side rear window and the front window Figure 10-170-2
provide exits.

Right Side Rear Window

Figure 10-170-1

P128563A

Open the front window and exit [Figure 10-170-2].

P132085
NOTE: If the excavator has a Special Applications Kit
installed, the front window is NOT an
emergency exit.
Exit through the window [Figure 10-170-1].
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10-170-1 E85 Service Manual

10-170-2
E85 Service Manual
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SEAT BELT Figure 10-180-1

Inspection And Maintenance 1

WARNING 3

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. 2 4

Inspect the seat belt system thoroughly at least once

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

Any seat belt system that shows cuts, fraying, extreme or

unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,
retractor (if equipped), hardware or any other obvious
problem should be replaced immediately.
B-22283

The items below are referenced in [Figure 10-180-1].

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

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retractor, pull the webbing completely out and inspect

the full length of the webbing. Look for cuts, wear,
fraying, dirt and stiffness.

2. Check the buckle and latch for correct operation.

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

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

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

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

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

10-180-1 E85 Service Manual

10-180-2
E85 Service Manual
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CONTROL CONSOLE LOCKOUTS

Inspection And Maintenance

Figure 10-190-1

P132093

When the left console is raised [Figure 10-190-1], 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 10-190-1].

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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.

10-190-1 E85 Service Manual

10-190-2
E85 Service Manual
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TOWING THE EXCAVATOR

Procedure

There is not a recommended towing procedure for the

excavators.

• The excavator can be lifted onto the transport vehicle.

• The excavator can be skidded a short distance for

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

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

the weight of the excavator. (See Performance on
Page SPEC-10-3.)
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10-200-1 E85 Service Manual

10-200-2
E85 Service Manual
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REMOTE START TOOL KIT - MEL1563 Figure 10-210-2

Remote Start Tool - MEL1563

Tools that will be needed to complete the following steps

are: 1

MEL1563 - Remote Start Tool

MEL1565 Service Tool Harness Control
MEL1566 - Service Tool Harness Communicator
(Computer Interface)

Figure 10-210-1

P16117
1

The three function buttons (Item 1) [Figure 10-210-2] are

non-functional for excavators.

NOTE: Excavators can not be started by using the

Remote Start Tool.

Figure 10-210-3

P16114

1
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The Remote Start Tool (Item 1) [Figure 10-210-1] 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-

210-3] is not used for an excavator application.

10-210-1 E85 Service Manual

REMOTE START TOOL KIT - MEL1563 (CONT'D) Figure 10-210-5

Service Tool Harness Control - MEL1565

Figure 10-210-4

1
1

P-98952

Remove the plug (Item 1) [Figure 10-210-5] from the

P16114 excavator harness connector.

Connect the service tool harness to the excavator

The Service Tool Harness Control (Item 1) [Figure 10- harness.
210-4] is used to connect the Remote Start Tool to the
electrical system on the excavator. Connect the Service Tool Harness Communicator
(MEL1566) to the designated serial port on the Service
NOTE: Make all connections with the key or keyless PC.
panel in the OFF position.

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Open the right side cover. (See Opening And Closing on
Page 10-60-1.)

10-210-2 E85 Service Manual

REMOTE START TOOL KIT - MEL1563 (CONT'D) Figure 10-210-8

Service Tool Harness Communicator - MEL1566

NOTE: To monitor, diagnose or load new software

the Service PC must be connected to the
Remote Start Tool.
1
Figure 10-210-6

1 P114773

Turn the key (Item 1) [Figure 10-210-8] to the RUN

position on the excavator.

NOTE: DO NOT start the excavator.

P16119 Figure 10-210-9

The Service Tool Harness Communicator (Item 1)

[Figure 10-210-6] is required to connect the Service PC
to the Remote Start Tool.
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Figure 10-210-7
1

1 P-21334

Turn the key (Item 1) [Figure 10-210-9] to the RUN

position on the Remote Start Tool.

P114773

10-210-3 E85 Service Manual

10-210-4
E85 Service Manual
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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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10-211-1 E85 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-211-2
7217666 (CONT’D)
1
Remote Start Tool (Service Tool) - 7022042

Tools that will be needed to complete the following steps 1 1

are:

Order from Bobcat Parts P/N: 7217666 - Remote Start 1 1

Tool (Service Tool) Kit

Kit Includes:
7022042 - Remote Start Tool (Service Tool)
6689747 - Excavator Service Tool Harness
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
P-76439
Figure 10-211-1
The five function buttons (Item 1) [Figure 10-211-2] are
non-functional for excavators.

NOTE: Excavators can not be started by using the

Remote Start Tool.

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P-76678

The Remote Start Tool (Item 1) [Figure 10-211-1] 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.

10-211-2 E85 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-211-5
7217666 (CONT’D)

Excavator Service Tool Harness - 6689747

2 1
Figure 10-211-3

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 10-211-5] is always used for
connection to the excavator harness.
The service tool harness control (Item 1) is used to
connect the Remote Start Tool (Item 2) [Figure 10-211- The second connector (Item 2) [Figure 10-211-
3] to the electrical system on the excavator. 5] is not used for excavator applications. This
connector has a cap attached to it to prevent
The service tool harness communicator (Item 3) [Figure damage or corrosion when not in use.
10-211-3] is used to connect the Remote Start Tool to the
Service PC. Connect the Remote Start Tool (Service Tool) connector
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(Item 1) [Figure 10-211-5] to the excavator harness

NOTE: Make all connections with the key or keyless connector.
panel in the OFF position.
NOTE: The Key Switch or Keyless Instrument Panel
Open the right side cover. (See Opening And Closing on must be in the run position or the Remote
Page 10-60-1.) Start Tool (Service Tool) will not operate.

Figure 10-211-4

P-98952

Remove the plug (Item 1) [Figure 10-211-4] from the

excavator harness connector.

10-211-3 E85 Service Manual

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-211-7
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 10-211-6 1 2

P-76441

The gear icon with the left facing arrows (Item 1) [Figure
10-211-7] will illuminate and blink when the excavator key
is in the RUN position or excavator keyless panel is ON
and the excavator is communicating with the service tool.

2 NOTE: DO NOT start the excavator.

P-76450
The computer icon with the right facing arrows (Item 2)
[Figure 10-211-7] will illuminate and blink when the
The Computer Service Tool Harness (Item 1) [Figure 10- Remote Start Tool (Service Tool) is transmitting data to
211-6] is required to connect Remote Start Tool (Service and from the computer.
Tool) to the Service PC (Item 2) [Figure 10-211-6].

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10-211-4 E85 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-13

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-12

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-12

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-12

CYLINDER (CLAMP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-7

20-01 E85 Service Manual

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

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

Testing And Adjusting Port Relief Valve Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

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

Testing And Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-4

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Inlet Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9
Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12

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

Hydraulic Pump Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Pump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-17

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Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-19
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-20
Torque Limiter Valve Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-22
Torque Limiter Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-23
Torque Limiter Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-23
Torque Limiter Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-28
Initial Torque Limiter Valve Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-31
Torque Limiter Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-33
Pump Control Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-34
Pump Control Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-35
Pump Control Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-35
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-41
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-42
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-51

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4

20-02 E85 Service Manual

TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
Parts Identification Gear Reduction Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-15

SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-3

SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4

SWING MOTOR (DRIVE CARRIER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-3

CONTROL PATTERN SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
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Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-3

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Joystick Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-11

LEFT CONTROL LEVER (JOYSTICK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
Joystick Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-11

HYDRAULIC FILTER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

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

HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

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

20-03 E85 Service Manual

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

BLADE CONTROL LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-5
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-6

CASE DRAIN FILTER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

TRAVEL CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-3

REMOVING AIR FROM THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1

MANIFOLD (PIN GRABBER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-3

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SECONDARY AUXILIARY VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-4

VALVE (BOOM LOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1

VALVE (ARM LOCK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-221-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-221-1

20-04 E85 Service Manual

Printable Version Click Here

E85 HYDRAULIC/HYDROSTATIC SCHEMATIC

S/N B48411001 AND ABOVE
(PRINTED NOVEMBER 2017)
V-1656legend

LEGEND
TEST PORT - "JP3" PORT - Pressure
1 HYDRAULIC RESERVOIR: Pressurized with Fill 34 PORT RELIEF VALVE (With Anti-Cavitation 54
Strainer 18 SOLENOID ACTIVATED DIRECTIONAL Valve) - (Blade Cylinder Base and Rod): Reducing Valve
CONTROL VALVE – Boom Offset / 38000 kPa (380 bar) (5511 psi)
Reservoir Capacity (at Site Gauge) Secondary Auxiliary Hydraulics – If Equipped) 55 PILOT ACTIVATED DIRECTIONAL
. . . . . . 22.7 L (6.0 U.S. gal) PORT RELIEF VALVE (With Anti-Cavitation CONTROL VALVE - Second Auxiliary
35 Valve) - (Offset Cylinder Base and Rod):
System Capacity . . . . 83.0 L (22.0 U.S. gal) SOLENOID ACTIVATED DIRECTIONAL (Optional)
19 38000 kPa (380 bar) (5511 psi)
CONTROL VALVE – Boom Offset / 56 SOLENOID ACTIVATED DIRECTIONAL
2 PRESSURIZED BREATHER/FILL CAP Secondary Auxiliary Hydraulics – If Equipped) 36 ORIFICE – Straight Travel: 1,2 mm (0.05 in) CONTROL VALVE - Second Auxiliary (2)
with FILTER: (Optional)
20 SOLENOID ACTIVATED DIRECTIONAL
40 kPa (0.4 bar) (6 psi) – Outlet CHECK VALVE – Pressure Build Up:
CONTROL VALVE - Two Speed 37
4 kPa (0.04 bar) (0.6 psi) - Inlet 420 kPa (4,2 bar) (60 psi) 57 PORT RELIEF VALVE (With Anti-Cavitation
21 SOLENOID ACTIVATED DIRECTIONAL 38 Valve) - (Secondary Auxiliary) (Optional)
3 HYDRAULIC FILTER ELEMENT PRESSURE SENSOR – Auto Idle
CONTROL VALVE - Work group Lockout 4000 PSI (276 bar)
15 Micron
SOLENOID ACTIVATED DIRECTIONAL 39 COUNTERBALANCE VALVE - With restrictors
4 FILTER BY-PASS: 344 kPa (3.44 bar) (50 psi) 22 58 PRESSURE SENSOR – Pin Grabber (Optional)
CONTROL VALVE - Male Coupler
40 CROSSPORT RELIEF VALVE – Travel Motor
5 CHECK VALVE SOLENOID ACTIVATED DIRECTIONAL 28000 kPa (280 bar) (4061 psi) 59 SIGHT GAUGE
23
CONTROL VALVE - Female Coupler
6 HYDRAULIC BY-PASS SWITCH 41 SHUTTLE VALVE
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24 ACCUMULATOR
7 TORQUE LIMITER SUPPLY ORIFICE: 42 TWO SPEED SHIFT SPOOL
25 RELIEF VALVE – Two Speed
3450 kPa (34,5 bar) (500 psi) CROSSPORT RELIEF VALVE:
TORQUE LIMITER SUPPLY SPOOL - 43
8 21570 kPa (216 bar) (3129 psi)
2000 kPa (20 bar) (290 psi)
26 FLUSHING VALVE: 44 TIMER VALVE – 6 Sec.
9 PUMP MARGIN SPOOL - 2000 kPa (20 bar) (290 psi)
1500 kPa (15 bar) (218 psi)
27 LOAD SENSE BLEED CARTRIDGE 45 PILOT ACTIVATED DIRECTIONAL
10 PUMP CONTROLLER – TORQUE LIMITER 0.70 L/min (0.185 gpm) CONTROL VALVE – Brake Release Valve
With Back-up Relief Valve 390 kPa (3,9 bar) (57 psi)
28 LOAD SENSE RELIEF VALVE
11 HYDRAULIC PISTON PUMP . . . . . . 29500 kPa (295 bar) (4279 psi)
138,5 L/min (149.1 gpm) at High Engine RPM 46 SWING MOTOR BRAKE
29 COMPENSATOR
12 ON STROKE ORIFICE: 1,3 mm (0.05 in)
PORT RELIEF VALVE (With Anti-Cavitation 47 CHECK VALVE – Pressure Build Up
30 with Orifice: 310 kPa (3,1 bar) (45 psi)
13 STABILITY ORIFICE VALVE Valve) - (Bucket Cylinder Base and Rod): 1,2 mm (0.05 in)
34000 kPa (340 bar) (4931 psi)
CHECK VALVE – Cold Weather By-Pass:
PRESSURE SWITCH – Motion Alarm PORT RELIEF VALVE (With Anti-Cavitation 48
14 170 kPa (1,7 bar) (25 psi)
(If Equipped) 31
Valve) - (Arm Cylinder Base and Rod):
34000 kPa (340 bar) (4931 psi) 49 CASE DRAIN FILTER BY-PASS
15 SHUTTLE VALVE – Motion Alarm
PORT RELIEF VALVE (With Anti-Cavitation 50 TEST PORT – Air Bleed
PRESSURE REDUCING VALVE 32 Valve) - (Auxiliary):
16 51 SHUTTLE VALVE
3000 kPa (30 bar) (435 psi) 21000 kPa (210 bar) (3045 psi)
PORT RELIEF VALVE (With Anti-Cavitation 52 TEST PORT – LS PORT
17 CHECK VALVE - Accumulator 33
Valve) - (Boom Cylinder Base and Rod): NOTE: Unless otherwise specified
53 TEST PORT – P PORT Manifold
34000 kPa (340 bar) (4931 psi) springs have NO significant
pressure value.
Printed in U.S.A. V-1656legend (10-31-17)
TRAVEL MOTORS

SH
THUMB CYLINDER SLEW MOTOR W/ BRAKE
BOOM CYLINDER MALE FEMALE
D2 D1 D1 D2
(OPTIONAL) 46 OFFSET CYLINDER
GEAR BOX 45
BOOM LOAD HOLDING
C2 VALVE (OPTIONAL)
P2 P1 P1 P2 57
42 42 PG 2ND AUX VALVE
(OPTIONAL)
BLADE CYLINDERS (2) C D
ARM CYLINDER
FEMALE MALE
DB
P P
MALE FEMALE F
C2
41 40 41
ARM LOAD HOLDING E
VALVE (OPTIONAL) T
44
40 56
V2 Pil 40
C
T
40 PA 43
BUCKET CYLINDER PB

V2 Pil A B

A CP T B

B A A B
55

39
B D E H C A 39 F G

58
B1 A1 B2 A2 B3 A3 B4 A4 B6 A6 B7 A7 B8 A8 B9 A9 B10 A10 M
P3 CONTROL VALVE: RS15 P1 52
V1 V2

BUCKET ARM AUXILIARY BOOM SLEW OFFSET LS2 PIN GRABBER

LS3 TRAVEL RIGHT TRAVEL LEFT BLADE QUICK
29 29 COUPLER
38 29 29 29 29 (OPTIONAL)
29 29 LS1
29 28
PS

26

27

T2
P1 T P
T3 T1

37
36
30 31 32 33 34 35
b a b a a2 b a b2 b a b a b a b a b2 b a a2 b a
51

TRAVEL BUILD UP
CONTROL VALVE
1 5 T1 2
7
X1 X2
JOYSTICK PATTERN RH JOYSTICK 2 LH REV
PRESSURIZED
LH JOYSTICK SELECTOR VALVE 14 RH REV 47
4 2 A3 A1 12 BREATHER CAP
8 CASE DRAIN
3 L3 REAR RIGHT FILTER OIL
3
15 2 49 COOLER
48
REAR RIGHT L1 9
STD
T IMPLEMENT PUMP

LEFT LH FWD RH FWD 59

FRONT
ISO 4
B 1
LEFT FRONT
1 R1
3 4 50
1 10
R3
P1 P 13 FILTER W/ BYPASS
MB
P T B1 B3
P T 4
5
HYDRAULIC RESERVOIR
L

BLADE CONTROL
L1
T 11
S
P

3 6
REAR FRONT

2 1 LEGEND:
54 WORKING CIRCUIT
DRAIN/RETURN
PILOT
1
LOAD SENSE
Printable Version Click Here

PILOT AXA AXB T1 T2 JP1 JP2 JP3 2S OFA OFB T6

HYDRAULIC SCHEMATIC
MANIFOLD

MANUAL WITH ALL OPTIONS

T4
25 16

E85 (S/N B48411001 AND ABOVE)

24 53
(PRINTED OCTOBER 2017)
P
ACC
T5 T3 JP5 JP4
7298991 (A)

Printed In U.S.A. 23 22 21
20 19 18 17

NOTES: 1 OIL CLEANLINESS PER ISO-4406

- TARGET _/17/14
- MAX ALLOWED _/18/15

2 GEITH PRESSURE TRANSDUCER LOCATION:

MAIN CONTROL VALVE, BUCKET BASE

3 EQ. ORIFICE AREA BUCKET, ARM, AND SLEW

.012 sq. in. [7.8 sq. mm]

4 EQ. ORIFICE AREA BOOM, LH TRAVEL, AND RH

TRAVEL
.028 sq. in. [17.9 sq. mm]
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HYDRAULIC SYSTEM INFORMATION

Glossary Of Hydraulic / Hydrostatic Symbols

20-10-1
MC 2340 (6-2-98)
MS-1892-1

E85 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

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

20-10-2 E85 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

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MS-1892-3
MC 2340-3 (6-2-98)

20-10-3 E85 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Hydraulic Circuit

PROBLEM CAUSE CORRECTION

No hydraulic operation at one or Hydraulic oil level low Refill with correct oil
more circuits Hydraulic pump drive coupling damaged Replace
Hydraulic pump defective Repair or replace
Load Sense relief valve defective Readjust or replace
Hydraulic power insufficient to one Load Sense relief valve pressure setting incorrect Readjust or replace
or more circuits
All hydraulic speed too slow Hydraulic oil level or viscosity incorrect Fill to correct level 
Use correct viscosity oil
Engine rpm reduced Readjust 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 Fill to correct level
Non recommended hydraulic oil Replace
Relief valve excessively activated Use proper operating
procedures
One or more relief valves not set correctly Readjust or replace
Extreme operating conditions. High ambient
temperature (i.e.: Enclosed structure)
Engine accessory drive belt loose Replace Belt

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20-10-4 E85 Service Manual

HYDRAULIC SYSTEM TROUBLESHOOTING (CONT’D)

Troubleshooting The Cylinder Circuit

PROBLEM CAUSE CORRECTION

Cylinder inoperable Control console raised Lower control console.
Loose fittings or broken hoses Repair or replace
Low psi at joystick Check, repair or replace
pressure reducing valve
Lever linkage incorrectly adjusted Readjust
Control console lockout switch Readjust or replace
Cylinder internal leakage excessive Repair or replace
Joystick manifold pressure reducing valve defective Repair or replace
Joystick internal leakage excessive Repair or replace
Cylinder force insufficient Lever linkage incorrectly adjusted Readjust
Load Sense relief valve pressure to low Readjust or replace
Lever linkage incorrectly adjusted Readjust
Cylinder speed too slow Cylinder internal leakage excessive Repair or replace
Joystick manifold solenoid valve defective Repair or replace
Joystick manifold pressure reducing valve defective Repair or replace
Control valve internal leakage excessive Repair or replace
Low tie rod torque on control valves Tighten tie rods to correct
torque
Joystick internal leakage excessive Repair or replace
Low or dirty fluid Add or replace the hydraulic
fluid
Load Sense relief valve malfunctioning Readjust or replace
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20-10-5 E85 Service Manual

HYDRAULIC SYSTEM TROUBLESHOOTING (CONT’D)

Troubleshooting The Swing (Upperstructure Slew) Circuit

PROBLEM CAUSE CORRECTION

Slew not operating Control console raised Lower control console.
Control console lock out switch incorrectly adjusted Readjust or replace
or defective
Slew lock pin engaged Disengage lock pin
Joystick manifold pressure reducing valve defective Repair or replace
Slew motor gear defective Repair or replace
Joystick internal leakage excessive Repair or replace
Slew motor defective Repair or replace
Slew force Load Sense relief valve set too low Readjust or replace
Slew motor relief valve pressure too low Readjust or replace
Slew speed too low Pump flow low Check, repair or replace
Blocked or restricted line to slew motor Replace
Joystick internal leakage excessive Repair or replace
Control valve internal leakage excessive Repair or replace
Slew motor internal leakage excessive Repair or replace
Slew over run excessive Control valve spool sticking Repair or replace
Joystick spool sticking Repair or replace
Slew motor relief valve set too low Repair or replace
Slew motor internal leakage excessive Repair or replace
Slew motor seal leakage Case drain line plugged Replace

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20-10-6 E85 Service Manual

HYDRAULIC SYSTEM TROUBLESHOOTING (CONT’D)

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 counter balance 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
Load Sense relief valve pressure too low Readjust or replace
Travel power Track tension too tight Readjust
Load Sense relief valve pressure too low Readjust or replace
Swivel joint leaking Repair or replace
Travel motor counterbalance spool sticking Repair or replace
Lever linkage incorrectly adjusted Readjust
Speed too slow 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
Travel motor seal leakage Return line filter plugged Inspect, clean 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
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Travel motor counterbalance spool sticking Repair or replace

Load Sense Main relief valve pressure set too low Repair or replace
Swivel joint internal leakage excessive Repair or replace
Control valve internal leakage not equal Repair or replace
Machine will not hold on slope or Travel motor counterbalance valve leakage Repair or replace
while digging excessive
Hose damage Replace
Blade drops while machine is Lever linkage unaligned 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
High / low shift inoperative (2- Control valve defective Replace
speed) Low pressure to 2-speed valve Readjust

20-10-7 E85 Service Manual

20-10-8
E85 Service Manual
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CYLINDER (BOOM) Figure 20-20-3

Testing
2
Lower the boom / bucket and blade to the ground.
3
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic 1
pressure.

Figure 20-20-1

P-86897

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

20-3].

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

Figure 20-20-4

P131313

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

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20-1].
1
Figure 20-20-2

2
P-87000

Lower the cylinder (Item 1) [Figure 20-20-4].

1
Start the engine and fully retract the cylinder rod (Item 2)
[Figure 20-20-4].

P-86898 Stop the engine. Relieve hydraulic pressure.

Install a sling (Item 1) [Figure 20-20-2] and a lifting

device to the rod end of the boom cylinder.

20-20-1 E85 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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P131314

Remove the hose from the base end of the cylinder. Cap
the hose (Item 1) [Figure 20-20-5].

Start the engine and move the hydraulic control lever to

the boom cylinder retract position.

If there is any oil leakage from the base end fitting (Item
1) [Figure 20-20-5], remove the cylinder for repair or
replacement.

20-20-2 E85 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-8

Removal And Installation

NOTE: Dealer disassembly of the component(s) 1

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check 1
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Lower the boom / bucket and blade to the ground.

With the engine off, turn the key to the ON position and
P131315
move both hydraulic control levers to relieve hydraulic
pressure.
Remove the hoses (Item 1) [Figure 20-20-8].
Figure 20-20-6

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

I-2003-0888

Figure 20-20-9

P131313

2
Support the boom with a chain hoist (Item 1) [Figure 20-
20-6]. 3

Figure 20-20-7 1

P-86839

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

1 20-9].

Remove the rod end pivot pin (Item 3) [Figure 20-20-9].

P133233

Install a sling (Item 1) [Figure 20-20-7] and a lifting

device to the rod end of the boom cylinder.

20-20-3 E85 Service Manual

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

Removal And Installation (Cont’d)

2
Figure 20-20-10

1
1

P131312

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

P133239 20-11].

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

Lower the cylinder (Item 1) [Figure 20-20-10] until it rests 11].
on the blade.
Remove the cylinder.

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,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

20-20-4 E85 Service Manual

CYLINDER (BOOM) (CONT’D)

Parts Identification

1. Bushing
2. Tube
3. Screw
4. Nut
5. Piston
6. Back-up Ring 2
7. O-ring
8. Seal 1
9. Wear Ring
10. Seal Assembly
11. Cushion Ring
12. Snap Ring
13. Head
14. Bolt
15. Wiper
16. Rod
3

10 4

11
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5
6
7
8
9
13
9
8

14 6
7
1 12

8
15
12

16


1
NA13721S

20-20-5 E85 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-14

Disassembly 1

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Hold the hydraulic cylinder over a drain pan and slowly

move the rod in and out to remove the fluid from the
cylinder.
P-87077

Figure 20-20-12
Remove the rod assembly (Item 1) [Figure 20-20-14]
from the cylinder housing.

Remove the cylinder housing from the vise.

Figure 20-20-15

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1
P-86848

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

12].

Figure 20-20-13
P-86852

1
Clamp the rod end (Item 1) [Figure 20-20-15] in a vise.

1
P-86849

Remove the bolts (Item 1) [Figure 20-20-13].

20-20-6 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-20-16
1

P-86853

Remove the piston (Item 1) [Figure 20-20-18].

P-86850
Figure 20-20-19

Remove the set screw (Item 1) [Figure 20-20-16].

Figure 20-20-17 1

1
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P-86542

Remove the seal (Item 1) [Figure 20-20-19] from the

P-86851 piston.

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

17].

Remove the nut.

20-20-7 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-20-20 1

P-87030

Remove O-ring (Item 1) [Figure 20-20-22] from the

P-87032 piston.

Figure 20-20-23
Remove the wear ring (Item 1) [Figure 20-20-20] from
the piston.
1
Figure 20-20-21

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P-87029

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

P-87031 the piston.

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

20-20-8 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-20-24 1

P-87011

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

P-87028 the piston.

Figure 20-20-27
Remove the seal (Item 1) [Figure 20-20-24] from the
piston.

Figure 20-20-25
1
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P-86860

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

P-86862 the rod.

Remove the O-ring (Item 1) [Figure 20-20-25] from the

piston.

20-20-9 E85 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-30

Disassembly (Cont’d)

Figure 20-20-28

1
1

P-86865

Remove the back-up ring (Item 1) [Figure 20-20-30].

P-86861
Figure 20-20-31

Remove the head (Item 1) [Figure 20-20-28] from the

rod.

Figure 20-20-29

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1

P-86866

Remove the O-ring (Item 1) [Figure 20-20-31].

P-86864

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

20-20-10 E85 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-34

Disassembly (Cont’d)

Figure 20-20-32
1

P-87754

P-86867 Remove the two seals (Item 1) [Figure 20-20-34].

Figure 20-20-35
Remove the snap ring (Item 1) [Figure 20-20-32].

Figure 20-20-33

1 1
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P-86870

P-86868
Remove the snap ring (Item 1) and bushing (Item 2)
[Figure 20-20-35].
Remove the wiper seal (Item 1) [Figure 20-20-33].
Remove the rod from the vise.

20-20-11 E85 Service Manual

CYLINDER (BOOM) (CONT’D)

Disassembly (Cont’d)

Figure 20-20-36

P-887014

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

2) [Figure 20-20-36] from the rod end.

Figure 20-20-37

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2

P-87015

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

2) [Figure 20-20-37] from the base end.

20-20-12 E85 Service Manual

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

Assembly

Use the following tools to assemble the cylinder: 1

MEL1396 - Universal Seal Expander

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

Wash the cylinder parts in clean solvent and dry with

compressed air.

Inspect the cylinder parts for wear and damage. Replace

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

Lubricate all O-ring and seals with hydraulic oil during Install the bushing (Item 1) and snap ring (Item 2)
installation. [Figure 20-20-39] into the head.

Clamp the rod end in a vise. Figure 20-20-40

Figure 20-20-38

1
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P-87754
1
P-87010
Install the two seals (Item 1) [Figure 20-20-40] into the
head.
Support the end of the rod with a block (Item 1) [Figure
20-20-38].

20-20-13 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-20-41

P-86866

Install the O-ring (Item 1) [Figure 20-20-43] onto the

P-86868 head.

Figure 20-20-44
Install the wiper seal (Item 1) [Figure 20-20-41] into the
head.

Figure 20-20-42

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1

P-86865

Install the back-up ring (Item 1) [Figure 20-20-44] onto

P-86867 the head.

Install the snap ring (Item 1) [Figure 20-20-42] into the

head.

20-20-14 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-20-45 1

1
P86860

Install the cushion ring (Item 1) [Figure 20-20-47] onto

P-86864 the rod.

Figure 20-20-48
Install the O-ring (Item 1) [Figure 20-20-45].

Figure 20-20-46 1

1
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P-87011

P-86861 Install the back-up ring (Item 1) [Figure 20-20-48] into

the piston.

Install the head (Item 1) [Figure 20-20-46] onto the rod.

20-20-15 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-20-49

1 P-87029

Install the wear ring (Item 1) [Figure 20-20-51] onto the

P-86862 piston.

Figure 20-20-52
Install the O-ring (Item 1) [Figure 20-20-49] into the
piston.

Figure 20-20-50

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1

P-87030

Figure 20-20-53
P-87028

Install the seal (Item 1) [Figure 20-20-50] onto the

piston.

P-87031

Install the O-ring (Item 1) [Figure 20-20-52] and seal

(Item 2) [Figure 20-20-53] onto the piston.

20-20-16 E85 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-56

Assembly (Cont’d)

Figure 20-20-54

1
P-86853

Install the piston (Item 1) [Figure 20-20-56] onto the rod.

P-87032
Tighten the piston to 662 - 810 N•m (488 - 597 ft-lb)
torque.
Install the wear ring (Item 1) [Figure 20-20-54] onto the
piston. Figure 20-20-57

Figure 20-20-55
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2
P-86851

P-87033
Install the nut (Item 1) [Figure 20-20-57].

Install the seal (Item 1) [Figure 20-20-55] onto the Tighten the nut to 1151 - 1407 N•m (849 - 1038 ft-lb)
piston. torque.

Apply Loctite® 242 to the set screw and install the screw
(Item 2) [Figure 20-20-57].

Tighten the set screw to 14,7 N•m (10.8 ft-lb) torque.

20-20-17 E85 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-60

Assembly (Cont’d)

Figure 20-20-58

1
P-87077

Install the rod assembly (Item 1) [Figure 20-20-60] into

P-86850 the cylinder housing.

Figure 20-20-61
Use a center punch to deform the threads (Item 1)
[Figure 20-20-58] of the set screw bore. 2
Remove the rod end from the vise.

Figure 20-20-59 1

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2
P-86849

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

1 Apply Loctite® 242 to the bolts and install the bolts (Item
P-87013 2) [Figure 20-20-61].

Tighten the bolts to 275 - 314 N•m (203 - 232 ft-lb)

Support the housing with a block (Item 1) [Figure 20-20- torque.
59].

20-20-18 E85 Service Manual

CYLINDER (BOOM) (CONT’D)

Assembly (Cont’d)

Figure 20-20-62

1
2

P-87014

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

20-62] into both sides of the rod end of the cylinder.

Figure 20-20-63
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1
2

P-36183

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

20-63] into both sides of the base end of the cylinder.

20-20-19 E85 Service Manual

20-20-20
E85 Service Manual
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CYLINDER (ARM) Figure 20-21-3

Testing
3
Lower the work group to the ground.
2 1
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.

Figure 20-21-1

P131409

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

21-3].

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

Start the engine and fully retract the cylinder rod.

P131313

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

WARNING
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21-1].
Hydraulic fluid escaping under pressure can have
Figure 20-21-2 sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
1 and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290

P131408

Support the arm cylinder (Item 1) on a wood block (Item

2) [Figure 20-21-2].

20-21-1 E85 Service Manual

CYLINDER (ARM) (CONT’D)

Testing (Cont’d)

Figure 20-21-4

P131410

Remove the hose (Item 1) [Figure 20-21-4] from the

base end of the cylinder.

Install a plug on the tubeline (Item 2) [Figure 20-21-4].

Start the engine and retract the cylinder.

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If there is any leakage from the base end hose (Item 1)
[Figure 20-21-4], remove the cylinder for repair or
replacement.

20-21-2 E85 Service Manual

CYLINDER (ARM) (CONT’D) Support the arm cylinder (Item 1) on a wood block (Item
2) [Figure 20-21-6].
Removal And Installation
Figure 20-21-7
NOTE: Dealer disassembly of the component(s)
shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
3
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check 2
1
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Lower the work group to the ground.

With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.
P131409
Figure 20-21-5

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

21-7].

Remove the rod end pin (Item 3) [Figure 20-21-7].

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,
P131313 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Support the boom with a chain hoist (Item 1) [Figure 20-
21-5].
Figure 20-21-8
Figure 20-21-6

1
1

2
P131410

P131408

Remove the hoses (Item 1) [Figure 20-21-8].

20-21-3 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-11

Removal And Installation (Cont’d)

Figure 20-21-9
3 1

1 2

P131411

Remove the nuts (Item 1), bolt (Item 2), and base end
P131413 pivot pin (Item 3) [Figure 20-21-11].

Remove the cylinder.

Remove the hose (Item 1) [Figure 20-21-9].

Figure 20-21-10

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P133065

Install a sling (Item 1) [Figure 20-21-10] on both ends of

the cylinder.

20-21-4 E85 Service Manual

CYLINDER (ARM) (CONT’D)

Parts Identification

23
1. Bushing
2. Plug
3. O-ring
4. Spring Seat
5. Spring 1
6. Cushion Valve 23
7. Tube 7
8. Cushion Plunger
9. Ring Stop
10. Set Screw 6 5
11. Nut 4
3
12. Piston
13. Seal
14. Wear Ring 2
15. Seal Assembly 10
16. Back-up Ring
17. Cushion Ring
18. Snap Ring
19. Head 8
20. Bolt 9
21. Wiper
22. Rod 11
23. Dust Seal 17
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12
13
19
14 15 14
20 3 13
16
16
18 3
1

13 13
21
18 23

22

23

1 NA13720S

20-21-5 E85 Service Manual

CYLINDER (ARM) (CONT’D) Remove the rod assembly (Item 1) [Figure 20-21-13]
from the cylinder housing.
Disassembly
Remove the cylinder housing from the vise.
NOTE: Dealer disassembly of the component(s)
shown here may not be recommended under Figure 20-21-14
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
1
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Clean the outside of the cylinder before disassembly.

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

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

Clamp the base end cylinder in a vise. P-86852

Figure 20-21-12
Clamp the rod end (Item 1) [Figure 20-21-14] in a vise.
1
Support the end of the rod with a block.

Figure 20-21-15

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1

P131459

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

2
Figure 20-21-13
P131247

Remove both set screws (Item 1) and remove the nut

(Item 2) [Figure 20-21-15].
1
NOTE: It may be necessary to apply moderate heat to
the nut.

P131458

20-21-6 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-18

Disassembly (Cont’d)
1
Figure 20-21-16

P131250

1
Remove the wear ring (Item 1) [Figure 20-21-18] from
P131248 the seal.

Figure 20-21-19
Remove the piston (Item 1) [Figure 20-21-16].
1
Figure 20-21-17

2
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P131251

1 1
P131249 Remove the seal (Item 1) [Figure 20-21-19] from the
piston.

Remove the seals (Item 1) and wear rings (Item 2)

[Figure 20-21-17] from the piston.

20-21-7 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-22

Disassembly (Cont’d)
1
Figure 20-21-20

2
P131254

Remove the head (Item 1) [Figure 20-21-22] from the

P131252 rod.

Remove the rod from the vise.

Remove the O-ring (Item 1) and back-up ring (Item 2)
[Figure 20-21-20] from the piston. Figure 20-21-23

Figure 20-21-21

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1

P131255

P131253
Remove the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-21-23].
Remove the cushion ring (Item 1) [Figure 20-21-21] from
the rod.

20-21-8 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-26

Disassembly (Cont’d)

Figure 20-21-24

1 2

1
P131258

P131256 Remove the snap ring (Item 1) and bushing (Item 2)

[Figure 20-21-26].

Remove the snap ring (Item 1) and wiper seal (Item 2) Figure 20-21-27
[Figure 20-21-24].

Figure 20-21-25
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2 1

P131259
1
P131257
Remove the rod end cushion valve (Item 1) [Figure 20-
21-27] from the rod end.
Remove the wiper seal (Item 1) and two piece seal (Item
2) [Figure 20-21-25].

20-21-9 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-30

Disassembly (Cont’d)

Figure 20-21-28

1
1

P131417

Remove the O-ring (Item 1) [Figure 20-21-30] from the

P131260 plug.

Figure 20-21-31
Remove the O-ring (Item 1) and back-up ring (Item 2)
[Figure 20-21-28].

Figure 20-21-29

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1

P131418

Remove the spring seat (Item 1) [Figure 20-21-31].

P131416

Remove the plug (Item 1) [Figure 20-21-29].

20-21-10 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-34

Disassembly (Cont’d) 2

Figure 20-21-32
1

P-887014

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

P131419 (Item 2) [Figure 20-21-34] from the rod end.

Figure 20-21-35
Remove the spring (Item 1) [Figure 20-21-32].

Figure 20-21-33

1
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P-87015
1

P131420 Remove the seal (Item 1) (from both sides) and bushing
(Item 2) [Figure 20-21-35] from the base end.

Remove the base end cushion valve (Item 1) [Figure 20-

21-33].

20-21-11 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-37

Assembly

Use the following tools to assemble the cylinder: 1

MEL1396 - Universal Seal Expander

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

Wash the cylinder parts in clean solvent and dry with

compressed air.

Inspect the cylinder parts for wear and damage. Replace

any damaged parts.
P131419
Always install new O-rings and seals during assembly.

Lubricate all O-ring and seals with hydraulic oil during Install the spring (Item 1) [Figure 20-21-37].
installation.
Figure 20-21-38
Figure 20-21-36

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1

1
P131418
P131420

Install the spring seat (Item 1) [Figure 20-21-38].

Install the base end cushion valve (Item 1) [Figure 20-
21-36].

20-21-12 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-41

Assembly (Cont’d)
2
Figure 20-21-39

P131260
1

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

P131417 [Figure 20-21-41].

Figure 20-21-42
Install the O-ring (Item 1) [Figure 20-21-39] onto the
plug.

Figure 20-21-40

1
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P131259

Install the rod end cushion valve (Item 1) [Figure 20-21-

P131416 42].

Install the plug (Item 1) [Figure 20-21-40].

20-21-13 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-45

Assembly (Cont’d)

Figure 20-21-43

1
1

P131257

Install the two piece seal (Item 1) and wiper seal (Item 2)
P-86852 [Figure 20-21-45].

Figure 20-21-46
Clamp the rod end in a vise (Item 1) [Figure 20-21-43].

Support the end of the rod with a block.

Figure 20-21-44

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1 2

1
P131256
2

Install the wiper seal (Item 1) and snap ring (Item 2)

[Figure 20-21-46].
P131258

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

[Figure 20-21-44] into the head.

20-21-14 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-49

Assembly (Cont’d)

Figure 20-21-47
1

2
1
1

P131253

Install the cushion ring (Item 1) [Figure 20-21-49] on the

P131255 rod.

Figure 20-21-50
Install the O-rings (Item 1) and back-up ring (Item 2)
[Figure 20-21-47].

Figure 20-21-48
2

1
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P131252

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

P131254 [Figure 20-21-50] into the piston.

Install the head (Item 1) [Figure 20-21-48] onto the rod.

20-21-15 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-53

Assembly (Cont’d) 1

Figure 20-21-51

2 2
P131249

Install the wear rings (Item 1) and seals (Item 2) [Figure

P131251 20-21-53] on the piston.

Figure 20-21-54
Install the seal (Item 1) [Figure 20-21-51] on the piston.

Figure 20-21-52

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1
P131248

P131250 Install the piston (Item 1) [Figure 20-21-54] on the rod.

Tighten the piston to 441 - 539 N•m (325 - 398 ft-lb)

Install the wear ring (Item 1) [Figure 20-21-52] onto the torque.
piston.

20-21-16 E85 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-57

Assembly (Cont’d) 2
1
Figure 20-21-55

P131458

1
Install the rod assembly (Item 1) into the cylinder housing
P131247 (Item 2) [Figure 20-21-57].

Figure 20-21-58
Install the nut (Item 1) [Figure 20-21-55] and tighten to
728 - 842 N•m (537 - 621 ft-lb) torque.
2
Apply thread lock (Loctite® 242) on the set screws. Install
the set screws (Item 2) [Figure 20-21-55] and tighten to
13,5 - 16,5 N•m (10 - 12 ft-lb) torque.
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Figure 20-21-56

P131459

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

Apply thread lock (Loctite® 242) to the bolt threads.

Install the bolts (Item 2) [Figure 20-21-58] and tighten to
2 177 - 196 N•m (131 - 144 ft-lb) torque.
P-87013

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

[Figure 20-21-56] in a vise.

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

56].

20-21-17 E85 Service Manual

CYLINDER (ARM) (CONT’D)

Assembly (Cont’d)

Figure 20-21-59

1
2

P-87014

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

21-59] into both sides of the rod end of the cylinder.

Figure 20-21-60

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2
1

P-87015

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

21-60] into both sides of the base end of the cylinder.

20-21-18 E85 Service Manual

CYLINDER (BOOM SWING) Figure 20-22-3

Testing

Lower the work group to the ground. 1

Remove the floor mat and floorplate. (See Removal And

Installation on Page 40-100-1.)

Remove the tool box. (See Removal And Installation on

Page 40-210-1.)

Figure 20-22-1

P133061

Remove the hose (Item 1) [Figure 20-22-3] from the

base end of the cylinder.
1

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
P131628
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
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Place a block (Item 1) [Figure 20-22-1] under the rod physician familiar with this injury is not received
end of the boom swing cylinder. immediately.
W-2145-0290
Figure 20-22-2
Install a cap on the hose and tighten.
2
Start the engine and retract the cylinder.

If there is any oil leakage from the base end fitting on the
boom swing cylinder, remove the cylinder for repair or
replacement.

1
P131629

Remove the snap ring (Item 1) [Figure 20-22-2] and

washer from the rod end pin of the cylinder.

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

Start the engine and fully retract the cylinder rod.

Stop the engine.

20-22-1 E85 Service Manual

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

Removal And Installation

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under 2
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Position the machine so the pin can be removed from the

bottom. 1
P131629
Lower the work group to the ground.

Remove the floor mat and floorplate. (See Removal And Remove the snap ring (Item 1) [Figure 20-22-5] and
Installation on Page 40-100-1.) washer from the rod end pin of the cylinder.

Remove the tool box. (See Removal And Installation on Remove the pin (Item 2) [Figure 20-22-5].
Page 40-210-1.)
Figure 20-22-6
Figure 20-22-4

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1

P131630
P131628

Remove the hose (Item 1) [Figure 20-22-6] from the

Place a block (Item 1) [Figure 20-22-4] under the rod base end of the cylinder.
end of the boom swing cylinder.

20-22-2 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D)

Removal And Installation (Cont’d)

Figure 20-22-7

2
4

P131631

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

22-7].

Remove the pin (Item 3) [Figure 20-22-7] from the base

of the cylinder.

Slide the cylinder forward and remove the grease fitting

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hose (Item 4) [Figure 20-22-7].

Figure 20-22-8

P133061

Remove the hose (Item 1) [Figure 20-22-8]

Remove the cylinder.

20-22-3 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D)

Parts Identification

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

2
2
4
2 5
12
6

7
8

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9

10

5
7
5
7

13

11

NA13725S

20-22-4 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D) Insert the Adjustable Gland Nut Wrench into the two
holes (Item 1) [Figure 20-22-10] to loosen the head.
Disassembly
Figure 20-22-11
NOTE: Dealer disassembly of the component(s)
shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found 1
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.
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 2
P131617
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
Remove the head and the rod assembly from the cylinder
Put the base end of the cylinder in a vise. [Figure 20-22-11]. Put the rod end in a vise.
Figure 20-22-9
Remove the nut (Item 1), piston (Item 2), [Figure 20-22-
11] and head.

Figure 20-22-12

1
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P-98817

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

P131618
Figure 20-22-10
Remove the seal (Item 1) [Figure 20-22-12] from the
piston.

1
P-91893

20-22-5 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-22-13

1 2
2

P-81039

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

N-22356 15].

Figure 20-22-16
Remove the O-ring (Item 1) and back-up ring (Item 2)
[Figure 20-22-13].

Remove the O-ring (Item 3) [Figure 20-22-13]. 1

2
Figure 20-22-14

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3

P-53073

Remove the dust seals (Item 1) and bushing (Item 2)

[Figure 20-22-16].

N-22357

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

from the inside of the head (Item 3) [Figure 20-22-14].

20-22-6 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D) Figure 20-22-18

Assembly

Clean all parts in solvent and dry with compressed air.

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.

Use the following tools to assemble the cylinder:

1
MEL1396-1 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool P131618
MEL1396-2 - Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins Install the seal (Item 1) [Figure 20-22-18].

Figure 20-22-17 Figure 20-22-19

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P-7424 N-22358

Install the new seal on the tool and slowly stretch it until it Use a ring compressor to compress the seal to the
fits the piston [Figure 20-22-17]. correct size. Leave the piston in the compressor for about
three minutes [Figure 20-22-19].
Allow the seal to stretch for 30 seconds before installing it
on the piston.

20-22-7 E85 Service Manual

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

Assembly (Cont’d)

Figure 20-22-20

N-22359

Install the wiper seal with the wiper (Item 1) [Figure 20-
P-7427 22-22] toward the outside of the head.

Figure 20-22-23
Install the rod seal on the rod seal tool [Figure 20-22-20].

NOTE: During installation the spring side of the seal

must be toward the inside of the cylinder.

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

22-20].

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Figure 20-22-21

1
3 2 N-22356

Install the O-ring (Item 1) [Figure 20-22-23].

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

[Figure 20-22-23].

P-7425

Install the rod seal in the head [Figure 20-22-21].

20-22-8 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D) Tighten the plug to 50 N•m (37 ft-lb) torque.

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

Figure 20-22-24 Figure 20-22-26

2
1

1
P131617 P-91893

Install the head and the piston (Item 1) [Figure 20-22-24] Tighten the head (Item 1) [Figure 20-22-26] to 373 N•m
on the rod as shown. (275 ft-lb) torque.

NOTE: Clean and dry the rod threads. Install a NEW Figure 20-22-27
NUT with preapplied Loctite®.

Grease the piston where the nut contacts the piston. Do

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not get grease on the threads.

2
1
Provide an adequate support for the cylinder before
tightening.

Install the nut (Item 2) [Figure 20-22-24].

Tighten the nut to 2034 N•m (1500 ft-lb) torque.

Figure 20-22-25

P-53073

Install the bushing (Item 1) [Figure 20-22-27]. The

bushing must be aligned with the grease channel in the
rod end of the cylinder.

Install the dust seal (Item 2) [Figure 20-22-27] on both

sides of the rod end.
2

P-81039

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

25].

20-22-9 E85 Service Manual

CYLINDER (BOOM SWING) (CONT'D)

Assembly (Cont’d)

Figure 20-22-28

P-98817

Install the bolt (Item 1) [Figure 20-22-28].

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20-22-10 E85 Service Manual

CYLINDER (BUCKET) Removal And Installation

Testing NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Fully retract the bucket and arm cylinders. Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
Lower the boom to the ground. or by clicking here. Please click here to check
the list of affected part numbers in IRW before
With the engine off and the key in the run position, move proceeding. This only affects machines sold
the joysticks to relieve hydraulic pressure. in the US and Canada.

Figure 20-23-1 Fully retract the bucket cylinder.

Lower the boom until the bucket is on the ground.

Figure 20-23-2
1

P131619
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Remove the hydraulic hose (Item 1) [Figure 20-23-1]

from the base end of the bucket cylinder. P-87021

Install a plug on the hose.

Support the arm with a chain hoist (Item 1) [Figure 20-
Start the engine and retract the bucket cylinder. 23-2].

If there is any oil leakage from the base end fitting on the With the engine off and the key in the run position, move
bucket cylinder, remove the cylinder for repair or the joysticks to relieve hydraulic pressure.
replacement.

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

20-23-1 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-5

Removal And Installation (Cont’d)

2
Figure 20-23-3

P133045
2

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

P131619 23-5] from the base end pivot pin.

Figure 20-23-6
Remove the hose (Item 1) [Figure 20-23-3] from the
base end.

Remove the hose (Item 2) [Figure 20-23-3] from the rod 2

end.

Figure 20-23-4

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3

1
1
P131620

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

23-6] from the rod end pivot pin.

Remove the pivot pin (Item 3) [Figure 20-23-6].

P133046

Install a strap (Item 1) [Figure 20-23-4] and a lifting

device on the cylinder.

20-23-2 E85 Service Manual

CYLINDER (BUCKET) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-23-7

P133046

Remove the base end pivot pin (Item 1) [Figure 20-23-7]

and remove the cylinder.
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20-23-3 E85 Service Manual

CYLINDER (BUCKET) (CONT’D)

Parts Identification

1. Bushing
2. Tube
3. Set Screw
4. Nut 18
5. Piston
6. Seal
7. Wear Ring 1
8. Seal Assembly
9. Back-up Ring 2 18
10. O-ring
11. Snap Ring
12. Bushing
13. Head
14. Bolt
15. Wiper
16. Rod
3
17. Cushion Ring
18. Dust Seal

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6
13 7
8
7
10 6
17 9
14
9
15 10
11
12

6
6

11
18
16

18

1
 NA13722S

20-23-4 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Remove the bolts (Item 1) [Figure 20-23-9].

Disassembly Figure 20-23-10

NOTE: Dealer disassembly of the component(s)
shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

1
Hold the hydraulic cylinder over a drain pan and slowly
move the rod in and out to remove the fluid from the
P-87077
cylinder.

Clamp the base end of the cylinder in a vise.

Remove the rod assembly (Item 1) [Figure 20-23-10]
Figure 20-23-8 from the cylinder housing.

Remove the cylinder housing from the vise.

Figure 20-23-11

1
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1
P-86848

Support the cylinder with a block (Item 1) [Figure 20-23-

8].
P-86852
Figure 20-23-9
Clamp the rod end (Item 1) [Figure 20-23-11] in a vise.
1 Support the end of the rod with a block.

1
P-86849

20-23-5 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-23-12 1

P-86853

Remove the piston (Item 1) [Figure 20-23-14].

P-86850
Figure 20-23-15

Remove the set screw (Item 1) [Figure 20-23-12].

Figure 20-23-13
1

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P-86542

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

P-86851 piston.

Apply moderate heat to the nut (Item 1) [Figure 20-23-

13].

Remove the nut.

Photos may appear different but the procedure is the

same.

20-23-6 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-23-16

P-87030

Remove the O-ring (Item 1) [Figure 20-23-18] from the

P-87032 piston.

Figure 20-23-19
Remove the wear ring (Item 1) [Figure 20-23-16] from
the piston.

Figure 20-23-17
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P-87029

Remove the wear ring (Item 1) [Figure 20-23-19] from

P-87031 the piston.

Remove the seal (Item 1) [Figure 20-23-17].

20-23-7 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-23-20 1

P-87011

Remove the back-up ring (Item 1) [Figure 20-23-22] from

P-87028 the piston.

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

Figure 20-23-21
1

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1

P-86860

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

P-86862 the rod.

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

piston.

20-23-8 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-23-24

1
1

P-86865

Remove the back-up ring (Item 1) [Figure 20-23-26].

P-86861
Figure 20-23-27

Remove the head (Item 1) [Figure 20-23-24] from the

rod.

Figure 20-23-25

1
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P-86866

Remove the O-ring (Item 1) [Figure 20-23-27].

P-86864 Figure 20-23-28

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

P-86867

Remove the snap ring (Item 1) [Figure 20-23-28].

20-23-9 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-31

Disassembly (Cont’d)

Figure 20-23-29 2

1 1

P-86870

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

[Figure 20-23-31].

Remove the wiper seal (Item 1) [Figure 20-23-29]. Remove the rod from the vise.

Figure 20-23-30 Figure 20-23-32

1 1

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2
1

P-87754 P-887014

Remove the two seals (Item 1) [Figure 20-23-30]. Remove the seal (Item 1) (both sides) and bushing (Item
2) [Figure 20-23-32] from the rod end.

20-23-10 E85 Service Manual

CYLINDER (BUCKET) (CONT’D)

Disassembly (Cont’d)

Figure 20-23-33

2
1

P-87015

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

2) [Figure 20-23-33] from the base end.
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20-23-11 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-35

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander

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

Wash the cylinder parts in clean solvent and dry with

compressed air.

Inspect the cylinder parts for wear and damage. Replace

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

Lubricate all O-rings and seals with hydraulic oil during Install the bushing (Item 1) and snap ring (Item 2)
installation. [Figure 20-23-35] into the head.

Clamp the rod end in a vise. Figure 20-23-36

Figure 20-23-34

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1

P-87754
1
P-87010
Install the two seals (Item 1) [Figure 20-23-36] into the
head.
Support the end of the rod with a block (Item 1) [Figure
20-23-34].

20-23-12 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-39

Assembly (Cont’d)

Figure 20-23-37

P-86866

Install the O-ring (Item 1) [Figure 20-23-39] onto the

P-86868 head.

Figure 20-23-40
Install the wiper seal (Item 1) [Figure 20-23-37] into the
head.

Figure 20-23-38
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P-86865

Install the back-up ring (Item 1) [Figure 20-23-40] onto

P-86867 the head.

Install the snap ring (Item 1) [Figure 20-23-38] into the

head.

20-23-13 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-43

Assembly (Cont’d)

Figure 20-23-41 1

1
P86860

Install the cushion ring (Item 1) [Figure 20-23-43] on the

P-86864 rod.

Figure 20-23-44
Install the O-ring (Item 1) [Figure 20-23-41].

Figure 20-23-42 1

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P-87011

P-86861 Install the back-up ring (Item 1) [Figure 20-23-44] in the

piston.

Install the head (Item 1) [Figure 20-23-42] onto the rod.

20-23-14 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-47

Assembly (Cont’d)

Figure 20-23-45

1
1

P-87029

Install the wear ring (Item 1) [Figure 20-23-47] onto the

P-86862 piston.

Figure 20-23-48
Install the O-ring (Item 1) [Figure 20-23-45] into the
piston.

Figure 20-23-46

1
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P-87030

Figure 20-23-49
P-87028

Install the seal (Item 1) [Figure 20-23-46] onto the

piston.

P-87031

Install the O-ring (Item 1) [Figure 20-23-48] and seal

(Item 1) [Figure 20-23-49] onto the piston.

20-23-15 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-52

Assembly (Cont’d)

Figure 20-23-50

1
P-86853

Install the piston (Item 1) [Figure 20-23-52] onto the rod.

P-87032
Tighten the piston to 441 - 539 N•m (325 - 398 ft-lb)
torque.
Install the wear ring (Item 1) [Figure 20-23-50] onto the
piston. Figure 20-23-53

Figure 20-23-51

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1

P-86851

P-87033
Install the nut (Item 1) [Figure 20-23-53].

Install the seal (Item 1) [Figure 20-23-51] onto the Tighten the nut to 662 - 810 N•m (488 - 597 ft-lb) torque.
piston.
Apply Loctite® 242 to the set screw. Install the set screw
(Item 2) [Figure 20-23-53] and tighten to 15 N•m (11 ft-
lb) torque.

20-23-16 E85 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-56

Assembly (Cont’d)

Figure 20-23-54

1
P-87077

Install the rod assembly (Item 1) [Figure 20-23-56] into

P-86850 the cylinder housing.

Figure 20-23-57
Use a center punch to deform the threads (Item 1)
[Figure 20-23-54] of the set screw bore. 2
Remove the rod end from the vise.
1
Figure 20-23-55

2
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2
P-86849

Install the head (Item 1) [Figure 20-23-57].

1 Apply Loctite® 242 to the bolt threads. Install the bolts

P-87013 (Item 2) [Figure 20-23-57] and tighten to 177 - 196 N•m
(131 - 145 ft-lb) torque.

Support the housing with a block (Item 1) [Figure 20-23-

55].

20-23-17 E85 Service Manual

CYLINDER (BUCKET) (CONT’D)

Assembly (Cont’d)

Figure 20-23-58

P-87014

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

23-58] (both sides) into the rod end of the cylinder.

Figure 20-23-59

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1
2

P-36183

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

23-59] (both sides) into the base end of the cylinder.

20-23-18 E85 Service Manual

CYLINDER (BLADE) Figure 20-24-2

Testing

Lower the work group and blade to the ground.

Stop the engine.

1
With the engine off and the key in the run position, move
the blade lever to relieve hydraulic pressure.

Figure 20-24-1

P131624
2

Remove the hydraulic hose (Item 1) [Figure 20-24-2]

from the base end of the blade cylinders.

3 Install a plug on the hose.

1
Start the engine and retract the blade cylinders.

If there is any oil leakage from the base end fitting of the
P131623 blade cylinders, remove the cylinder for repair or
replacement.
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Remove the nuts (Item 1), bolt (Item 2), and pin (Item 3)
[Figure 20-24-1] from both blade cylinders.

Start the engine and retract the blade cylinders.

20-24-1 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-4

Removal And Installation

NOTE: Dealer disassembly of the component(s)

2
shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold 3
in the US and Canada. 1
NOTE: The left blade cylinder is shown. The
procedure is the same for the right blade
cylinder.
P131623

Lower the work group and blade to the floor.

Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-
With the engine off and the key in the RUN position, 24-4] from the rod end pivot pin.
move the blade lever to relieve hydraulic pressure.
Remove the pivot pin (Item 3) [Figure 20-24-4].

Figure 20-24-5
IMPORTANT
When repairing hydrostatic and hydraulic systems, 2
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
damage the system. 3
I-2003-0888

Figure 20-24-3
1

P133047

1
Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-
24-5] from the base end pivot pin.

Remove the pivot pin (Item 3) [Figure 20-24-5].

Remove the cylinder.

2
P131624

Remove the hose (Item 1) [Figure 20-24-3] from the

base end of the cylinder.

Remove the hose (Item 2) [Figure 20-24-3] from the rod

end of the cylinder.

20-24-2 E85 Service Manual

CYLINDER (BLADE) (CONT'D)

Parts Identification

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

2
10
8

9
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11
12

13
14
15 12

16

17

NA13724S

20-24-3 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-7

Disassembly

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold 1
in the US and Canada.

IMPORTANT P-86501

When repairing hydrostatic and hydraulic systems,

Straighten the head lock ring (Item 1) [Figure 20-24-7].
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Figure 20-24-8
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

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

Figure 20-24-6 1

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1

P103657

Remove the head (Item 1) [Figure 20-24-8] from the

housing.

2 P-86500

Clamp the base end (Item 1) [Figure 20-24-6] of the

cylinder housing in a vise.

Install a block (Item 2) [Figure 20-24-6] to support the

cylinder.

20-24-4 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-11

Disassembly (Cont’d)

Figure 20-24-9

P-86504

Remove the set screw (Item 1) [Figure 20-24-11].

P-86503
Figure 20-24-12

Remove the rod assembly (Item 1) [Figure 20-24-9] from

the housing.
1
Figure 20-24-10
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P-86506

1
Apply moderate heat to the nut (Item 1) [Figure 20-24-
12].
P-86505
Remove the nut.

Clamp the rod end in a vise. Support the end of the rod
with a block (Item 1) [Figure 20-24-10].

20-24-5 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-24-13

P-86541

Remove the wear ring (Item 1) [Figure 20-24-15].

P-86508
Figure 20-24-16

Remove the piston (Item 1) [Figure 20-24-13].

Figure 20-24-14

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1

P-86548

Remove the back-up ring (Item 1) [Figure 20-24-16].

P-86542
NOTE: The slipper seal consists of four separate
pieces that are removed individually.
Remove the seal (Item 1) [Figure 20-24-14].

20-24-6 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-24-17

P-86532

Remove the slipper seal (Item 1) [Figure 20-24-19].

P-86508
Figure 20-24-20

Remove the wear ring (Item 1) [Figure 20-24-17].

Figure 20-24-18

1
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P-86531

Remove the seal (Item 1) [Figure 20-24-20].

P-86533

Remove the back-up ring (Item 1) [Figure 20-24-18].

20-24-7 E85 Service Manual

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

Disassembly (Cont’d)

Figure 20-24-21 1

P-86517

Remove the back-up ring (Item 1) [Figure 20-24-23].

P-86515
Figure 20-24-24

Remove the back-up ring (Item 1) [Figure 20-24-21] from

the inside of the piston.
1
Figure 20-24-22

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P-86518
1

Remove the head (Item 1) [Figure 20-24-24] from the

cylinder rod.
P-86516

Remove the O-ring (Item 1) [Figure 20-24-22].

20-24-8 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-27

Disassembly (Cont’d)

Figure 20-24-25

P-86524
1

Remove the O-ring (Item 1) [Figure 20-24-27].

P-86519
Figure 20-24-28

Remove the O-ring (Item 1) [Figure 20-24-25] from the

head.
1
Figure 20-24-26
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P-86525

Remove the snap ring (Item 1) [Figure 20-24-28] from

the inside of the head.
P-86523

Remove the back-up ring (Item 1) [Figure 20-24-26].

20-24-9 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-31

Disassembly (Cont’d)

Figure 20-24-29

P-86529

Remove the seal (Item 1) [Figure 20-24-31].

P-86508
Figure 20-24-32

Remove the wiper seal (Item 1) [Figure 20-24-29].

Figure 20-24-30
2 1

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1 P-86531

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

P-86527 [Figure 20-24-32].

Remove the seal (Item 1) [Figure 20-24-30].

20-24-10 E85 Service Manual

CYLINDER (BLADE) (CONT'D)

Disassembly (Cont’d)

Figure 20-24-33

P-86544

Remove the bushing (Item 1) [Figure 20-24-33] from the

rod.

Figure 20-24-34
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P-86533

Remove the bushing (Item 1) [Figure 20-24-34] from the

base end.

20-24-11 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-36

Assembly

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander

MEL1033 - Rod Seal Installation Tool
MEL1396-2 - Piston Ring Compressor
1
Wash the cylinder parts in clean solvent and dry with
compressed air.

Inspect the cylinder parts for wear and damage. Replace

any damaged parts.
P-86544
Always install new O-rings and seals during assembly.

Lubricate all O-rings and seals with hydraulic oil during Install the bushing (Item 1) [Figure 20-24-36] into the
assembly. rod.

Figure 20-24-35 Figure 20-24-37

2 1

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1

P-86543 P-86530

Install the bushing (Item 1) [Figure 20-24-35] into the Install the bushing (Item 1) and snap ring (Item 2)
base end of the housing. [Figure 20-24-37] into the head.

20-24-12 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-40

Assembly (Cont’d)

Figure 20-24-38

1 1

P-86526

Install the wiper seal (Item 1) [Figure 20-24-40].

P-86529
Figure 20-24-41

Install the seal (Item 1) [Figure 20-24-38].

Figure 20-24-39

1
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P-86525

Install the snap ring (Item 1) [Figure 20-24-41].

P-86527

Install the seal (Item 1) [Figure 20-24-39].

20-24-13 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-44

Assembly (Cont’d)

Figure 20-24-42

P-86519

Install the O-ring (Item 1) [Figure 20-24-44].

P-8624
Install the rod end in a vise.

Install the O-ring (Item 1) [Figure 20-24-42]. Figure 20-24-45

Figure 20-24-43

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1

P-86518

P-86523
Install the head (Item 1) [Figure 20-24-45] onto the
cylinder rod.
Install the back-up ring (Item 1) [Figure 20-24-43].

20-24-14 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-48

Assembly (Cont’d)

Figure 20-24-46
1

P-86515

Install the back-up ring (Item 1) [Figure 20-24-48].

P-86517
Figure 20-24-49

Install the back-up ring (Item 1) [Figure 20-24-46].

Figure 20-24-47

1
1
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P-86531

Install the seal (Item 1) [Figure 20-24-49].

P-86516

Install the O-ring (Item 1) [Figure 20-24-47].

20-24-15 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-52

Assembly (Cont’d)

Figure 20-24-50
1

P-86540

Install the wear ring (Item 1) [Figure 20-24-52].

P-86532
Figure 20-24-53

Install the slipper seal (Item 1) [Figure 20-24-50].

Figure 20-24-51

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1

P-86548

Install the back-up ring (Item 1) [Figure 20-24-53].

P-86533

Install the back-up ring (Item 1) [Figure 20-24-51].

20-24-16 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-56

Assembly (Cont’d)

Figure 20-24-54

P-86507

Install the piston (Item 1) [Figure 20-24-56] onto the

P-86541 cylinder rod.

Tighten the piston to 441 - 539 N•m (325 - 398 ft-lb)

Install the wear ring (Item 1) [Figure 20-24-54]. torque.

Figure 20-24-55 Figure 20-24-57

2
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P-86542 P-86506

Install the seal (Item 1) [Figure 20-24-55]. Install the nut (Item 1) [Figure 20-24-57].

Tighten the nut to 662 - 808 N•m (488 - 596 ft-lb) torque.

Apply Loctite® 242 to the threads of the set screw. Install

the set screw (Item 2) [Figure 20-24-57] and tighten to
15 N•m (11 ft-lb) torque.

20-24-17 E85 Service Manual

CYLINDER (BLADE) (CONT'D) Figure 20-24-60

Assembly (Cont’d)

Figure 20-24-58

P103657

Install the head (Item 1) [Figure 20-24-60] onto the

P-86504 housing.

Tighten the head to 661 - 809 N•m (488 - 597 ft-lb)

Use a center punch to deform the threads (Item 1) torque.
[Figure 20-24-58] of the set screw bore.
Figure 20-24-61
Remove the rod assembly from the vise.

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

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Figure 20-24-59

1
1

P-86501

Bend the lock ring tab (Item 1) [Figure 20-24-61] into the
groove on the head.
P-86503

Install the rod assembly (Item 1) [Figure 20-24-59] into

the housing.

20-24-18 E85 Service Manual

CYLINDER (CLAMP) Figure 20-25-3

Testing

Start the engine and close the clamp.

Stop the engine.

Figure 20-25-1

P133048

Disconnect the hydraulic hose (Item 1) [Figure 20-25-3]

from the base end of the cylinder.
1
Plug the hose.

P131632 Start the engine and retract the cylinder.

If there is any oil leakage from the base end fitting on the
Remove the snap ring (Item 1) [Figure 20-25-1] and cylinder, remove the cylinder for repair or replacement.
washer from the clamp cylinder pin.
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Figure 20-25-2

P131636

Remove the pin (Item 1) [Figure 20-25-2] from the rod

end of the clamp cylinder.

20-25-1 E85 Service Manual

CYLINDER (CLAMP) (CONT'D) Figure 20-25-6

Removal And Installation

Start the engine and close the clamp.

Stop the engine. 1

Figure 20-25-4

P133049

Disconnect the quick couplers (Item 1) [Figure 20-25-6].

1 Figure 20-25-7

P131632

Remove the snap rings (Item 1) [Figure 20-25-4] and

1 2
washers.

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Figure 20-25-5

P133050

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

25-7].

1 Remove the pin (Item 3) [Figure 20-25-7] and remove

the cylinder.

P131636

Remove the pin (Item 1) [Figure 20-25-5].

Start the engine and retract the cylinder.

Stop the engine.

20-25-2 E85 Service Manual

CYLINDER (CLAMP) (CONT'D)

Parts Identification

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

1
5

3
4
3 4

6
7
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4
9
10
11
4
12
13

14

2
1

NA14369S

20-25-3 E85 Service Manual

CYLINDER (CLAMP) (CONT'D) Figure 20-25-9

Disassembly

NOTE: The drawings may appear different. The

procedure is the same.

Clean the outside of the cylinder before disassembly.

The following tools will be needed to disassemble and

assemble the cylinders:

MEL1075 - Adjustable Gland Nut Wrench

MEL1074 - O-ring Seal Hook
MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool B-7001

Put the base end of the hydraulic cylinder in a drain pan.

Remove the rod assembly from the cylinder housing
Move the rod in and out to remove the fluid from the [Figure 20-25-9].
cylinder. Move the rod slowly so the fluid will go directly
into the drain pan. Remove the cylinder housing from the vise.

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

Figure 20-25-8 Figure 20-25-10

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B-7000 B-13816

Use the Adjustable Gland Nut Wrench to loosen the head Loosen the nut from the piston end of the rod [Figure 20-
[Figure 20-25-8]. 25-10].

20-25-4 E85 Service Manual

CYLINDER (CLAMP) (CONT'D) Figure 20-25-13

Disassembly (Cont'd)

Figure 20-25-11

1 2

B-7005

Remove the wiper seal [Figure 20-25-13].

B-13817
Figure 20-25-14

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

20-25-11].

Figure 20-25-12
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1
2

3
B-7006

Remove the oil seal from the head [Figure 20-25-14].

B-13743

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

[Figure 20-25-12] or seal from the head.

Remove the O-ring (Item 3) [Figure 20-25-12].

NOTE: The seal kit may contain the O-ring / back-up

ring or seal.

20-25-5 E85 Service Manual

CYLINDER (CLAMP) (CONT'D)

Disassembly (Cont'd)

Figure 20-25-15

B-3689

Cut the old Teflon™ seal and remove the seal from the
piston [Figure 20-25-15].

Figure 20-25-16

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B-3703

Remove the O-ring from the piston [Figure 20-25-16].

20-25-6 E85 Service Manual

CYLINDER (CLAMP) (CONT'D) Figure 20-25-19

Assembly

Clean all parts in solvent and dry with compressed air.

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.

Figure 20-25-17

B-12813

Install the seal on the piston [Figure 20-25-19].

Figure 20-25-20

B-12812
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Install the O-ring on the piston [Figure 20-25-17].

NOTE: Do not overstretch the seal.

Figure 20-25-18
B-12811

Use a ring compressor to compress the seal to the

correct size [Figure 20-25-20].

Leave the piston in the ring compressor for three

minutes.

B-12809

Install the seal on the tool and stretch it until it fits the
piston [Figure 20-25-18].

Allow the seal to stretch for 30 seconds before removing

it from the tool.

20-25-7 E85 Service Manual

CYLINDER (CLAMP) (CONT'D) Figure 20-25-23

Assembly (Cont'd)

Figure 20-25-21

O-ring 
B-3682
Side

Install the wiper seal with the lip toward the outside of the
B-3702 head [Figure 20-25-23].

Figure 20-25-24
Install the oil seal on the rod seal tool [Figure 20-25-21].

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

Figure 20-25-22
1

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B-7008

Install the O-ring (Item 1) [Figure 20-25-24] on the head.

B-3671

Install the oil seal in the head [Figure 20-25-22].

20-25-8 E85 Service Manual

CYLINDER (CLAMP) (CONT'D) Figure 20-25-27

Assembly (Cont'd)

Figure 20-25-25

1
1
B-7002

Tighten the nut (Item 1) [Figure 20-25-27] to 1491 N•m

B-13743 (1100 ft-lb) torque.

Inspect the inside of the cylinder housing for nicks and

Install the back-up ring (Item 1) and O-ring (Item 2) scratches. If the cylinder housing has minor scuffing the
[Figure 20-25-25] on the head. cylinder housing can be honed. Use a flexible hone and
lubricate with oil during the honing process.
Apply grease to the inside of the head and to the lips of
the seals. The following hones can be ordered from OTC Service
Tools:
Figure 20-25-26
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MEL1418 - 2 in
OEM6275 - 2 3/4 in - 3 in
2
OEM6270 - 3 in - 3 1/2 in
OEM6271 - 3 1/2 in - 4 in

Thoroughly wash the inside of the housing after the

honing process.

Figure 20-25-28

B-7198

Inspect the beveled edge of the rod for nicks or sharp

edges (Item 1) [Figure 20-25-26]. Remove these with a
file prior to installing the head on the rod or damage to
the seals may occur.

Install the head (Item 2) [Figure 20-25-26] on the rod.

B-7013
Install the piston (Item 3) [Figure 20-25-26] on the rod.

Clean and dry the cylinder rod threads. Grease the Apply oil to the seal surface of the housing [Figure 20-
shoulder of the cylinder rod. 25-28].

20-25-9 E85 Service Manual

CYLINDER (CLAMP) (CONT'D) Figure 20-25-31

Assembly (Cont'd)

Figure 20-25-29

B-7014

Apply oil to the seals on the head [Figure 20-25-31].

B-7012
Apply oil to the threads of the head.

Apply oil to the Teflon™ seal on the piston [Figure 20-25- Figure 20-25-32
29].

Figure 20-25-30

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B-7000

B-7001 Tighten the head to 373 N•m (275 ft-lb) torque [Figure
20-25-32].

Install the rod assembly in the housing [Figure 20-25- Move rod in and out of cylinder housing and make sure
30]. that it moves freely.

20-25-10 E85 Service Manual

VALVE (MAIN RELIEF)

Testing And Adjusting

The E85 excavator does not have a main relief valve,

which can be removed or adjusted. The system pressure
is regulated by several components within the hydraulic
system. For pressure adjustment, go to the Hydraulic
Pump. (See HYDRAULIC PUMP on Page 20-50-1.)
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20-30-1 E85 Service Manual

20-30-2
E85 Service Manual
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VALVE (PORT RELIEF) Figure 20-31-1

Testing And Adjusting Port Relief Valve Pressure 4

1 2 3 5 6

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.
1 2 3 4 5 6
I-2003-0888

P129829
When testing the port relief valves with a hydraulic hand
pump, slowly pressurize the valve. If the hand pump is
pumped fast, the pressure will be altered by as much as Boom Swing Port Relief set at:
345 kPa (3,5 bar) (50 psi). Base end and rod end (Item 1) [Figure 20-31-1]
38000 kPa (380 bar) (5511 psi).
When testing port relief valves with a hydraulic hand
pump, valve crack pressure should be observed. Blade Port Relief set at:
Base end and rod end (Item 2) [Figure 20-31-1]
A portable hydraulic hand pump will be used to test the 38000 kPa (380 bar) (5511 psi).
work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with Bobcat hydraulic Boom Port Relief set at:
fluid. Base end and rod end (Item 3) [Figure 20-31-1]
34000 kPa (340 bar) (4931 psi).
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Auxiliary Port Relief set at:

Male and female quick coupler (Item 4) [Figure 20-
31-1] 21000 kPa (210 bar) (3045 psi).

Arm Port Relief set at:

Base and rod end (Item 5) [Figure 20-31-1] 34000
kPa (340 bar) (4931 psi).

Bucket Port Relief set at:

Base and rod end (Item 6) [Figure 20-31-1] 34000
kPa (340 bar) (4931 psi).

20-31-1 E85 Service Manual

VALVE (PORT RELIEF) (CONT’D) Figure 20-31-3

Testing And Adjusting Port Relief Valve Pressure

(Cont’d)

Figure 20-31-2

P131650

The port relief valve is not adjustable. If the correct

pressure can not be obtained, remove the port relief
P131649 valve (Item 1) [Figure 20-31-3].

Figure 20-31-4
Install the hand pump hose and a 34474 kPa (345 bar)
(5000 psi) pressure gauge 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

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the port relief valve opens and make a note of the
pressure reading.

IMPORTANT 1

This notice identifies procedures which must be

P131651
followed to avoid damage to the machine.
I-2019-0284
Inspect the relief valve (Item 1) [Figure 20-31-4] to verify
no damage. If damaged replace the relief valve
assembly.

Reinstall the relief valve in the valve section.

Repeat the test procedure.

If the correct pressure could not be achieved, replaced

the relief valve.

20-31-2 E85 Service Manual

VALVE (CROSS PORT RELIEF) TEST CONDITIONS

Testing And Adjusting 1. Engine High Idle Speed

The following tools will be needed for the testing at the 2. Warm oil over relief function to minimum 66°C
diagnostic coupler: (150°F). Cycle all functions during warm up
procedure.
MEL1355 - Test Kit includes the following: Warm oil until the pressure build-up valve stabilizes
MEL1355-3 - 34474 kPa (345 bar) (5000 psi) Gauge near its target pressure.
MEL1355-12 - Coupler
MEL1355-9 - Thermometer 3. Activate function until cylinder movement stops. Hold
over relief for 5 - 10 seconds.
System Pressures At Gauge Port Specifications Record pressure.

 FUNCTION CIRCUIT TEST PORT TARGET ACCEPTABLE

SYSTEM CHECK TO ENGAGE PRESSURIZED (psi) RANGE (psi)
JOYSTICK PILOT PRESSURE ANY JOYSTICK JOYSTICK PILOT MANIFOLD 428 406 - 450
FUNCTION JP3
SYSTEM STANDBY PRESSURE NONE - CONSOLE THROUGH MANIFOLD 410 363 - 460
DOWN NEUTRAL P
SYSTEM RELIEF PRESSURE ANY EXCEPT SLEW P1 MANIFOLD 3710 3610 - 3760
AND AUXILIARY P
SWING MOTOR - CROSS PORT SLEW RIGHT P1 MANIFOLD 3495 3423 - 3626
RELIEF P 3129
SWING MOTOR - CROSS PORT SLEW LEFT P1 MANIFOLD 3495 3423 - 3626
RELIEF P 3129
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Open the right side cover. (See Opening And Closing on

Page 10-60-1.)

20-32-1 E85 Service Manual

VALVE (CROSS PORT RELIEF) (CONT’D) Figure 20-32-3

Testing And Adjusting (Cont’d)

Figure 20-32-1

1
1

P133063

Install plug (Item 1) [Figure 20-32-3] on the hose.

P131402
Lower the control console and fasten the seat belt.

Connect the test gauge coupler and 34474 kPa (345 bar) Start the engine and run at full rpm until hydraulic fluid is
(5000 psi) gauge from the test kit to the P diagnostic at operating temperatures 66°C (150°F).
coupler (Item 1) [Figure 20-32-1].
Engage the upperstructure slew right function. Record
Remove the floor mat and floorplate. (See Removal And the pressure on the gauge.
Installation on Page 40-100-1.)
Engage the upperstructure slew left function. Record the

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Figure 20-32-2 pressure on the gauge.

The crossport relief valve pressure should be as follows:

1 A target pressure of 24097 kPa (241 bar) (3495 psi) with

an acceptable range of 23601 - 25000 kPa (236 - 250
bar) (3423 - 3626 psi).

Stop the engine.

P131953

Disconnect the hose (Item 1) [Figure 20-32-2] from the

swing motor.

20-32-2 E85 Service Manual

VALVE (CROSS PORT RELIEF) (CONT’D)

Testing And Adjusting (Cont’d)

Figure 20-32-4

P133062

The cross port relief valves (Item 1) [Figure 20-32-4] are

located on the swing motor.

Figure 20-32-5
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P-87591

NOTE: Swing motor is removed for photo clarity.

To adjust the relief valve, loosen the nut (Item 1) [Figure

20-32-5].

Turn the adjustment screw (Item 2) [Figure 20-32-5]

clockwise to increase the pressure or counterclockwise
to decrease the pressure

NOTE: 1/2 turn is approximately 1724 kPa (17,2 bar)

(250 psi).

20-32-3 E85 Service Manual

VALVE (CROSS PORT RELIEF) (CONT’D)

Removal And Installation

Drain the hydraulic reservoir. (See Removing And

Replacing The Hydraulic Fluid on Page 10-130-3.)

Remove the floor mat. (See Removal And Installation on

Page 40-100-1.)

Remove the tool box. (See Removal And Installation on

Page 40-210-1.)

Figure 20-32-6

P133062

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Mark and remove the crossport relief valves (Item 1)
[Figure 20-32-6].

NOTE: Install the valves in the original location.

Figure 20-32-7

P-89691

Remove the O-ring (Item 1) [Figure 20-32-7] from the

relief valve.

20-32-4 E85 Service Manual

VALVE (PRESSURE REDUCING) Figure 20-33-2

Testing And Adjusting

The pressure reducing valve supplies lower hydraulic

pressure to joysticks.

The following tools will be needed for testing the pressure

reducing valve:

MEL1355 - Test Kit includes the following

MEL1355-2 - 6895 kPa (69 bar) (1000 psi) Gauge
MEL1355-9 - Thermometer
1
Open the right side cover. (See Opening And Closing on
Page 10-60-1.) P131639

Figure 20-33-1
Install a 6895 kPa (69 bar) (1000 psi) gauge on the JP3
diagnostic port (Item 1) [Figure 20-33-2].

Lower the control console and fasten the seat belt.

1
Start the engine and warm the hydraulic fluid to a
minimum operating temperature of 66°C (150°F).

With the hydraulic fluid at operating temperature, run the

engine at full rpm.
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Engage the bucket curl circuit and fully curl the bucket.

The pilot pressure relief valve pressure should be as

P131641 follows:

A target pressure of 2951 kPa (30 bar) (428 psi) with an

The JP3 diagnostic port (Item 1) [Figure 20-33-1] will be acceptable range of 2799 - 3103 kPa (28 - 31 bar) (406 -
used to check the pressure reducing valve. 450 psi).

With the engine off, and the key in the run position, lower Move the engine speed control to low idle speed.
the left console and move both joysticks to relieve
hydraulic pressure. Stop the engine.

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

20-33-1 E85 Service Manual

VALVE (PRESSURE REDUCING) (CONT’D) Figure 20-33-4

Testing And Adjusting (Cont’d)

Figure 20-33-3 2

2
1

1 P-95311

Inspect the valve (Item 1) [Figure 20-33-4] on the

P131640 manifold assembly to verify no damage. If damaged
replace the manifold assembly.
Loosen the nut (Item 1) [Figure 20-33-3]. Inspect the O-rings (Item 2) [Figure 20-33-4] on the
valve. If O-rings are worn or damaged, replace O-rings.
Turn the adjustment screw (Item 2) [Figure 20-33-3]
clockwise to increase the pressure or counterclockwise Reinstall the valve in the manifold assembly.
to decrease the pressure.
Repeat the test procedure.
NOTE: 1/4 turn is approximately 276 kPa (2,8 bar) (40

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psi). If the O-rings are not worn or damaged and the correct
pressure could not be achieved, replace the valve.
Tighten the nut (Item 1) [Figure 20-33-3].

Retest the pressure reducing valve after adjustment.

If the pressure is still incorrect, relieve hydraulic pressure

and remove the valve from the manifold assembly for
inspection or repair.

If the amount of oil pressure is at or over the service

limits, it is an indication of worn O-rings and back-up
rings on the valve or a stuck valve.

20-33-2 E85 Service Manual

HYDRAULIC CONTROL VALVE Mark all hoses and tubelines for proper installation.

Description Figure 20-40-1

The hydraulic control valve is a ten section closed center

system and has one load sense relief valve. The load
sense relief valve operates at 29500 kPa (295 bar) (4279
psi). The bucket, arm and boom sections have 28999 kPa
(290 bar) (4206 psi) work port reliefs.

The auxiliary section has 20995 kPa (210 bar) (3045 psi)
work port reliefs.

The boom, arm and bucket section has a 34000 kPa (340
bar) (4931 psi) work port relief.

The boom swing and blade section has a 38000 kPa (300
bar) (5511 psi) work port relief. P133273

Removal And Installation

Remove the pilot pressure hoses and tubelines from the
NOTE: Dealer disassembly of the component(s) valve [Figure 20-40-1].
shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found Figure 20-40-2
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.
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Lower the work equipment to the ground.

1
Stop the engine.

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

Remove the right upperstructure cover. (See Removal P131773

And Installation on Page 40-70-1.)

Remove the manifold assembly / accumulator. (See Disconnect the wire harness (Item 1) [Figure 20-40-2].
Removal And Installation on Page 20-60-2.)

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

20-40-1 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-5

Removal And Installation (Cont’d)

Figure 20-40-3

P133319

Install a hoist and lifting strap to support the control valve

P131774 [Figure 20-40-5].

Disconnect the wire harness (Item 1) [Figure 20-40-3].

Figure 20-40-4

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P131775

Remove the high pressure hoses [Figure 20-40-4].

20-40-2 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-8

Removal And Installation (Cont’d)

Figure 20-40-6

1
1

1
P133320

Remove the control valve from the excavator [Figure 20-

P133284 40-8].

Figure 20-40-7

1
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P133286

Remove the bolts (Item 1) [Figure 20-40-6] and [Figure

20-40-7].

20-40-3 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Parts Identification

8 9 11
2 4 5 6 7 10
1 3

12

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P129829

1. Inlet Valve Section 7. Boom Valve Section

2. Boom Swing Valve Section 8. Auxiliary Valve Section

3. Slew Valve Section 9. Arm Valve Section

4. Blade Valve Section 10. Bucket Valve Section

5. Left Travel Valve Section 11. Outlet Valve Section

6. Right Travel Valve Section 12. Load Sense Pressure Switch

20-40-4 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-10

Disassembly And Assembly

NOTE: Dealer disassembly of the component(s) 1

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.
1
Clean the outside of the control valve before disassembly.
1

P129828

IMPORTANT Remove the tie rod nuts (Item 1) [Figure 20-40-10].

When repairing hydrostatic and hydraulic systems, Assembly: Tighten the tie rod nuts to 32 - 38 N•m (24 -
clean the work area before disassembly and keep all 28 ft-lb) torque.
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-40-11
damage the system.
I-2003-0888
1

Figure 20-40-9
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2
3

P129830

1
Remove the inlet section (Item 1) [Figure 20-40-11].
P129829
Remove the O-rings (Item 2) and remove the offset valve
section (Item 3) [Figure 20-40-11].
Remove the load sense pressure switch (Item 1) [Figure
20-40-9].

20-40-5 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-14

Disassembly And Assembly (Cont’d)

Figure 20-40-12

1 2

P129833
1

1 2
Remove the O-rings (Item 1) and remove the left travel
P129831 valve section (Item 2) [Figure 20-40-14].

Figure 20-40-15
Remove the O-rings (Item 1) and remove the slew valve
section (Item 2) [Figure 20-40-12].

Figure 20-40-13

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1

1 2

1 P129834

1 2
Remove the three O-rings (Item 1) and remove the right
P129832 travel valve section (Item 2) [Figure 20-40-15].

Remove the O-rings (Item 1) and remove the blade valve

section (Item 2) [Figure 20-40-13].

20-40-6 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-18

Disassembly And Assembly (Cont’d)

Figure 20-40-16

1
2
1
P129837
1

1 2 Remove the O-rings (Item 1) and remove the arm valve

P129835 section (Item 2) [Figure 20-40-18].

Figure 20-40-19
Remove the O-rings (Item 1) and remove the boom valve
section (Item 2) [Figure 20-40-16].

Figure 20-40-17
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1 2
P129838
1

1 2
Remove the O-rings (Item 1) and remove the bucket
P129836 section (Item 2) [Figure 20-40-19].

Remove the four O-rings (Item 1) and remove the

auxiliary valve section (Item 2) [Figure 20-40-17].

20-40-7 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-40-20

1 2
P129839

Remove the O-rings (Item 1) from the outlet section (Item

2) [Figure 20-40-20].

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20-40-8 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-23

Inlet Valve Section Disassembly And Assembly

Figure 20-40-21

1
1

P129846

Remove the spring (Item 1) and spool (Item 2) [Figure

P129844 20-40-23].

Figure 20-40-24
Remove the plug (Item 1) [Figure 20-40-21].

Figure 20-40-22
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1 1
P129847
2

P129845 Remove the load sense relief valve (Item 1) [Figure 20-
40-24].

Remove the O-ring (Item 1) and shims (Item 2) [Figure Installation: Tighten the plug to 41 - 49 N•m (30 - 36 ft-
20-40-22]. lb) torque.

20-40-9 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-27

Inlet Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-25 1

P-95183
1
2
Check that the port (Item 1) [Figure 20-40-27] in the load
sense bleed valve is not plugged.
P129848
Figure 20-40-28

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

[Figure 20-40-25] from the load sense relief valve.

Figure 20-40-26

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1

P-95184

Check the filter (Item 1) [Figure 20-40-28] at the end of

the load sense bleed valve.
P129849

Remove the load sense bleed valve (Item 1) [Figure 20-

40-26] from the Inlet section.

Assembly: Tighten the load sense bleed valve to 18 - 20

N•m (13 - 16 ft-lb) torque.

20-40-10 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Inlet Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-29

P-95185

Remove the plug (Item 1) [Figure 20-40-29].

Figure 20-40-30

1 1
3 4
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2
1

P129850

Remove the O-ring (Item 1), back-up ring (Item 2), valve
(Item 3), spring (Item 4), and shims (Item 5) [Figure 20-
40-30].

20-40-11 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-33

Valve Section Disassembly And Assembly

The disassembly and assembly procedure is the same

for all valve sections except where noted.

Figure 20-40-31 1
1
1

P129853

Remove the screws and remove the spool covers (Item

1) [Figure 20-40-33].

Figure 20-40-34
P129851

Remove the port relief valves (if equipped) (Item 1)

[Figure 20-40-31].

Figure 20-40-32

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1

P129854

1
Remove the O-ring (Item 1) [Figure 20-40-34].

P129852

Remove the O-ring (Item 1) [Figure 20-40-32].

20-40-12 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-37

Valve Section Disassembly And Assembly (Cont’d)

Figure 20-40-35

1
2

P129857
2 1

Compress the spring (Item 1) and remove the retainer

P129866 (Item 2) [Figure 20-40-37]. Remove the spring from the
spool.

Measure and record the overall length of the spool stroke Figure 20-40-38
limiter (Item 1). Remove the nut (Item 2) [Figure 20-40-
35] and stroke limiter (upperstructure slew section only).

Figure 20-40-36 1
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P129858

Turn the valve section over and remove the plug (Item 1)
P129855 [Figure 20-40-38].

Remove the spool (Item 1) [Figure 20-40-36].

NOTE: The spools are not interchangeable with other

valve sections.

20-40-13 E85 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-41

Valve Section Disassembly And Assembly (Cont’d) 1

Figure 20-40-39
1

P129860

Remove the load check valves (Item 1) [Figure 20-40-

P-35253 41].

Figure 20-40-42
Remove the O-ring (Item 1) [Figure 20-40-39].
4
Figure 20-40-40

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1 2 3

P129861

P129859 Remove the seat (Item 1) and spring (Item 2) from the
load check body (Item 3) [Figure 20-40-42].

Remove the compensator (Item 1) [Figure 20-40-40]. Remove the O-ring (Item 4) [Figure 20-40-42].

20-40-14 E85 Service Manual

HYDRAULIC PUMP

Hydraulic Pump Work Sheet

(Please review pump procedure as illustrated in “Pump Testing”.) (See Pump Testing on Page 20-50-5.)

The outline listed below, gives the six adjustments for setting the hydraulic pump. The adjustments are listed in the order
in which they MUST be performed. Below each adjustment is a list of the steps. Behind each adjustment is the page
location within the Service Manual for the complete adjustment procedure.

1. Run engine at High Idle. Record no load engine rpm. (See Engine on Page SPEC-10-4.)

__________ ENGINE RPM

I. Test Fitting Installation. (See Test Fitting Installation on Page 20-50-5.)

2. Remove the cap from the outlet section of the hydraulic control valve. Install the adapter and the return hose from the
hydraulic tester to the return fitting on the control valve.

3. Remove the pump to inlet section of the hydraulic control valve hose. Remove the fitting from the valve and install the
tee fitting and adapter from the test kit. Install the pump to valve hose. Install the inlet hose from the tester to the tee
fitting on the hydraulic control valve.

4. Install the jumper hose on the load sense test port located on the hydraulic control valve and the P port of the pilot
manifold assembly.

5. Start the engine and run at High Idle, turn the hydraulic tester flow control clockwise until 6895 kPa (69 bar) (1000 psi)
is shown on the gauge. Restrict the oil until it is at a minimum of 66°C (150°F).
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6. Turn the hydraulic tester flow control counterclockwise until all restriction is removed and stop engine.

II. Minimum Displacement Adjustment. (See Minimum Displacement Adjustment on Page 20-50-7.)

7. Remove the load sense hose from the hydraulic pump control at the hydraulic control valve inlet section. Plug the hose
and cap the fitting. Remove the plug from the load sense pump control, install the fitting, and hose. Route the hose to
the reservoir.

8. Install a 34474 kPa (345 bar) (5000 psi) gauge to the test port on the jumper hose.

9. Run engine at high idle.

10. Adjust hydraulic tester to 9653 - 10342 kPa (97 - 103 bar) (1400 - 1500 psi), pump flow should be 9,5 - 17 L/min
(2.5 - 4.5 U.S. gpm).

11. Record the flow.

__________ FLOW

12. Adjust the minimum displacement adjustment stop screw at the pump as needed.

13. At the pilot manifold assembly, disconnect the hose from the P port to the load sense port on the inlet section of the
hydraulic control valve.

20-50-1 E85 Service Manual

HYDRAULIC PUMP (CONT'D)

Hydraulic Pump Work Sheet (Cont’d)

14. Remove the hose and fitting from the load sense pump control on the hydraulic pump and plug the port.

15. Remove the cap and plug from the load sense line and fitting at the hydraulic control valve. Install the load sense line
on the valve.

III. Torque Limiter Supply Pressure Adjustment (See Torque Limiter Supply Pressure Adjustment on Page 20-50-10.)

16. Install a 3447 kPa (34,5 bar) (500 psi) gauge to the P port of the pilot manifold assembly.

17. Bottom out pump margin spool located in the hydraulic pump control (Approximately 6 Turns In.)

18. Remove the plug from the torque limiter supply spool. Install the fitting and hose. Route the hose to the reservoir.

19. Start the engine and run at high idle.

20. Adjust as necessary to get 1999 ± 137,9 kPa (20 ± 1,37 bar) (290 ± 20 psi) at 60,6 L/min (16 U.S. gpm)

21. Record pressure.

__________ TLS PRESSURE

22. Remove the hose and fitting from the torque limiter supply spool and plug the port.

23. Reset pump margin spool (Approximately 6 Turns Out.)

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IV. Pump Margin Pressure Adjustment (See Pump Margin Pressure Adjustment on Page 20-50-11.)

24. Remove the load sense hose at the valve. Plug the hose and cap the fitting. Remove the plug from the load sense
pump control, install the fitting and hose. Route the hose to the reservoir.

25. Run engine at high idle and restrict the flow to 37,8 L/min (10 U.S. gpm).

26. Adjust as necessary to get 1516 ± 68,9 kPa (15 ± 0,7 bar) (220 ± 10 psi).

27. Record the pressure.

__________ PM PRESSURE

28. Stop the engine. Remove the hose and fitting from the pump margin spool and install the plug.

29. Remove the cap and plug from the load sense line and fitting at the valve. Install the load sense line on the valve.

20-50-2 E85 Service Manual

HYDRAULIC PUMP (CONT'D)

Hydraulic Pump Work Sheet (Cont’d)

V. Load Sense Relief Valve Adjustment. (See Load Sense Relief Valve Adjustment on Page 20-50-13.)

30. Install 34474 kPa (345 bar) (5000 psi) Gauge on the P port of the pilot manifold assembly.

31. Turn the hydraulic tester flow control clockwise until maximum restriction.

32. Start the engine and lower the left console. With the engine at high idle, raise the blade and dead-head in the UP
position.

33. Adjust load sense relief valve as necessary to get 29500 kPa (295 bar) (4279 psi).

34. Record pressure

__________ PUMP PRESSURE

35. Stop the engine and remove the 34474 kPa (345 bar) (5000 psi) gauge, from the P port of the pilot manifold assembly.

VI. Torque Limiter Adjustment. (See Torque Limiter Adjustment on Page 20-50-14.)

36. Install jumper hose with a test port, between the P port of the pilot manifold assembly and the load sense port at the
inlet section of the hydraulic control valve.

37. Install a 34474 kPa (345 bar) (5000 psi) Gauge to the test port on the jumper hose.

38. Start the engine and run at high idle. Adjust the hydraulic tester to 12410 kPa (124 bar) (1800 psi).
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39. Adjust the torque limiter to obtain 125 - 140 L/min (33 - 37 U.S. gpm).

40. Record flow and engine rpm.

__________ FLOW

__________ ENGINE RPM

20-50-3 E85 Service Manual

HYDRAULIC PUMP (CONT'D)

Hydraulic Pump Work Sheet (Cont’d)

41. Adjust the hydraulic tester to 24132 kPa (241 bar) (3500 psi).

42. Adjust the torque limiter to obtain 53 - 68 L/min (14 - 18 U.S. gpm).

43. Record flow and engine rpm.

__________ FLOW

__________ ENGINE RPM

ALL PUMP ADJUSTMENTS ARE NOW COMPLETED

44. Stop the engine. Remove the jumper hose.

45. Remove the hydraulic tester and all test fittings.

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20-50-4 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-50-2

Pump Testing

The testing of the piston pump must be done in the

following order:

Minimum Displacement Adjustment

Torque Limiter Supply Pressure
Pump Margin Pressure Adjustment
Load Sense Relief Valve Adjustment
Torque Limiter Adjustment

Record the no load engine rpm, registered on the right 1

hand operator panel display.
P131371
See high idle specification. (See Engine on Page SPEC-
10-4.)
Install the adapter (Item 1) [Figure 20-50-2].
Stop the engine.
Figure 20-50-3
Test Fitting Installation

The following tools will be needed to do the procedure:

MEL1744 - Hydraulic Tester

MEL1598 - Jumper Hose / Couplers
7335495 - Fitting Kit
3447 kPa (34 bar) (500 psi) gauge
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34474 kPa (345 bar) (5000 psi) gauge

Figure 20-50-1

P131374

Install the return hose (Item 1) [Figure 20-50-3] from the

1 flow meter to the adapter.

P131370

Remove the cap (Item 1) [Figure 20-50-1] from the outlet

section of the hydraulic control valve.

20-50-5 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-50-6

Pump Testing (Cont’d)

Test Fitting Installation (Cont’d)

Figure 20-50-4

2
P131372

Install the adapter (Item 1) [Figure 20-50-6] on the tee.

1
Figure 20-50-7
P131414

Remove the hose (Item 1) from the valve. Remove the

fitting (Item 2) [Figure 20-50-4].

Figure 20-50-5
1

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3

1 P131373

Install the inlet hose (Item 1) [Figure 20-50-7] from the

2 flow meter to the adapter.

P131368

Install the tee fitting (Item 1), adapter (Item 2), and hose
(Item 3) [Figure 20-50-5].

NOTE: The hose (Item 3) [Figure 20-50-6] may need to

be loosened at the pump. Orientate the hose
as needed to provide clearance at the valve.

20-50-6 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Minimum Displacement Adjustment

Pump Testing (Cont’d) Figure 20-50-10

Test Fitting Installation (Cont’d)

Figure 20-50-8

1
1

P131385

Remove the load sense line (Item 1) [Figure 20-50-10]

P131462 from the valve.

Figure 20-50-11
Connect the jumper hose (Item 1) [Figure 20-50-8] to the
load sense port and P port of the pilot manifold assembly.

Figure 20-50-9

1
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2
2

P131386

1
Install a plug (Item 1) on the line and a cap (Item 2)
P-16340 [Figure 20-50-11] on the fitting.

With the engine at high idle, turn the hydraulic tester flow
control (Item 1) clockwise until 6895 kPa (69 bar) (1000
psi) is shown on the gauge (Item 2) [Figure 20-50-9].

Continue the procedure until the hydraulic oil is at a

minimum of 66°C (150°F).

NOTE: The values read at the Hydraulic Tester

(MEL10003) are based on the use of 19,05 mm
(3/4 in) hoses on the tester. Different size
hoses will cause variation on the readings.

Test Fittings are now installed.

20-50-7 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-50-14

Pump Testing (Cont’d)

Minimum Displacement Adjustment (Cont’d)

Figure 20-50-12

P131387

Route the hose (Item 1) [Figure 20-50-14] to the

1 reservoir.

P131380 Figure 20-50-15

Remove the plug (Item 1) [Figure 20-50-12] from the

load sense pump control.

Figure 20-50-13

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1

P131378

Install a 34474 kPa (345 bar) (5000 psi) gauge on the

1 jumper hose test port (Item 1) [Figure 20-50-15].

P131381

Install a fitting and hose (Item 1) [Figure 20-50-13] on

the load sense pump control.

20-50-8 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-50-18

Pump Testing (Cont’d)

Minimum Displacement Adjustment (Cont’d)

Figure 20-50-16 1

2
1

P131460

To adjust the flow, loosen the locknut (Item 1) and turn

the adjustment stop screw (Item 2) [Figure 20-50-18]
clockwise to increase the flow and counterclockwise
P-16340 to decrease the flow.

NOTE: 1/2 turn is approximately 3,8 L/min (1.0 U.S.

Start the engine and run at high idle. Turn the hydraulic gpm).
tester flow control (Item 1) [Figure 20-50-16] clockwise
until 9653 - 10342 kPa (97 - 103 bar) (1400 - 1500 psi) is Disconnect the hose from the P port of the pilot manifold
shown on the pressure gauge. assembly.
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Record the amount of flow. At the pump, remove the hose and fitting from the load
sense pump control.
The flow should be 9,5 - 17 L/min (2.5 - 4.5 U.S. gpm).
At the valve, reconnect the load sense hose that was
Figure 20-50-17 removed in [Figure 20-50-10].

Minimum Displacement Adjustment is now

completed.

P131461

Remove the cap (Item 1) [Figure 20-50-17].

20-50-9 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-50-21

Pump Testing (Cont’d)

Torque Limiter Supply Pressure Adjustment

1
NOTE: This circuit is capable of high pressure.

Figure 20-50-19

P131387

1
Remove the cap from the hydraulic reservoir and route
the hydraulic hose (Item 1) [Figure 20-50-21] into the
reservoir.

Figure 20-50-22
P131402

Connect a 500 psi pressure gauge (Item 1) [Figure 20-

50-19] to the pump diagnostic coupler at the control
valve. 2

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Figure 20-50-20

2
1
1
P-16340

Turn the hydraulic tester flow control (Item 1) [Figure 20-

3 50-22] counterclockwise so there is no restriction on the
hydraulic system.

Start the engine and allow the hydraulic fluid to warm to

60°C (140° F).
P131375

NOTE: Do not engage any hydraulic functions at this

Loosen the nut (Item 1) on the pump margin spool. With time, hydraulic pressure will damage the
an Allen wrench turn the pump margin spool adjustment gauge.
(Item 2) [Figure 20-50-20] all the way in (approximately 6
With the engine at high idle, turn the hydraulic tester flow
turns).
control (Item 1) clockwise to 60,6 L/m (16 U.S. gpm) flow
is shown at the hydraulic tester gauge (Item 2) [Figure
NOTE: To adjust the Torque Limiter Supply Pressure,
20-50-22].
the Pump Margin Spool must be temporarily
bottomed out. Check the torque limiter supply pressure at the gauge.
Remove the plug (Item 3) [Figure 20-50-20] from the
torque limiter supply spool and install a fitting and hose.

20-50-10 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-50-24

Pump Testing (Cont’d)

Torque Limiter Supply Pressure Adjustment (Cont’d)

1
Figure 20-50-23

P131398

Turn the pump margin spool (Item 1) back out

2
3 (approximately 6 turns) and tighten the nut (Item 2)
[Figure 20-50-24].
P131465
Torque limiter supply pressure adjustment is now
completed.
If the torque limiter supply pressure is not 1999 ± 137,9
kPa (20 ± 1,37 bar) (290 ± 20 psi) turn the torque limiter Pump Margin Pressure Adjustment
supply spool (Item 1) [Figure 20-50-23] clockwise to
increase the pressure, and counterclockwise to decrease Figure 20-50-25
the pressure. (Approximately 1/4 turn per 50 psi)
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NOTE: Changing the Torque Limiter Supply

Adjustment Screw will affect the pressure and
the flow. The Hydraulic Tester must be reset 1
to 60,6 L/m (16 U.S. gpm).

Repeat the procedure listed above until the pressure

is set.

If correct procedure cannot be obtained, disassemble

and clean the torque limit supply pressure spool.
2
When the correct pressure is obtained, tighten the nut
(Item 2) and remove the hose and fitting (Item 3) [Figure P131386
20-50-23] from the torque limiter spool. Replace the plug
in the torque limiter spool and tighten.
Remove the load sense hose at the valve. Install a plug
(Item 1) in the hose and cap (Item 2) [Figure 20-50-25]
on the fitting.

20-50-11 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-50-28

Pump Testing (Cont’d)

Pump Margin Pressure Adjustment (Cont’d) 2

Figure 20-50-26

1
P-16340

Figure 20-50-29
1

P131380

Remove the plug (Item 1) [Figure 20-50-26] from the

pump margin pressure spool. Install a fitting and hose.

Figure 20-50-27 1

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1

P131402

With the engine at high idle, turn the hydraulic tester flow
control (Item 1) clockwise until 37,8 L/min (10 U.S. gpm)
flow is shown at the hydraulic tester gauge (Item 2)
[Figure 20-50-28].

Check the pump margin pressure at the gauge (Item 1)

P131387 [Figure 20-50-29].

Remove the cap from the hydraulic reservoir and route

the hydraulic hose (Item 1) into the reservoir [Figure 20-
50-27].

20-50-12 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Load Sense Relief Valve Adjustment

Pump Testing (Cont’d) Figure 20-50-31

Pump Margin Pressure Adjustment (Cont’d)

Figure 20-50-30 1

P131402
2

Install a 34474 kPa (345 bar) (5000 psi) gauge (Item 1)

P131466 [Figure 20-50-31] on the P port of the pilot manifold
assembly.

If the pump margin pressure is not 1516 ± 68,9 kPa (15 ± Figure 20-50-32
0,7 bar) (220 ± 10 psi), turn the pump margin pressure
adjustment screw (Item 1) [Figure 20-50-30] clockwise
to increase the pressure, and counterclockwise to
decrease the pressure. (Approximately 1/4 turn per 344
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kPa [50 psi] [3,4 bar])

NOTE: Changing the Pump Margin Pressure

Adjustment Screw, will effect the pressure
and flow. The Hydraulic Tester must be reset
to 37,8 L/min (10 U.S. gpm).

Repeat the procedure listed above until the

pressure is set.
1
If correct pressure cannot be obtained, disassemble and P-16340
clean the pump margin spool.

When the correct pressure is obtained, tighten the jam Turn the hydraulic tester flow control (Item 1) [Figure 20-
nut (Item 2) [Figure 20-50-30] and remove the hose and 50-32] clockwise until maximum restriction.
fitting from the pump margin spool. Replace the plug in
the pump margin spool and tighten. Start the engine and run at high idle.

Remove the 500 psi test gauge from the pump P port of Raise the blade until the blade cylinder is fully retracted
the pilot manifold assembly. and the relief valve opens.
Have another person check the pressure gauge and
At the valve, connect the load sense line.
record the pressure.
The Pump Margin Pressure Adjustment is now
The load sense relief valve should be 29500 ± 345 kPa
completed.
(295 ± 3,44 bar) (4279 ± 50 psi).

20-50-13 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Torque Limiter Adjustment

Pump Testing (Cont’d) Figure 20-50-35

Load Sense Relief Valve Adjustment (Cont’d)

Figure 20-50-33
1

2
P131468

Connect a jumper hose (Item 1) to the load sense test

P131406 port located on the inlet section of the hydraulic control
valve and P port of the pilot manifold assembly. Install a
34474 kPa (345 bar) (5000 psi) gauge (Item 2) [Figure
Remove the cap (Item 1) [Figure 20-50-33]. 20-50-35] on the jumper hose.

Figure 20-50-34 Figure 20-50-36

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2 3 2

1
P131407 P-16340

Loosen the nut (Item 1) [Figure 20-50-34]. Turn the hydraulic tester flow control (Item 1) [Figure 20-
50-36] counterclockwise so there is no restriction on the
Turn the adjustment screw (Item 2) [Figure 20-50-34] in hydraulic system.
to increase pressure and out to decrease pressure.
Start the engine and run at high idle.
NOTE: 1/4 turn is approximately 586 kPa (5,9 bar) (85
psi).
If equipped with air conditioning, turn air conditioning on
When the load sense relief pressure is set, tighten the and turn temperature switch to the lowest setting.
nut (Item 1) [Figure 20-50-34].
Turn the hydraulic tester flow control (Item 1) [Figure 20-
Stop the engine and remove the gauge from the P port of 50-36] clockwise until the gauge (Item 2) [Figure 20-50-
the pilot manifold assembly 35] reads 12410 kPa (124 bar) (1800 psi).

Load Sense Relief Valve adjustment is now Record the amount of flow at the tester gauge (Item 3)
completed. [Figure 20-50-36], which is the flow at low pressure.

20-50-14 E85 Service Manual

HYDRAULIC PUMP (CONT'D) When the proper flow is obtained, 125 - 140 L/min (33 -
37 U.S. gpm) at 12410 kPa (124 bar) (1800 psi), tighten
Pump Testing (Cont’d) the large nut (Item 2) [Figure 20-50-38].

Torque Limiter Adjustment (Cont’d) If the flow at low pressure cannot be obtained,
disassemble and clean the torque limiter spool assembly.
The flow should be 125 - 140 L/min (33 - 37 U.S. gpm).
If after cleaning the flow at low pressure cannot be
Figure 20-50-37 obtained, remove and replace the torque limiter spool
assembly.

Figure 20-50-39

3
1
2

P131399

1
If the flow at low pressure must be adjusted, stop the
P-16340
engine and remove the cap (Item 1) [Figure 20-50-37]
from the hydraulic pump torque limiter.
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Turn the hydraulic tester flow control (Item 1) clockwise

Figure 20-50-38 until the gauge (Item 2) reads 22753 kPa (228 bar) (3300
psi). Record the amount of flow at the tester gauge (Item
3) [Figure 20-50-39], which is the flow at high pressure.

The flow should be approximately 53 - 68 L/min (14 - 18

U.S. gpm).
2
If the flow at high pressure must be adjusted, adjust the
flow at the hydraulic pump torque limiter. Stop the engine.

P131401

Check that the small nut (Item 1) [Figure 20-50-38] is

locked in place.

Adjust the flow at the hydraulic pump torque limiter

loosening the large nut (Item 2) [Figure 20-50-38]. With
a hex wrench adjust the flow at low pressure.

Start the engine and retest the flow rate.

20-50-15 E85 Service Manual

HYDRAULIC PUMP (CONT'D)

Pump Testing (Cont’d)

Torque Limiter Adjustment (Cont’d)

Figure 20-50-40

2 1

P131401

Loosen the small nut (Item 1) and with a hex wrench

adjust the flow at high pressure (Item 2) [Figure 20-50-
40].

If the flow at high pressure cannot be obtained,

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disassemble and clean the torque limiter spool assembly.

If after cleaning the flow at high pressure cannot be

obtained, remove and replace the torque limiter spool
assembly.

When the proper flow is obtained, 53 - 68 L/min (14 - 18

U.S. gpm) at 24132 kPa (241 bar) (3500 psi), lock the
small nut (Item 1) [Figure 20-50-40].

NOTE: If adjustments were made to flow at high

pressure verify the flow at low pressure. (See
Torque Limiter Adjustment on Page 20-50-14.)

Install the cap on the hydraulic pump torque limiter.

Torque Limiter Adjustment is now completed.

ALL PUMP ADJUSTMENTS ARE NOW COMPLETED

Remove the hydraulic tester and all test fittings from the
excavator.

20-50-16 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-50-42

Removal And Installation

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check 2
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada. 1

IMPORTANT P128236

When repairing hydrostatic and hydraulic systems, Remove the bolts (Item 1) and remove the hose (Item 2)
clean the work area before disassembly and keep all [Figure 20-50-42].
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-50-43
damage the system.
I-2003-0888

2
Drain the hydraulic reservoir. (See Removing And
Replacing The Hydraulic Fluid on Page 10-130-3.)

Remove the counterweight. (See Removal And

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Installation on Page 40-80-1.)

Figure 20-50-41
1

P128515
1

1
Remove the bolts (Item 1) and inlet (Item 2) [Figure 20-
50-43].

P128235

Mark and remove the hoses (Item 1) [Figure 20-50-41].

20-50-17 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-46

Removal And Installation (Cont’d)

Figure 20-50-44 1

P133301

Remove the two bolts (Item 1) [Figure 20-50-45] and

P133298 [Figure 20-50-46].

Figure 20-50-47
Using a hoist and lifting strap (Item 1) [Figure 20-50-44].
Support the pump.

Figure 20-50-45

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1

P133302

Remove the hydraulic pump [Figure 20-50-47].

P133300
Installation: Tighten the bolts to 122 - 136 N•m (90 - 100
ft-lb) torque.

Pump Installation: Whenever the hydraulic system has

been drained and refilled, the hydraulic pump must be
purged of air. (See Hydraulic Pump Startup on Page 20-
50-20.)

20-50-18 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Coupler Removal And Installation

Removal And Installation (Cont’d) Figure 20-50-49

Figure 20-50-48

48 mm
(1.89 in)
NA5031S

P-98057
When installing the coupler, maintain 48 mm (1.89 in)
over all length from the pump housing to the coupler
Remove the bolt (Item 1) [Figure 20-50-48] from the edge [Figure 20-50-49].
coupler.

Slide the coupler off of the pump shaft.

Installation: Tighten the bolt (Item 1) [Figure 20-50-48]

to 49 - 60 N•m (36 - 44 ft-lb) torque.
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20-50-19 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-52

Hydraulic Pump Startup

NOTE: This procedure is to prevent a dry startup of

the hydraulic pump.
1
Figure 20-50-50

1
P131647

Remove the fill cap from the reservoir. Route the hose
(Item 1) [Figure 20-50-52] into the reservoir.

Figure 20-50-53
P128235

Loosen the hose (Item 1) [Figure 20-50-50] until all the 1

air is purged from the pump housing.

Figure 20-50-51

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1

P100685

To crank the engine without starting, the machine key

switch must be bypassed. Obtain the push button starter
switch (MEL1712) (Item 1) [Figure 20-50-53].

P131648

Install a female quick coupler and hose on the male quick

coupler (Item 1) [Figure 20-50-51].

20-50-20 E85 Service Manual

HYDRAULIC PUMP (CONT’D) With the excavator parked on a level surface, check and
fill the hydraulic reservoir as required. Check for hydraulic
Hydraulic Pump Startup (Cont’d) leaks. (See Removing And Replacing The Hydraulic
Fluid on Page 10-130-3.)
Figure 20-50-54

P133057

Figure 20-50-55

BATTERY TERMINAL
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S TERMINAL
P133056

Connect the push button starter switch (MEL1712) to the

starter solenoid battery terminal and S terminal. Crank
the engine for 15 seconds, then stop for at least 30
seconds. Again, crank the engine for 15 seconds.
Remove the starter switch tool [Figure 20-50-54] and
[Figure 20-50-55].

Start the excavator from the operator cab and run the
engine at low idle for 1-2 minutes without operating the
hydraulics.

Operate the auxiliary hydraulic over relief without any

attachment connected to the auxiliary quick couplers.
This will force the air from the pump inlet / outlet to the oil
cooler / reservoir.

20-50-21 E85 Service Manual

HYDRAULIC PUMP (CONT'D)

Torque Limiter Valve Parts Identification

1. Plug
2. O-ring
3. Spring
4. Spring Seat
5. Outer Spool 7
6. Inner Spool
7. Bolt 1 8
8. Housing 2
9. Gasket
10. Body
11. Nut
12. Washer
13. Adjustment Screw
14. Cap 9

4
6

5
4
3

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2

14
11
13
12

11

10

NA13699S

20-50-22 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-57

Torque Limiter Valve Removal

IMPORTANT
When repairing hydrostatic and hydraulic systems, 2
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

P129721
Figure 20-50-56

Using a screwdriver gently pry up on the torque limiter

valve (Item 1) and remove it from the pump. Remove the
1
gasket (Item 2) [Figure 20-50-57].

Torque Limiter Valve Disassembly

Figure 20-50-58
2
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2 P129719

1
Remove the tubeline (Item 1) [Figure 20-50-56] from the
pump control and torque limiter valve.

NOTE: Mark the tubeline for correct installation.

Remove the bolts (Item 2) [Figure 20-50-56] from the N-23327

torque limiter valve.

Installation: Tighten the bolts to 9,5 - 10,5 N•m (7.0 - 7.5 Remove the plug (Item 1) [Figure 20-50-58] from the
ft-lb) torque. torque limiter valve to relieve pressure on the torque
limiter valve spool.

NOTE: Care should be taken not to scratch or

damage the mounting surface on the valve
body.

NOTE: The plug (Item 1) [Figure 20-50-58] is under

spring pressure.

20-50-23 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-61

Torque Limiter Valve Disassembly (Cont'd)

Figure 20-50-59
1

P129722

Remove the control spool assembly (Item 1) [Figure 20-

N-23328 50-61].

NOTE: Use care not to scratch or damage the spool.

Installation: Replace the O-ring (Item 1) [Figure 20-50- Scratches in the spool can cause internal
59]. leakage.

Figure 20-50-60 Figure 20-50-62

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2

2 1

N-23329 P129723

Remove the spring (Item 1) and spring guide (Item 2) Remove the metering spool (Item 1) from the control
[Figure 20-50-60]. spool (Item 2) [Figure 20-50-62].

20-50-24 E85 Service Manual

HYDRAULIC PUMP (CONT’D)

Torque Limiter Valve Disassembly (Cont'd)

Figure 20-50-63

N-23334

Remove the plug (Item 1) [Figure 20-50-63].

Figure 20-50-64
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N-23335

Check the O-ring (Item 1) [Figure 20-50-64] and replace

as needed.

Install the plug.

20-50-25 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-67

Torque Limiter Valve Disassembly (Cont'd)

The following procedures are only used if the adjustment

assembly is removed.
1
1
Figure 20-50-65

P129726

Remove the springs (Item 1) [Figure 20-50-67].

Figure 20-50-68

P129724

Remove the dust cap (Item 1) [Figure 20-50-65].

Figure 20-50-66

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2
1
P129727

Remove the spring seat (Item 1) [Figure 20-50-68].

1

P129725

Loosen the large nut (Item 1). With a 13 mm wrench on

the small nut (Item 2) [Figure 20-50-66] remove the
adjustment body from the valve body.

20-50-26 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-71

Torque Limiter Valve Disassembly (Cont'd)

Figure 20-50-69
1

2
1

N-23343

Remove the O-ring (Item 1) [Figure 20-50-71] from the

N-23338 torque limiter valve body.

Apply oil to the O-ring. Install the O-ring in the torque

With an Allen wrench hold the adjustment bolt (Item 1) limiter valve body.
and loosen the nut (Item 2) [Figure 20-50-69].

Figure 20-50-70

5
4
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2
1

N-23341

Remove the nut (Item 1) adjustment bolt (Item 2) O-ring

washer (Item 3) and large nut (Item 4) from the
adjustment body (Item 5) [Figure 20-50-70].

20-50-27 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-74

Torque Limiter Valve Assembly

1
Clean all the parts in solvent and dry with compressed
air.
2
Inspect seats and spools for wear.

Apply clean oil to new O-rings.

Figure 20-50-72

1 N-23346

Install the adjustment bolt (Item 1) [Figure 20-50-74] and

locknut into the adjustment body.

NOTE: Turn the adjustment screw into the valve body

approximately 6 complete turns.

Hold the adjustment screw with an Allen wrench and

N-23343
tighten the jam nut (Item 2) [Figure 20-50-74].

Figure 20-50-75
Install the O-ring (Item 1) [Figure 20-50-72] in the torque
limiter body.

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Figure 20-50-73

1
P129727
1 3
Install the spring seat (Item 1) [Figure 20-50-75].
N-23345

Put oil on the new O-ring washer (Item 1) and install on

the adjustment screw (Item 2). Install the nut (Item 3)
[Figure 20-50-73] on the adjustment screw.

20-50-28 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-78

Torque Limiter Valve Assembly (Cont'd)

Figure 20-50-76
1

1
1

N-23348

Install the large nut (Item 1) [Figure 20-50-78] and finger

P129726 tighten.

Figure 20-50-79
Install the springs (Item 1) [Figure 20-50-76].

Figure 20-50-77
2

1
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P129723

N-23347 Apply oil on the metering spool (Item 1). Install the spool
in the control spool (Item 2) [Figure 20-50-79].

Install the adjustment body (Item 1) [Figure 20-50-77] NOTE: The end of the metering spool with the three
and locknut into the valve body. rings enters the control spool first.

20-50-29 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-82

Torque Limiter Valve Assembly (Cont'd)

Figure 20-50-80

2
1
1

N-23328

Apply oil on the O-ring (Item 1) and install the O-ring on

P129722 the plug (Item 2) [Figure 20-50-82].

Figure 20-50-83
Apply oil on the control spool assembly (Item 1) [Figure
20-50-80] and install it in the valve body.

NOTE: Use care not to scratch or damage the spool

(Item 1) [Figure 20-50-80]. Scratches in the
spool can cause internal leakage. 1

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Figure 20-50-81

1 2 N-23327

Install the plug (Item 1) [Figure 20-50-83] on the torque

limiter valve.

N-23329

Install the spring guide (Item 1) [Figure 20-50-81] in the

valve body, with the smaller diameter end toward the
spring.

Install the spring (Item 2) [Figure 20-50-81] in the valve

body.

20-50-30 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-86

Initial Torque Limiter Valve Setting

Use the following procedure to set the torque limiter valve 2

after being disassembled and assembled.
1
Figure 20-50-84

N-23348

After the large adjustment screw is just seated, tighten

the large nut (Item 1) [Figure 20-50-86].

Loosen the small nut (Item 2) [Figure 20-50-86].

N-23348
Figure 20-50-87

Remove the large nut (Item 1) [Figure 20-50-84].

Lock the small nut (Item 2) [Figure 20-50-84].

1
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Figure 20-50-85

2
1

N-23349

Turn the small adjustment screw (Item 1) [Figure 20-50-

87] in until it bottoms in the valve.

N-23347

Both the large (Item 1) and small (Item 2) adjusting

screws must be lightly bottomed out in the valve. The
large adjustment screw (Item 1) [Figure 20-50-85] must
be bottomed out (just touching) first, make sure the small
adjustment screw is turned out a small amount so it will
not hit first.

20-50-31 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-90

Initial Torque Limiter Valve Setting (Cont'd)

Figure 20-50-88

2 1

N-23352

Tighten the large nut (Item 1) [Figure 20-50-90].

N-23350
This is the initial adjustment to the torque limiter valve, for
the final adjustment. (See Torque Limiter Supply
Back out the small adjustment screw (Item 1) [Figure 20- Pressure Adjustment on Page 20-50-10.)
50-88] ten and one fourth turns.

Tighten the small nut (Item 2) [Figure 20-50-88].

Loosen the large nut (Item 3) [Figure 20-50-88].

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Figure 20-50-89

N-23351

With an Allen wrench in the small adjustment screw (Item

1) [Figure 20-50-89] back out the large adjustment screw
five and three quarter turns.

20-50-32 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-92

Torque Limiter Valve Installation

Figure 20-50-91

4 1

1 P129719
3
5
Install and tighten the bolts (Item 1) [Figure 20-50-92] to
P129721 9,5 - 10,5 N•m (7.0 - 7.5 ft-lb) torque.

Install the tubeline (Item 2) [Figure 20-50-92].

Install the gasket (Item 1) [Figure 20-50-91] on the pump
body.

Align the linkage pin (Item 2) on the hydraulic piston

pump into the hole (Item 3) [Figure 20-50-91] in the
torque limiter valve.
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Turn the valve slightly to align the dowel pin (Item 4) on

the hydraulic piston pump into the hole (Item 3) [Figure
20-50-91] in the torque limiter valve. Apply pressure to
the valve to compress the spring.

NOTE: Care should be taken not to scratch or

damage the valve spool.

NOTE: Before tightening the bolts, make sure the

dowel pin is aligned with the housing.

20-50-33 E85 Service Manual

HYDRAULIC PUMP (CONT'D)

Pump Control Parts Identification

1. Nut
2. Adjustment Housing
3. O-ring 1
4. Back-up Ring
5. Adjustment Screw
6. Spring Seat 2
7. Spring
8. Spool Seat
9. Spool
10. Plug
3
11. Bolt
12. Body 4
13. Orifice
14. Gasket
3

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7

9
14
10

13

12
11

10

NA13700S

20-50-34 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Pump Control Disassembly And Assembly

Pump Control Removal And Installation Figure 20-50-95

Figure 20-50-93

1 1

P129729

P129719
Remove the gasket (Item 1) [Figure 20-50-95] from the
valve.
Remove the tubeline (Item 1) [Figure 20-50-93].

Figure 20-50-94

2
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1 1

P129728

Remove the four bolts (Item 1) and pump control (Item 2)

[Figure 20-50-94] from the hydraulic piston pump.

Installation: Tighten to 13 N•m (10 ft-lb) torque.

20-50-35 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-50-98

Pump Control Disassembly And Assembly (Cont'd)

Pump Margin Control

4
4
Figure 20-50-96 1

5 2 3

P129732

Remove the nut (Item 1) and turn the adjustment screw

(Item 2) all the way into the housing (Item 3) [Figure 20-
50-98].
P129730
Remove the O-rings (Item 4) and back-up ring (Item 5)
[Figure 20-50-98].
Before disassembling the pump margin control, measure
the adjustment screw (Item 1) [Figure 20-50-96] thread
length for the correct initial adjustment.

Figure 20-50-97

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3
2
1

P129731

Remove the adjustment assembly (Item 1) [Figure 20-

50-97].

Remove the spring seat (Item 2) and springs (Item 3)

[Figure 20-50-97].

20-50-36 E85 Service Manual

HYDRAULIC PUMP (CONT'D)

Pump Control Disassembly And Assembly (Cont'd)

Pump Margin Control (Cont’d)

Figure 20-50-99

2
3

P129734

Remove the spool (Item 1) and plug (Item 2). Remove the
O-ring (Item 3) [Figure 20-50-99] from the plug.

Figure 20-50-100
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P129735

Check the spool for scratches. Make sure the orifice

(Item 1) [Figure 20-50-100] is not plugged.

20-50-37 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-50-103

Pump Control Disassembly And Assembly (Cont'd)

Torque Limiter Supply Control

Figure 20-50-101

P129738

Remove the spring seat (Item 1) [Figure 20-50-103].

Figure 20-50-104
P129736

Before disassembling the torque limiter supply control,

3
measure the adjustment screw (Item 1) [Figure 20-50- 4
101] thread length for the correct initial adjustment. 1

Figure 20-50-102

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5 2
3
2
1 P129732

Remove the nut (Item 1) and turn the adjustment screw

(Item 2) all the way into the housing (Item 3) [Figure 20-
50-104].

Remove the O-rings (Item 4) and back-up ring (Item 5)

P129737 [Figure 20-50-104].

Remove the adjustment assembly (Item 1) [Figure 20-

50-102].

Remove the spring seat (Item 2) and springs (Item 3)

[Figure 20-50-102].

20-50-38 E85 Service Manual

HYDRAULIC PUMP (CONT'D) Figure 20-50-107

Pump Control Disassembly And Assembly (Cont'd)

Torque Limiter Supply Control (Cont’d)

Figure 20-50-105

1
P129752

3
Remove the orifice from the control [Figure 20-50-107].

Figure 20-50-108
P129739

Remove the spool (Item 1) and plug (Item 2). Remove the
O-ring (Item 3) [Figure 20-50-105] from the plug.

Figure 20-50-106
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1
1

P129753

Inspect the orifice (Item 1) [Figure 20-50-108] for

contamination and damage.

P129740

Check the spool for scratches. Make sure the orifices

(Item 1) [Figure 20-50-106] are not plugged.

NOTE: The pump margin control spool has two

orifices.

20-50-39 E85 Service Manual

HYDRAULIC PUMP (CONT'D)

Pump Control Disassembly And Assembly (Cont'd)

Torque Limiter Supply Control (Cont’d)

Figure 20-50-109

P-95117

Remove the plug (Item 1) [Figure 20-50-109] from the

pump control.

Figure 20-50-110

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1

P-69399

Remove the O-ring (Item 1) [Figure 20-50-110] from the

plug.

20-50-40 E85 Service Manual

HYDRAULIC PUMP (CONT’D)

Parts Identification

1. Snap Ring
2. Seal
3. Housing
4. Plug 15
5. O-ring 8
14
6. Swash Plate Bearing
7. Pin Assembly 8 10 11
8. Bolt
9. Gasket
10. Torque Limiter 5
11. Tubeline
12. Bearing Race 9
13. Bearing 8
14. Swash Plate
7 13
15. Shaft
3 12
16. Piston
17. Piston Retainer
18. Ball Guide
19. Cylinder Block 5
20. Pin
6
21. Washer
1
22. Spring
22
23. Piston 5
24. Piston Guide 2 21
4
25. Adjustment Screw 1 20
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26. End Cap 19

27. Valve Plate
28. Nut
29. Cap 18
30. Gasket 17 8 29
31. Fitting 5
32. Pump Control 16 28
5
26
25
5
24
4
22 5

27 32
23
30

21 5
5
12 31 8

13
21 24
23

NA13698S

20-50-41 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-112

Disassembly

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before 3
proceeding. This only affects machines sold 1
in the US and Canada.
2

IMPORTANT N-23355

When repairing hydrostatic and hydraulic systems, Remove the pin assembly (Item 1) [Figure 20-50-112].
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, NOTE: Note the position of the dowel pin (Item 2) on
tubelines and ports to keep dirt out. Dirt can quickly the pin assembly, with the locating hole on
damage the system. the swash plate cradle (Item 3) [Figure 20-50-
I-2003-0888 112].

Remove the hydraulic piston pump from the machine. Figure 20-50-113
(See Removal And Installation on Page 20-50-17.)

Clean the outside of the hydraulic piston pump.

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Remove the torque limiter valve. (See Torque Limiter
Valve Removal on Page 20-50-23.)

Remove the pump control assembly. (See Pump Control

Disassembly And Assembly on Page 20-50-35.) 1

Figure 20-50-111

P129748

Remove the plug (Item 1) [Figure 20-50-113] from the

1
pump housing and drain the oil.

Mark the pump housing for proper installation.

P129747

Remove the screw (Item 1) [Figure 20-50-111] from the

pin assembly.

20-50-42 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-116

Disassembly (Cont’d)

Figure 20-50-114

1 1

2
1

N-23387

1 1

Inspect the destroking piston (Item 1) [Figure 20-50-116]

P129749 for scratches and replace as needed.

Figure 20-50-117
Remove the bolts (Item 1) [Figure 20-50-114].

Remove the end cap (Item 2) [Figure 20-50-114] from

the pump.
2
Figure 20-50-115 1
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3
2

N-23388

Remove the spring (Item 1) from the stroking piston (Item

2) [Figure 20-50-117], inspect all parts and replace as
needed.
N-23386

Remove the O-ring (Item 1) [Figure 20-50-115].

Remove the destroking piston (Item 2) [Figure 20-50-

115].

Remove the stroking piston / spring assembly (Item 3)

[Figure 20-50-115].

20-50-43 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-120

Disassembly (Cont’d)

Figure 20-50-118
1

N-23391

Lay the pump assembly on its side and remove the rotary
N-23389 group, swash plate, and shaft (Item 1) [Figure 20-50-
120] from the housing.

Remove the bearing (Item 1) [Figure 20-50-118]. Figure 20-50-121

Figure 20-50-119

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1

N-23392

N-23390
Slide the rotary group (Item 1) from the shaft assembly
(Item 2) [Figure 20-50-121].
Remove the spacer(s) (Item 1) [Figure 20-50-119] from
the pump shaft. NOTE: It is NOT important that the pistons are
installed in their original positions.

NOTE: Check that there are no scratches or metal

deposits on the sliding surface. (pistons must
be replaced in sets).

20-50-44 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-124

Disassembly (Cont’d)

Figure 20-50-122
1
1
2

P-91159
2

Using a press and an appropriate sized spacer (Item 1),

P129750 compress the spring in the cylinder block (Item 2) [Figure
20-50-124].

Remove the retainer plate and pistons (Item 1) from the Figure 20-50-125
cylinder block (Item 2) [Figure 20-50-122].

Figure 20-50-123
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1
1

P-91160

P129751 Remove the snap ring (Item 1) [Figure 20-50-125].

Remove the cylinder block from the press.

Remove the retainer ball (Item 1) [Figure 20-50-123].

20-50-45 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-128

Disassembly (Cont’d)

Figure 20-50-126

1 2 3
3
3
1 2

N-23395

Remove the bolt (Item 1) and remove the torque limiter

N-15291 plate (Item 2) [Figure 20-50-128].

NOTE: The caps (Item 3) [Figure 20-50-128] cannot be

Remove the spring (Item 1) the washer (Item 2) and the replaced, a new swash plate must be ordered.
pins (Item 3) [Figure 20-50-126] from the cylinder block.

Figure 20-50-127

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1 2

N-23393

Remove the swash plate (Item 1) from the shaft (Item 2)

[Figure 20-50-127].

20-50-46 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-131

Disassembly (Cont’d)

Figure 20-50-129
1

N-23394

Remove the snap ring (Item 1) [Figure 20-50-131] from

N-15284 the housing.

Figure 20-50-132
Press the shaft (Item 1) from the bearing (Item 2) [Figure
20-50-129].

Figure 20-50-130

1
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1
1

N-23396

Remove the seal (Item 1) [Figure 20-50-132] from the

N-15277 housing.

NOTE: The shaft seal can be removed without

Remove the brass bearings (Item 1) [Figure 20-50-130] removing the shaft.
from the housing.

20-50-47 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-135

Disassembly (Cont’d)

Figure 20-50-133

N-23398

Remove the valve plate (Item 1) [Figure 20-50-135] from

N-15280 the housing.

Figure 20-50-136
Remove the race (Item 1) [Figure 20-50-133] from the
housing.

Figure 20-50-134

1 1

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1

N-23415

1
With a bearing puller (Item 1) [Figure 20-50-136] remove
N-23397 the bearing race from the back port assembly.

Remove the O-rings (Item 1) [Figure 20-50-134].

20-50-48 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-139

Disassembly (Cont’d)

Figure 20-50-137

N-23419

Remove the destroking piston (Item 1) [Figure 20-50-

N-23416 139].

Figure 20-50-140
Remove the spacer (Item 1) [Figure 20-50-137].

Figure 20-50-138 1
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N-23420

N-23418 Remove the cap (Item 1) [Figure 20-50-140] from the

stroking piston adjustment.

Remove the stroking piston (Item 1) [Figure 20-50-138]

(Spring Side).

20-50-49 E85 Service Manual

HYDRAULIC PUMP (CONT’D)

Disassembly (Cont’d)

Figure 20-50-141

N-23421

Before loosening the nut (Item 1) measure the distance

(Item 2) [Figure 20-50-141] of the stroking piston
adjustment screw to the nut.

Loosen the nut.

Figure 20-50-142

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N-23422

Remove the adjustment screw and nut [Figure 20-50-

142] from the housing.

20-50-50 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-144

Assembly

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

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

N-23418
Clean parts in solvent and dry with compressed air.

Apply oil or assembly lube to new O-rings. Apply Loctite® #241 on the threads and install the
stroking piston (Item 1) [Figure 20-50-144] in the hole
Figure 20-50-143 and tighten.

Figure 20-50-145
1

2
1
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N-23419

N-23416
Apply Loctite® #241 on the threads and install the
destroking piston (Item 1) in the hole next to the
alignment pin (Item 2) [Figure 20-50-143] and tighten. Install the spacer (Item 1) [Figure 20-50-145].

20-50-51 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-148

Assembly (Cont'd)

Figure 20-50-146

1
N-23396

Install the shaft seal (Item 1) [Figure 20-50-148] in the

N-23417 housing.

Figure 20-50-149
Install the bearing race (Item 1) [Figure 20-50-146] in the
back port assembly.

Figure 20-50-147
1

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N-23394

Install the snap ring (Item 1) [Figure 20-50-149].

N-15296

Press the race into the housing [Figure 20-50-147].

20-50-52 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-152

Assembly (Cont'd)

Figure 20-50-150
1

N-23425

Install the bearing (Item 1) [Figure 20-50-152] on the

N-15285 shaft.

Figure 20-50-153
Press the bearing (Item 1) onto the shaft (Item 2) [Figure
20-50-150]. 2 1
Figure 20-50-151

1 2
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N-23428

Install the end plate (Item 1) on the housing using two

N-23423 bolts (Item 2) [Figure 20-50-153].

To find the correct shim washer thickness for bearing end

play, the shaft / bearing assembly (Item 1) [Figure 20-50-
151] must be installed in the housing.

20-50-53 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Example: (In Inches):

Assembly (Cont'd) 0.150 Measure movement of shaft

Figure 20-50-154 0.001 Nominal Preload

=0.151 ± thickness of the spacer needed.

When the proper thickness of shim washer is

determined, remove the dial indicator from the pump
housing.

Remove the two end plate mounting bolts from the pump.

Remove the shaft / bearing assembly from the pump

housing.

Figure 20-50-156

N-23429

1
Turn the housing over [Figure 20-50-154]. 1

Figure 20-50-155

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N-15277

Install the brass bearings (Item 1) [Figure 20-50-156]

into the pump housing.

Figure 20-50-157

N-23430

3
Install a dial indicator on the housing as shown [Figure
20-50-155] and set it to zero.

Pull the shaft up as far as it will go and record the reading

on the dial indicator. Repeat the procedure several times.
The reading must be the same each time.

Add the nominal preload of 0,025 mm (0.001 in), the 2

actual preload is 0,000 mm (0.000 in) to 0,050 mm (0.002 1
in) to the reading found on the dial indicator [Figure 20-
N-15283
50-155].

Apply Loctite® #241 and install the torque limiter plate

(Item 1) and bolt (Item 2) on the swash plate (Item 3)
[Figure 20-50-157].

20-50-54 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-160

Assembly (Cont'd)

Figure 20-50-158
1

2
1 2

P-91159

Using a press and an appropriate sized spacer (Item 1),

N-23393 compress the spring in the cylinder block (Item 2) [Figure
20-50-160].

Install the swash plate (Item 1) on the shaft (Item 2) Figure 20-50-161
[Figure 20-50-158].

Figure 20-50-159
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3
2 1 1

P-91160

N-15291 Install the snap ring (Item 1) [Figure 20-50-161].

Apply clean grease to the pins (Item 1) [Figure 20-50-

159] and install them in the appropriate groove.

Install the washer (Item 2) and the spring (Item 3)

[Figure 20-50-159].

NOTE: If the rotating group is damaged, the parts can

not be ordered separately and must be
ordered as an assembly.

20-50-55 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-164

Assembly (Cont'd)
1
Figure 20-50-162
2

N-15281

Slide the rotary group assembly (Item 1) on the shaft

P129751 (Item 2) [Figure 20-50-164].

Install the retainer ball (Item 1) [Figure 20-50-162].

Figure 20-50-163

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2

P129750

Install the retainer and piston assembly (Item 1) in the

cylinder block (Item 2) [Figure 20-50-163].

NOTE: It is NOT important that the pistons are

installed in their original positions.

20-50-56 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-167

Assembly (Cont'd)

Figure 20-50-165 3

1 2

N-23386

Install the bearing (Item 1) [Figure 20-50-167] on the

N-15276 shaft.

Install a new O-ring (Item 2) [Figure 20-50-167].

Lay the pump housing on its side and install the rotary
group assembly, swash plate, and shaft in the housing Install the spring (Item 3) [Figure 20-50-167].
[Figure 20-50-165].
Figure 20-50-168
Figure 20-50-166
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2
1

3 N-23399
N-23390

Install the valve plate (Item 1) on the back port assembly.

Set the pump housing in the up-right position [Figure 20- The valve plate can only be installed one way by aligning
50-166]. the groove (Item 2) with the pin (Item 3) [Figure 20-50-
168].
Install the shim washer (Item 1) [Figure 20-50-166]. For
procedure to determine shim washer thickness see
[Figure 20-50-151 on Page 20-50-53].

20-50-57 E85 Service Manual

HYDRAULIC PUMP (CONT’D)

Assembly (Cont'd)

Figure 20-50-169

1
1

N-23397

Install the O-rings (Item 1) [Figure 20-50-169] on the

back port assembly.

Figure 20-50-170

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2

N-23431

Grease the inside of the control piston (Item 1) [Figure

20-50-170].

Slide it over the control piston shaft (Item 2) [Figure 20-

50-170].

20-50-58 E85 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-173

Assembly (Cont'd)

Figure 20-50-171

1
1 2
2

N-23354

Apply Loctite® #241 on the bolt (Item 1) and install the

N-23434 load sensing assembly (Item 2) [Figure 20-50-173].
Tighten to 13 N•m (10 ft-lb) torque.

Install the stroking piston adjustment screw (Item 1) Install the torque limiter valve. (See Torque Limiter Valve
[Figure 20-50-171], and adjust the screw to the Installation on Page 20-50-33.)
measurement taken in the disassembly procedure. (See
[Figure 20-50-141 on Page 20-50-50]). Install the pump control assembly. (See Pump Control
Disassembly And Assembly on Page 20-50-35.)
Tighten the adjustment nut (Item 2) [Figure 20-50-171].
Place the hydraulic piston pump on its side and fill
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NOTE: The final adjustment on the pump must be approximately half full.
done on the excavator. (See Pump Testing on
Page 20-50-5.) Install the O-ring on the plug.

Figure 20-50-172 Figure 20-50-174

N-23385 N-23384

Install the cap (Item 1) [Figure 20-50-172]. Install the plug (Item 1) [Figure 20-50-174].

20-50-59 E85 Service Manual

20-50-60
E85 Service Manual
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MANIFOLD ASSEMBLY / ACCUMULATOR

Description

The manifold body contains two boom offset solenoids,

two speed solenoid, system bypass solenoid and two
auxiliary hydraulic solenoids.

There is a 2999 kPa (30 bar) (435 psi) pressure reducing

valve.

The body is connected to the accumulator.

The manifold supplies target pressure of 2999 kPa (30

bar) (435 psi) with an acceptable range of 2799 - 3103
kPa (28 - 31 bar) (406 - 450 psi) to the joysticks to
activate the control valve spools.

The accumulator provides short term reserve pressure

for joystick function with the engine off and the key in the
ON position.
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20-60-1 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Disconnect the wire harness from the coils.

Removal And Installation Figure 20-60-2

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

Drain the hydraulic reservoir. (See Removing And

Replacing The Hydraulic Fluid on Page 10-130-3.)

Remove the right upperstructure cover. (See Removal

And Installation on Page 40-70-1.)

IMPORTANT
When repairing hydrostatic and hydraulic systems,
P133287
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 Remove the hoses and tubelines from the top and the
damage the system. side of the manifold [Figure 20-60-2].
I-2003-0888
Figure 20-60-3

WARNING 1
1

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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

Mark the hoses and wire harness for correct installation. P133293

Figure 20-60-1
Remove the nuts (Item 1) [Figure 20-60-3] and remove
the manifold.

P131662

Remove the hoses and tubelines from the bottom of the

manifold [Figure 20-60-1].

20-60-2 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT'D)

Parts Identification

1. Accumulator
2. Screw 5
3. Coil / Solenoid
4. O-ring 4
5. Nut
6. Coil 6
7. Solenoid
8. Back-up Ring
9. Plug
4
10. Check Valve
11. Body
3 2
12. Pressure Reducing Valve  7

2
4
3
1
4
8
4
8 4

4
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4
11
9

4
8
8
4
10 9 4

8
9 4

12

NA1976S

20-60-3 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-6

Disassembly And Assembly

Clean the outside of the manifold assembly / accumulator

before disassembly.

Figure 20-60-4 1

P-95292
1

Remove the screws (Item 1) [Figure 20-60-6].

Installation: Tighten the screws to 3 N•m (27 in-lb)

torque.
P-95291
Figure 20-60-7

Remove the accumulator (Item 1) [Figure 20-60-4] from

the manifold.

Figure 20-60-5

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1
1

P-95293

Remove the solenoid (Item 1) [Figure 20-60-7].

P-91704

Remove the O-ring (Item 1) [Figure 20-60-5].

20-60-4 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-10

Disassembly And Assembly (Cont’d)

Figure 20-60-8

P-95295

1
Remove the nut (Item 1) [Figure 20-60-10].
P-95294
Installation: Tighten the nut to 4,1 - 6,1 N•m (36 - 54 in-
lb) torque.
Repeat the procedure for the next solenoid (Item 1)
[Figure 20-60-8]. Figure 20-60-11

Figure 20-60-9
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1
3
2

1 1
P-95296

P-91707
Remove the O-ring (Item 1), coil (Item 2) and O-ring
(Item 3) [Figure 20-60-11].
Remove the O-rings (Item 1) [Figure 20-60-9] from the
solenoids.

20-60-5 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-14

Disassembly And Assembly (Cont’d)

Figure 20-60-12

3
2

P-95299
1

Remove the O-ring (Item 1), coil (Item 2), and O-ring
P-95297 (Item 3) [Figure 20-60-14].

Figure 20-60-15
Remove the spool (Item 1) [Figure 20-60-12].

Installation: Tighten the spool to 30 N•m (22 ft-lb)

torque.

Figure 20-60-13

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1

P-95300

1
Remove the spool (Item 1) [Figure 20-60-15].

Installation: Tighten the spool to 30 N•m (22 ft-lb)

P-95298 torque.

Remove the nut (Item 1) [Figure 20-60-13].

Installation: Tighten the nut to 4,1 - 6,1 N•m (36 - 54 in-

lb) torque.

20-60-6 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-18

Disassembly And Assembly (Cont’d)

1
Figure 20-60-16

2
2
2

1
P-91707

1
1 Remove the O-rings (Item 1) [Figure 20-60-18].
P-91712
Figure 20-60-19

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

[Figure 20-60-16] from both spools.

Figure 20-60-17
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P-95302
1
1
Remove the plugs (Item 1) [Figure 20-60-19].

P-95301

Remove the screws and solenoids (Item 1) [Figure 20-

60-17].

Installation: Tighten the screws to 3 N•m (27 in-lb)

torque.

20-60-7 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-22

Disassembly And Assembly (Cont’d)

Figure 20-60-20
1

P-91719
1

Remove the O-rings (Item 1) [Figure 20-60-22].

P-91717
Figure 20-60-23

Remove the O-ring (Item 1) [Figure 20-60-20] from both

plugs.

Figure 20-60-21 1

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P-91720

1
Remove the plug (Item 1) [Figure 20-60-23].

P-91718

Remove the check valve assembly (Item 1) [Figure 20-

60-21].

Installation: Tighten the plug to 40 N•m (29 ft-lb) torque.

20-60-8 E85 Service Manual

MANIFOLD ASSEMBLY / ACCUMULATOR (CONT’D) Figure 20-60-26

Disassembly And Assembly (Cont’d)

Figure 20-60-24
3
1

6
5 4

2
7

1 P-91553

Remove the spring seat (Item 1), spring (Item 2), spring
P-91717 seat (Item 3) and seat (Item 4). Remove the cap (Item 5)
and remove the adjustment screw (Item 6). Remove the
O-rings (Item 7) [Figure 20-60-26].
Remove the O-ring (Item 1) [Figure 20-60-24] from the
plug. Clean all parts in solvent and dry with compressed air.

Figure 20-60-25 Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

Inspect all parts for wear or damage. Replace any worn

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or damaged parts.

P-91721

Remove the pilot relief valve (Item 1) [Figure 20-60-25].

Installation: Tighten the pilot relief valve to 30 N•m (22

ft-lb) torque.

20-60-9 E85 Service Manual

20-60-10
E85 Service Manual
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TRAVEL MOTOR Figure 20-70-2

Removal And Installation

2
NOTE: Dealer disassembly of the component(s)
shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Lift and block the side of the track frame where the travel 1
motor will be removed.
P128250
Release the track tension and remove the track. (See
Track Removal And Installation on Page 30-20-4.)
Remove the hoses (Item 1) and bolts (Item 2) [Figure 20-
Remove the drive sprocket. (See Sprocket Removal And 70-2] from the travel motor.
Installation on Page 30-20-34.)
Installation: Apply thread lock (Loctite® 242) to the bolt
Figure 20-70-1 threads. Tighten the bolts to 265 N•m (195 ft-lb) torque.

Remove the travel motor from the track frame.

1
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P133066

Remove the bolts (Item 1) [Figure 20-70-1] from the

track frame cover.

Remove the cover.

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

Mark the hoses for correct installation.

20-70-1 E85 Service Manual

TRAVEL MOTOR (CONT'D)

Parts Identification

1
2
1 Spring
2 Piston Assembly 4 3
3 Pin 5
6
4 Pivot
5 Seal 7
6 Bearing 8
7 Shaft
8 Swash Plate
9 Piston 9
10 Retainer Plate 10
11 Thrust Ball
12 Washer
13 Pin
14 Cylinder
15 Snap Ring
16 Mating Plate
11
17 Friction Plate 12
18 O-ring 13
19 Valve Plate
20 Plug 14
21 Rear Flange 12
1 16
22 Spring Retainer 17
12
23 Filter 15
24 Ball 18

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25 Valve 18
26 Spool
27 Bolt 1
28 Back-up Ring 20 20
29 Sleeve 18 18 19
1
30 Shim 21 6
22
31 Poppet 20 18
1 25
3
1 23
26 24
18 18 20
1 20 26
22
20 18 22
30 1
18 18
20
29 18 1
27
28 18
20
28
31 18

22 1
28
18 18
20
29
30

NA13664S

20-70-2 E85 Service Manual

TRAVEL MOTOR (CONT'D)

Parts Identification Gear Reduction Hub

1 Bolt
2 Thrust Washer
3 Planetary Gear
4 Roller Bearing
5 Inner Ring
6 Collar
7 Nut
8 Ball Bearing
9 Hub
2 1
10 Seal 3
11 Spindle 4
12 Pin
5
13 O-ring 2
14 Plug
15 Snap Ring 7
16 Cover 8 6
17 Steel Ball
9
18 Sun Gear
19 Carrier
8
10
11
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14
15 13
16
12 13
13
3 2 1 17

4
5
19
18

15

18

B-23946

20-70-3 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-4

Disassembly

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found 1
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Clean the outside of the travel motor before disassembly.

IMPORTANT P129755

Remove the snap ring (Item 1) [Figure 20-70-4] and

When repairing hydrostatic and hydraulic systems,
cover.
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Figure 20-70-5
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Drain the fluid from the travel motor.

Recycle or dispose of the used fluid in an

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environmentally safe manner.

Figure 20-70-3

1 P129756

Remove the O-ring (Item 1) [Figure 20-70-5] from the

cover.

P129754

Remove the plug (Item 1) [Figure 20-70-3].

Remove and discard the O-rings from the plugs.

NOTE: The gear reduction side of the travel motor can

not be fully disassembled. The spindle will be
damaged when the nut is removed.

20-70-4 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-8

Disassembly (Cont’d)

Figure 20-70-6

1 1

P129759

2
Remove the gears (Item 1) [Figure 20-70-8].
P129757
Figure 20-70-9

Remove the steel ball (Item 1) [Figure 20-70-6] from the

sun gear.

Remove the sun gear (Item 2) [Figure 20-70-6].

Figure 20-70-7
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P129778

Remove the bearings (Item 1) [Figure 20-70-9] and

2 races.

P129758

Remove the bolts (Item 1) and plates (Item 2) [Figure 20-

70-7].

NOTE: Do not reuse the bolts holding the planetary

gears to the carrier.

20-70-5 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-12

Disassembly (Cont’d)

Figure 20-70-10

1
1

P129781

Remove the bolts (Item 1) and thrust washers (Item 2)

P129779 [Figure 20-70-12].

NOTE: Do NOT reuse the bolts holding the planetary

Remove the carrier (Item 1) [Figure 20-70-10]. gears to the carrier.

Figure 20-70-11 Figure 20-70-13

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1

P129780 P129782

Remove the snap ring (Item 1) and sun gear (Item 2) Remove the planetary gears (Item 1) [Figure 20-70-13].
[Figure 20-70-11] from the carrier.

20-70-6 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-16

Disassembly (Cont’d)

Figure 20-70-14

2
1

P129785

NOTE: The gear reduction side of the travel motor

P129783 should not be disassembled any farther than
shown. The spindle (Item 1) will be damaged if
the nut (Item 2) [Figure 20-70-16] is removed.
Remove the bearings (Item 1) [Figure 20-70-14] and
races. Figure 20-70-17

Figure 20-70-15

1
1
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1
1

P129786

P129784
Remove the relief valves (Item 1) [Figure 20-70-17].

Remove the thrust washers (Item 1) [Figure 20-70-15].

20-70-7 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-20

Disassembly (Cont’d)
2
Figure 20-70-18 1

6
7 7

4 3 2 1
6 5 P129789

Remove the spring (Item 1) and spring seat (Item 2)

P129787 [Figure 20-70-20] from both sides of the rear flange.

Figure 20-70-21
To disassemble the relief valve remove the plug (Item 1),
shims (Item 2), spring (Item 3), and spring seat (Item 4)
from the relief body (Item 5). Remove the O-rings (Item 6)
and back-up rings (Item 7) [Figure 20-70-18].

Figure 20-70-19 1

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1
1

P129790

Remove the spool (Item 1) [Figure 20-70-21].

P129788

Remove the plugs (Item 1) [Figure 20-70-19].

20-70-8 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-24

Disassembly (Cont’d)

Figure 20-70-22
1

P129793

Remove the plug (Item 1) [Figure 20-70-24].

P129791
Figure 20-70-25

Remove the plug (Item 1) [Figure 20-70-22] from both

sides of the rear flange.
2
Figure 20-70-23 1

2
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P129794
1

Remove the spring (Item 1) and spool (Item 2) [Figure

20-70-25].
P129792

Remove the spring (Item 1) and valve (Item 2) [Figure

20-70-23] from both sides of the rear flange.

20-70-9 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-28

Disassembly (Cont’d)
3
Figure 20-70-26

1 2

3
P129797

1 Remove the pin (Item 1) and bearing (Item 2) [Figure 20-

P129795 70-28].

Inspect the orifice (Item 3) [Figure 20-70-28].

Remove the bolts (Item 1) [Figure 20-70-26] from the
rear flange. Figure 20-70-29

Remove the rear flange. 1

Figure 20-70-27

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1

1
P129798
1
2
Remove the O-rings (Item 1) [Figure 20-70-29].
P129824

Remove the springs (Item 1) and valve plate (Item 2)

[Figure 20-70-27].

20-70-10 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-32

Disassembly (Cont’d)

Figure 20-70-30

1
P129801
2

Remove the mating plates and friction plates (Item 1)

P129799 [Figure 20-70-32].

Figure 20-70-33
Remove the piston (Item 1) by injecting low air pressure
into the access hole (Item 2) in the spindle [Figure 20-
70-30].

Figure 20-70-31
1
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P129804
P-

1
Remove the cylinder block assembly (Item 1) [Figure 20-
1 70-33].
P129800

Remove the O-rings (Item 1) [Figure 20-70-31].

20-70-11 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-36

Disassembly (Cont’d)

Figure 20-70-34

P129807

2
Remove the washer (Item 1) from the cylinder block (Item
P129805 2) [Figure 20-70-36].

Figure 20-70-37
Remove the pistons (Item 1) and retainer plate from the
cylinder block (Item 2) [Figure 20-70-34].

Figure 20-70-35

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1

1
2

P129808

Remove the pins (Item 1) [Figure 20-70-37] from the

P129806 cylinder block.

Remove the thrust ball (Item 1) from the cylinder block

(Item 2) [Figure 20-70-35].

20-70-12 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-40

Disassembly (Cont’d)

Figure 20-70-38 2 1
3

P-87617

Remove the top washer (Item 1), spring (Item 2) and

P-87615 bottom washer (Item 3) [Figure 20-70-40].

Figure 20-70-41
Using a press and an approximately sized spacer (Item
1), compress the spring in the cylinder block (Item 2)
[Figure 20-70-38].

Figure 20-70-39
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1
1 P129809

Remove the swash plate (Item 1) and shaft assembly

(Item 2) [Figure 20-70-41].
P-87616

Remove the snap ring (Item 1) [Figure 20-70-39].

Remove the cylinder block from the press.

20-70-13 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-44

Disassembly (Cont’d)

Figure 20-70-42 2

1 1 1
1
P129811

Remove the parallel pins (Item 1) [Figure 20-70-44].

P129810
Remove the two-speed piston (Item 2) [Figure 20-70-44]
and spring.
Remove the swash pivots (Item 1) [Figure 20-70-42]
from the bottom of the swash plate. Figure 20-70-45

Figure 20-70-43
1

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2

P129813

P-89336
Remove the seal (Item 1) [Figure 20-70-45].

Place the shaft (Item 1) in a press and remove the

bearing (Item 2) [Figure 20-70-43].

20-70-14 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-48

Assembly

Clean all parts in solvent and dry with compressed air.

1
Inspect all parts and replace those that are damaged. If
any of the planetary gears are damaged, replace all the
planetary gears and the sun gear from that planetary.

One damaged gear can cause a microscopic fatigue

crack in the mating teeth and cause premature failure
after servicing.
2 2
Apply oil to all O-rings (as noted) and light grease to the
ball and roller bearings before installation.
P129811
Figure 20-70-46

Install the piston assembly (Item 1) and parallel pins

(Item 2) [Figure 20-70-48] into the spindle.

Figure 20-70-49

2
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1
1
P129813

Install the oil seal (Item 1) [Figure 20-70-46] into the

spindle.
P-89069
Figure 20-70-47

Heat the bearing (Item 1) to 72 - 128°C (162 - 262°F) and

install the shaft (Item 2) [Figure 20-70-49].

P129812

Install the spring (Item 1) [Figure 20-70-47] into the

piston.

20-70-15 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-52

Assembly (Cont’d)

Figure 20-70-50 2 3
1

1 1

P-87617

Install the washer (Item 1), spring (Item 2) and top

P129810 washer (Item 3) [Figure 20-70-52].

Figure 20-70-53
Install the pivots (Item 1) [Figure 20-70-50] into the
swash plate.

Figure 20-70-51
1

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2
1

2
P-87615

Using a press and an appropriate sized spacer (Item 1),

P129809 compress the spring in the cylinder block (Item 2) [Figure
20-70-53].

Install the shaft assembly (Item 1) and swash plate (Item

2) [Figure 20-70-51].

NOTE: Make sure the pivots mounted on the spindle

enter the pivot holes of the swash plate.

20-70-16 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-56

Assembly (Cont’d)

Figure 20-70-54

1
P129807

Install the washer (Item 1) [Figure 20-70-56] onto the

P-87616 cylinder block.

Figure 20-70-57
Install the snap ring (Item 1) [Figure 20-70-54]. Remove
the cylinder block from the press.

Figure 20-70-55
1
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P129806

1
Install the thrust ball (Item 1) [Figure 20-70-57] onto the
P129808 cylinder block.

Install the pins (Item 1) [Figure 20-70-55] into the

cylinder block.

20-70-17 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-60

Assembly (Cont’d)

Figure 20-70-58

P129803

Prepare the mating and friction plates by laying them out

P129805 in the order as shown [Figure 20-70-60]. Note the
alternating order.

Install the piston and retainer assembly (Item 1) [Figure NOTE: Immerse the friction plates in hydraulic fluid
20-70-58] into the cylinder block. prior to installation.

Figure 20-70-59 Figure 20-70-61

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P129804 P129801

Install the cylinder block assembly (Item 1) [Figure 20- Install the mating plate. Install the remaining friction
70-59] onto the shaft. plates and mating plates alternatively [Figure 20-70-61].

20-70-18 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-64

Assembly (Cont’d) 1

Figure 20-70-62 2
2

1
P129798
1
1
Install the O-rings (Item 1) and dowel pins (Item 2)
P129800 [Figure 20-70-64] into the rear flange.

Figure 20-70-65
Install the O-rings (Item 1) [Figure 20-70-62] onto the
piston.

Figure 20-70-63

1
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P129797
1

Install the bearing (Item 1) and pin (Item 2) [Figure 20-

P129799 70-65] into the rear flange.

Install the piston (Item 1) [Figure 20-70-63].

20-70-19 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-68

Assembly (Cont’d)

Figure 20-70-66
1

P129794

1
Install the spool and spring (Item 1) [Figure 20-70-68].
P129824
Figure 20-70-69

Install the valve plate (Item 1) and springs (Item 2)

[Figure 20-70-66].

NOTE: Apply a small amount of assembly lube or 1

grease to retain the springs in the location.

Figure 20-70-67

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1

P129793

Install the plug (Item 1) [Figure 20-70-69]. Tighten the

plug to 78 - 117 N•m (58 - 86 ft-lb) torque.

2
P129795

Install the rear flange (Item 1) [Figure 20-70-67] onto the

spindle. Make sure the dowel pins on the spindle align
with the holes in the rear flange.

Install and tighten the bolts (Item 2) [Figure 20-70-67] to

85 - 118 N•m (63 - 87 ft-lb) torque.

20-70-20 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-72

Assembly (Cont’d)

Figure 20-70-70

1
1

2 P129790

Install the spool (Item 1) [Figure 20-70-72].

P129792
Figure 20-70-73

Install the valve (Item 1) and spring (Item 2) [Figure 20-

70-70] on both sides of the rear flange. 1
2
Figure 20-70-71

1
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P129789

Install the spring seat (Item 1) and spring (Item 2)

[Figure 20-70-73] on both sides of the rear flange.
P129791

Install the plug (Item 1) [Figure 20-70-71] on both sides

of the rear flange. Tighten the plug to 78 - 117 N•m (58 -
86 ft-lb) torque.

20-70-21 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-76

Assembly (Cont’d)

Figure 20-70-74
1
1
1
1

P129786

Install the relief valves (Item 1) [Figure 20-70-76].

P129788 Tighten the valves to 122 - 152 N•m (90 - 112 ft-lb)
torque.

Install the plugs (Item 1) [Figure 20-70-74]. Tighten the Figure 20-70-77
plugs to 313 - 392 N•m (231 - 289 ft-lb) torque.
1
Figure 20-70-75

2 2 6

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1 1

3 4 5 1
1 1
P129784

P129787 Install the thrust washers (Item 1) [Figure 20-70-77].

To assemble the relief valve install the O-rings (Item 1)

and back-up rings (Item 2). Install the spring seat (Item
3), spring (Item 4) and shims (Item 5). Install the plug
(Item 6) [Figure 20-70-75].

20-70-22 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-80

Assembly (Cont’d)

Figure 20-70-78
2 1

P129781

Install the thrust washers (Item 1) and new bolts (Item 2)

P129783 [Figure 20-70-80].

Tighten the bolts to 49 - 68 N•m (36 - 50 ft-lb) torque.

Install the bearings and races (Item 1) [Figure 20-70-78].
Figure 20-70-81
Figure 20-70-79

1
1
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P129780
P129782

Install the sun gear (Item 1) and snap ring (Item 2)

Install the planetary gears (Item 1) [Figure 20-70-79]. [Figure 20-70-81].

20-70-23 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-84

Assembly (Cont’d)
1
Figure 20-70-82

P129759

Install the planetary gears (Item 1) [Figure 20-70-84].

P129779
Figure 20-70-85

Install the carrier assembly (Item 1) [Figure 20-70-82].

Figure 20-70-83 1

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2

P129758

Install the thrust washers (Item 1) and bolts (Item 2)

P129778 [Figure 20-70-85]. Tighten the bolts to 28 - 39 N•m (21 -
29 ft-lb) torque.

Install the bearings (Item 1) [Figure 20-70-83] and races.

20-70-24 E85 Service Manual

TRAVEL MOTOR (CONT'D) Figure 20-70-88

Assembly (Cont’d)

Figure 20-70-86

P129755

2
Install the hub cover (Item 1) [Figure 20-70-88].
P129757
Install the snap ring (Item 2) [Figure 20-70-88].

Install the sun gear (Item 1) and steel ball (Item 2) Figure 20-70-89
[Figure 20-70-86].

Figure 20-70-87

1
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P129754
1

P129756 Install the plug (Item 1) [Figure 20-70-89].

Tighten the plugs to 49 - 68 N•m (36 - 50 ft-lb) torque.

Install the O-ring (Item 1) [Figure 20-70-87] on the cover.

20-70-25 E85 Service Manual

20-70-26
E85 Service Manual
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SWIVEL JOINT Figure 20-80-3

Removal And Installation

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Figure 20-80-1

P131657

Remove the hoses from the top and side of the swivel
joint [Figure 20-80-3].

Figure 20-80-4

P-92247
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1
Block the excavator up as shown [Figure 20-80-1].

Remove the floor mat and floor panel. (See Removal And
Installation on Page 40-100-1.)

Drain the hydraulic reservoir. (See Removing And

Replacing The Hydraulic Fluid on Page 10-130-3.)
P131656
Figure 20-80-2
Mark and remove the hoses from the bottom of the swivel
joint [Figure 20-80-4].
2
1 Remove the four bolts and nuts (Item 1) [Figure 20-80-4]
1 from the swivel joint.
1 Lower the swivel joint at the bottom of the excavator.
1

P-92245

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

(Item 2) [Figure 20-80-2].

20-80-1 E85 Service Manual

SWIVEL JOINT (CONT’D)

Parts Identification

1. Rotor
2. Stop
3. O-ring
4. Plug
5. Seal 1
6. Nylon Washer 2
7. Crown Seal 8
8. Back-up Ring
9. Seal Assembly 9
10. Snap Ring
11. Cover 8
12. Bolt 8
13. Housing
9
8
8
3 9
4 8

9
5
8

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7

8
13
9
8

9
8 6
8

9 10
8
8 3
9

8 11

12

NA13650S

20-80-2 E85 Service Manual

SWIVEL JOINT (CONT’D) Figure 20-80-7

Disassembly And Assembly

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Figure 20-80-5 1

P131140

Remove the snap ring (Item 1) [Figure 20-80-7].

Figure 20-80-8

1 1
2
P131138
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Remove the bolts (Item 1) and cover (Item 2) [Figure 20-

80-5].
1
Figure 20-80-6
P131141

1 Remove the nylon washer (Item 1) [Figure 20-80-8]

P131139

Remove the O-ring (Item 1) [Figure 20-80-6]

20-80-3 E85 Service Manual

SWIVEL JOINT (CONT’D) Figure 20-80-11

Disassembly And Assembly (Cont’d)

Figure 20-80-9

1
P131152
1

Remove the seal (Item 1) [Figure 20-80-11].

P131142
Figure 20-80-12

Tap the rotor (Item 1) out of the housing. [Figure 20-80- 1

9].

Figure 20-80-10

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1

P131145

Remove the crown seal (Item 1) [Figure 20-80-12].

P131151

Remove the nylon washer (Item 1) [Figure 20-80-10].

20-80-4 E85 Service Manual

SWIVEL JOINT (CONT’D) Figure 20-80-15

Figure 20-80-13
1

P131150

P131146
Remove the O-ring (Item 1) [Figure 20-80-15].

Remove the seal (Item 1) [Figure 20-80-13]. Remove the remaining seal / O-ring / back-up ring
assemblies from the rotor. Remove the top crown seal
Figure 20-80-14 assembly.
1 Assembly: Heat the crown seals and seals in hydraulic
oil for three minutes at 54°C (130°F) before installing the
seals on the rotor.
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P131149

Remove the back-up ring and seal (Item 1) [Figure 20-

80-14].

20-80-5 E85 Service Manual

20-80-6
E85 Service Manual
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SWING MOTOR Figure 20-90-3

Removal And Installation

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under 1
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before 1
proceeding. This only affects machines sold
in the US and Canada.

Remove the hydraulic reservoir. (See Removal And 1

Installation on Page 20-90-1.)
1
P131952
Figure 20-90-1

Remove the hoses (Item 1) [Figure 20-90-3] from the

swing motor.
1

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,
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tubelines and ports to keep dirt out. Dirt can quickly

damage the system.
P131950 I-2003-0888

Remove the cable tie strap (Item 1). Remove the bolt NOTE: Mark all hoses before removal for ease of
(Item 2) [Figure 20-90-1]. installation.

Figure 20-90-2 Figure 20-90-4

1 1

P131953
P131951

Remove the bolt (Item 1) and remove the bracket (Item 2) Remove the hoses (Item 1) [Figure 20-90-4].
[Figure 20-90-2].

20-90-1 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-7

Removal And Installation (Cont’d)

Figure 20-90-5

P131956

Install a hoist on the swing motor and remove the motor

P131954 [Figure 20-90-7].

Figure 20-90-8
Remove the bolts (Item 1) [Figure 20-90-5].

Installation: Tighten the bolts to 85,7 - 117,7 N•m (63-

87 ft-lb) torque.

Figure 20-90-6
1

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1

P131957

Remove the O-ring (Item 1) [Figure 20-90-8].

P131955

Install two bolts (Item 1) [Figure 20-90-6] (removed in

previous step) in the threaded holes in the swing motor.
Tighten the bolts evenly to separate the swing motor from
the swing motor drive carrier.

20-90-2 E85 Service Manual

SWING MOTOR (CONT’D)

Parts Identification

1. Relief Valve
2. Bolt
3. Plug
4. O-ring
5. Spring 3
1
6. Anti-Cavitation Valve
7. End Cap
8. Bearing 2
9. Valve Plate
10. Spring 6
11. Brake Piston 7 5
12. Separation Plate
13. Friction Plate 3
8
14. Snap Ring
15. Washer 4
9
16. Cylinder Block
17. Ball Guide 10
18. Piston Assembly 11
19. Piston Retainer
4
20. Thrust Plate 4
21. Pipe Plug 14
22. Dipstick Assembly 12
23. Brake Valve 15
13 10
15
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16

15
17

18

19
2 20
21
23
22
8

14

NA-1044

20-90-3 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-2

Disassembly And Assembly

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual 2
or by clicking here. Please click here to check 2
the list of affected part numbers in IRW before
proceeding. This only affects machines sold 1
in the US and Canada.

Figure 20-90-1 1

P-87586

Remove the springs (Item 1) and spools (Item 2) [Figure

20-90-2].

Figure 20-90-3
1

1
P-87584

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Remove the three bolts and remove the brake valve (Item
1) [Figure 20-90-1].

Figure 20-90-1

P-87587
1 1
Remove the plug (Item 1) [Figure 20-90-3] from both
sides of the end cap.

Installation: Tighten the plugs to 79 - 98 N•m (58 - 72 ft-

lb) torque.

P-87585

Remove the O-rings (Item 1) [Figure 20-90-1].

20-90-4 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-6

Disassembly And Assembly (Cont’d)

Figure 20-90-4

1
1

P-87590

Remove the spool (Item 1) [Figure 20-90-6] from both

P-87588 sides of the end cap.

Figure 20-90-7
Remove the O-ring (Item 1) [Figure 20-90-4] from both
plugs.

Figure 20-90-5
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1
1

P-87591

Remove the relief valves (Item 1) [Figure 20-90-7].

P-87589
Installation: Tighten the relief valves to 148 - 167 N•m
(109 - 123 ft-lb) torque.
Remove the spring (Item 1) [Figure 20-90-5] from both
sides of the end cap.

20-90-5 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-10

Disassembly And Assembly (Cont’d)

Figure 20-90-8
1

P-87594

Remove the valve plate (Item 1) [Figure 20-90-10] from

P-87592 the end cap.

Figure 20-90-11
Remove the O-ring (Item 1) [Figure 20-90-8] from both
relief valves.

Figure 20-90-9
1

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2

1
1

P-87596
1

Installation: The hole (Item 1) in the valve plate must

P-87593 engage the pin (Item 2) [Figure 20-90-11] on the end
cap.

Remove the four bolts (Item 1) [Figure 20-90-9] and

remove the end cap.

Installation: Tighten the bolts to 85 - 118 N•m (63 - 87 ft-

lb) torque.

20-90-6 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-14

Disassembly And Assembly (Cont’d)

Figure 20-90-12
1

P-87598

Installation: Do not install springs in the spring bores

P-87595 with threaded holes (Item 1) [Figure 20-90-14].

Figure 20-90-15
Remove the bearing (Item 1) [Figure 20-90-12].

Figure 20-90-13 1

2
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P-87599

P-87597 Install two screws (Item 1) [Figure 20-90-15] in the

threaded holes of the brake piston. Pull up on the screws
and remove the brake piston.
Remove the O-ring (Item 1). Remove the sixteen springs
(Item 2) [Figure 20-90-13].

20-90-7 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-18

Disassembly And Assembly (Cont’d)

1
Figure 20-90-16

P-87602

Remove the second friction plate (Item 1) [Figure 20-90-

P-87600 18].

Figure 20-90-19
Remove the friction plate (Item 1) [Figure 20-90-16].

Figure 20-90-17
1

1
1

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P-86577

P-87601 Remove the O-rings (Item 1) [Figure 20-90-19].

Remove the separation plate (Item 1) [Figure 20-90-17].

20-90-8 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-22

Disassembly And Assembly (Cont’d)

Figure 20-90-20 1

1
P-87605

Remove the piston assemblies (Item 1) [Figure 20-90-

P-87603 22] from the retainer.

Figure 20-90-23
Tip the housing and remove the rotating group (Item 1)
[Figure 20-90-20].
1
Figure 20-90-21
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P-87606

Remove the ball guide (Item 1) [Figure 20-90-23].

P-87604

Remove the piston assemblies / retainer (Item 1) [Figure

20-90-21] from the cylinder block.

NOTE: It is not important that the pistons are

installed in the original bores.

20-90-9 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-26

Disassembly And Assembly (Cont’d)

Figure 20-90-24

2
1

P-87615

Using a press and an appropriately sized spacer (Item 1),

P-87607 compress the spring in the cylinder block (Item 2) [Figure
20-90-26].

Remove the washer (Item 1) [Figure 20-90-24]. Figure 20-90-27

Figure 20-90-25

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1
1
1

P-87616

P-87608
Remove the snap ring (Item 1) [Figure 20-90-27].
Remove the cylinder block from the press.
Remove the three pins (Item 1) [Figure 20-90-25].

20-90-10 E85 Service Manual

SWING MOTOR (CONT’D) Figure 20-90-30

Disassembly And Assembly (Cont’d)

Figure 20-90-28

1
3 2
1

P-87611

Remove the snap ring (Item 1) [Figure 20-90-30] from

P-87617 the shaft.

Figure 20-90-31
Remove the top washer (Item 1), spring (Item 2), and
bottom washer (Item 3) [Figure 20-90-28].

Figure 20-90-29
1
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P-87612

Remove the shaft (Item 1) [Figure 20-90-31].

P-87609

Remove the thrust plate (Item 1) [Figure 20-90-29].

20-90-11 E85 Service Manual

SWING MOTOR (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-90-32

P-87613

Remove the bearing (Item 1) [Figure 20-90-32].

Figure 20-90-33

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1

P-87614

Remove the seal (Item 1) [Figure 20-90-33].

Prior to assembly perform the following steps:

Clean all parts in solvent and dry with compressed air.

Check the components for wear and damage.

Always use new O-rings and seals.

Apply clean hydraulic oil to the components during

installation.

20-90-12 E85 Service Manual

SWING MOTOR (DRIVE CARRIER) Figure 20-91-3

Removal And Installation

Remove the swing motor. (See Removal And Installation

on Page 20-90-1.)

Figure 20-91-1
1

P131962

Install two bolts (Item 1) [Figure 20-91-3] (removed in

previous step) in the threaded holes in the swing motor
2
drive carrier. Tighten the bolts evenly to separate the
swing motor drive carrier from the frame.
1 P131960
Figure 20-91-4

Remove the bolts (Item 1). Install lifting brackets (Item 2) 1

[Figure 20-91-1] on the carrier.

Figure 20-91-2
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P131963

Install a sling (Item 1) [Figure 20-91-4] and hoisting

device to the swing motor drive carrier.
P131961
Remove the swing motor drive carrier.

Remove the grease hose (Item 1) [Figure 20-91-2].

NOTE: Mark the swing motor drive carrier and frame

for proper installation.

20-91-1 E85 Service Manual

SWING MOTOR (DRIVE CARRIER) (CONT’D)

Parts Identification

1. Snap Ring
2. Thrust Washer
3. Bearing Race
1
4. Needle Bearing 2
5. Planetary Gear
6. Sun Gear 3
7. Carrier 4
8. Screw 5
9. Thrust Plate 6
2
10. Collar 2
11. O-ring
12. Bearing 7
13. Seal
14. Housing
15. Plug
16. Dust Seal 6 2
17. Pinion Shaft
8
3
9 4
5
7
2

10

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12

11
13

14

15
12

16

17

NA-1043

20-91-2 E85 Service Manual

SWING MOTOR (DRIVE CARRIER) (CONT’D) Figure 20-91-7

Disassembly And Assembly

1
Figure 20-91-5 2
3

1 4
5
7 6

NA-1114

Remove the snap ring (Item 1), thrust washer (Item 2),
NA-1110 planetary gear (Item 3), bearing (Item 4) bearing race
(Item 5), and thrust washer (Item 6) [Figure 20-91-7].

Remove the sun gear (Item 1) [Figure 20-91-5]. Remove the sun gear thrust washer (Item 7) [Figure 20-
91-7].
Figure 20-91-6
Figure 20-91-8

1
1
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NA-1111

NA-1112

Remove the carrier assembly (Item 1) [Figure 20-91-6].

Remove the sun gear (Item 1) [Figure 20-91-8].

20-91-3 E85 Service Manual

SWING MOTOR (DRIVE CARRIER) (CONT’D) Figure 20-91-11

Disassembly And Assembly (Cont’d) 1

Figure 20-91-9 2

1 4
3

NA-1116

Remove the thrust washer (Item 1), planetary gear (Item

NA-1113 2), bearing (Item 3), bearing race (Item 4), and thrust
washer (Item 5) [Figure 20-91-11].

Remove the carrier assembly (Item 1) [Figure 20-91-9]. Figure 20-91-12

Figure 20-91-10
1
1
1

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2

NA-1117

NA-1115
Remove both halves of the collar (Item 1) [Figure 20-91-
12].
Heat the screws (Item 1) [Figure 20-91-10] to melt the
thread adhesive.

Remove the screws (Item 1) and remove the thrust plate

(Item 2) [Figure 20-91-10].

20-91-4 E85 Service Manual

SWING MOTOR (DRIVE CARRIER) (CONT’D) Figure 20-91-15

Disassembly And Assembly (Cont’d)

1
Figure 20-91-13

1 NA-1119

Remove the bearing (Item 1) [Figure 20-91-15].

NA-1118
Figure 20-91-16

Remove the pinion shaft (Item 1) [Figure 20-91-13].

1
Figure 20-91-14

1
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NA-1120

Remove the seal (Item 1) [Figure 20-91-16].

NA-1130

Remove the bearing (Item 1) and dust seal (Item 2)

[Figure 20-91-14] from the pinion shaft.

20-91-5 E85 Service Manual

20-91-6
E85 Service Manual
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CONTROL PATTERN SELECTOR VALVE Figure 20-100-2

Removal And Installation

1
Remove the tool box.

Mark all hydraulic hoses for proper installation.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
P131316
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 Remove the bolts (Item 1) [Figure 20-100-2].

Figure 20-100-1 Remove the control pattern selector valve from the
excavator.
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P131317

Remove the eight hydraulic hoses from the control

pattern selector valve (Item 1) [Figure 20-100-1].

20-100-1 E85 Service Manual

CONTROL PATTERN SELECTOR VALVE (CONT’D)

Parts Identification

1. Snap Ring
2. Nylon Washer
3. O-ring
4. Body
5. Ball
6. Spring
7. Spool
8. Handle
9. Plug

1
2

3 4

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5

9
3
7
2

1
5

NA2118

20-100-2 E85 Service Manual

CONTROL PATTERN SELECTOR VALVE (CONT’D) Figure 20-100-5

Disassembly And Assembly

Clean the outside of the valve before disassembly.

Figure 20-100-3

P-92292

Wrap a shop towel around the spool and pull the spool
out of the valve [Figure 20-100-5].

P-92290 Figure 20-100-6

Remove the snap ring (Item 1) [Figure 20-100-3].

Figure 20-100-4
1
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2
1 1
P-92293

Remove the detent balls (Item 1) and spring (Item 2)

[Figure 20-100-6].
P-92291

Remove the nylon washers (Item 1) [Figure 20-100-4].

20-100-3 E85 Service Manual

CONTROL PATTERN SELECTOR VALVE (CONT’D)

Disassembly And Assembly (Cont’d)

Figure 20-100-7

P-92294

Remove the O-ring (Item 1) and nylon washer (Item 2)

[Figure 20-100-7].

Figure 20-100-8

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1

P-92296

Remove the O-ring (Item 1) [Figure 20-100-8] from the

valve body.

20-100-4 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) Figure 20-110-2

Testing

The following tools will be needed to do the procedure:

1
MEL1355 - Hydraulic Test Kit

Stop the engine.

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

Page 10-60-1.)

Figure 20-110-1

P131643

From the test kit Install a 3447 kPa (35 bar) (500 psi)
1
gauge (Item 1) [Figure 20-110-2] on the pilot line. Start
the excavator, and warm the hydraulic oil to operating
temperature.

Engage the circuit to be tested. Record the operating

2 pressure.

The operating pressure should be approximately 2799 -

3103 kPa (28 - 31 bar) (406 - 450 psi).
P131642
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If the operating pressure is correct, check the valve

section spool for proper operation. If the operating
At the control valve assembly, find the pilot line (Item 1) pressure is incorrect, remove the pressure reducing
[Figure 20-110-1] of the control lever (joystick) that is to valve, clean, install and retest. (See Testing And
be checked. (Boom, Arm, Slew, Bucket) Adjusting on Page 20-33-1.)

Disconnect the hydraulic fitting (Item 2) [Figure 20-110- If the pressure is still incorrect replace the pressure
1] from the control valve. reducing valve. (See Testing And Adjusting on Page 20-
33-1.)

20-110-1 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-5

Handle Removal And Installation

Remove the right console cover. (See Console Cover

Removal And Installation on Page 40-40-1.)

Figure 20-110-3

1
P129235

Raise the joystick and remove the wire harness (Item 1)

[Figure 20-110-5] from the console.

Figure 20-110-6
P129233

Disconnect the electrical connector (Item 1) [Figure 20-

110-3] from the excavator wiring harness.

Figure 20-110-4

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1

1
2

P129236

Slide the grommet / wire harness (Item 1) [Figure 20-

110-6] out of the joystick body.

P-92090

Raise the boot (Item 1) and remove the bolts (Item 2)

[Figure 20-110-4].

20-110-2 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)

Handle Removal And Installation (Cont’d)

Figure 20-110-7

P-92091

Pull the boot down and pull the wire harness (Item 1) out
of the boot. Loosen the nut (Item 2) [Figure 20-110-7]
and remove the handle.

Figure 20-110-8
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P-32521

Installation: Align the top of the dust boot (Item 1) with

the groove (Item 2) [Figure 20-110-8].

20-110-3 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)

Joystick Assembly Removal And Installation

IMPORTANT
Remove the console cover. (See Console Removal And
Installation on Page 40-50-7.) When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Figure 20-110-9 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 20-110-11

1
1

P129233
2
2

Disconnect the wire harness (Item 1) [Figure 20-110-9].

Figure 20-110-10 2
P-92093

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Pull the boot (Item 1) [Figure 20-110-11] up from the
mounting plate.

Remove the bolts (Item 2) [Figure 20-110-11].

1
Remove the joystick assembly.

P129237

Mark and remove the hoses (Item 1) [Figure 20-110-10]

and tubelines.

20-110-4 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)

Parts Identification

1. Handle
2. Dust Boot
3. Coupler
4. Control Plate
5. U-Joint
6. Grommet 1
7. Plate
8. Plunger
9. Spool
10. Spring
11. Housing
12. Wire Harness 2
13. Lock
14. Connector

4
6
5

7
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10

11

12

13

14

MS-1352

20-110-5 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-14

Disassembly

Remove the right handle. (See Handle Removal And

Installation on Page 20-110-2.)
2
Clean the outside of the control lever before disassembly.

Figure 20-110-12
1

1
P-32576

Loosen the nut (Item 1) and remove the connector (Item

2) [Figure 20-110-14].

Figure 20-110-15

P-32560 1

Remove the boot (Item 1) [Figure 20-110-12].

2

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Figure 20-110-13

3
2
3
P-32574

1
Mark the coupler (Item 1), control plate (Item 2), and
plate (Item 3) [Figure 20-110-15] for ease of assembly.

P-32568

Mark the coupler (Item 1), nut (Item 2), and connector
(Item 3) [Figure 20-110-13] for ease of assembly.

20-110-6 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-18

Disassembly (Cont'd)
1
Figure 20-110-16

1 2

P-32578

Mark the plate and housing for correct installation.

P-32574 Remove the U-joint (Item 1) [Figure 20-110-18].

NOTE: The plate (Item 2) [Figure 20-110-18] is spring

Remove the coupler (Item 1) from the control plate (Item loaded and will come up as the U-joint is
2) [Figure 20-110-16]. removed.

Figure 20-110-17 Figure 20-110-19

2
1
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2
P-32577 P-32582

Remove the control plate (Item 1) from the U-Joint (Item Remove the plate (Item 1) [Figure 20-110-19].
2) [Figure 20-110-17].

20-110-7 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-22

Disassembly (Cont'd)
1
Figure 20-110-20

P-32588

Remove the spool assemblies (Item 1) [Figure 20-110-

P-32583 22].

Figure 20-110-23
Remove the plunger assemblies (Item 1) [Figure 20-110-
20].

Figure 20-110-21 1

1
2

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3

P-32591

Compress the spring (Item 1) and remove the seat (Item

P-32587 2) [Figure 20-110-23].

Remove the O-ring (Item 1) and plunger (Item 2) from the

bushing (Item 3) [Figure 20-110-21].

20-110-8 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-26

Disassembly (Cont'd)
1
Figure 20-110-24 1

2 1

P-32579

Clamp the housing in a vise that is equipped with padded

P-32590 jaws [Figure 20-110-26].

Remove the two bolts (Item 1) [Figure 20-110-26].

Remove the spring (Item 1) and shim (Item 2) from the
spool (Item 3) [Figure 20-110-24]. Figure 20-110-27

Figure 20-110-25 1

1
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P-32593

P-32592
Remove the end cap (Item 1) [Figure 20-110-27].

Remove the springs (Item 1) [Figure 20-110-25] from the

housing.

20-110-9 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)

Disassembly (Cont'd)

Figure 20-110-28

P-32594

Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

110-28].

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20-110-10 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-31

Assembly

Clean all parts in solvent and dry with compressed air.

1 1
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.

Figure 20-110-29

P-32580
1
2
Install the two bolts (Item 1) [Figure 20-110-31].

Turn the housing over.

P-32594
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Clamp the housing in a vise equipped with padded jaws.

Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
110-29].

Figure 20-110-30

P-32593

Install the end cap (Item 1) [Figure 20-110-30].

20-110-11 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-34

Assembly (Cont'd)

Figure 20-110-32 2

P-32591

Compress the spring (Item 1) and install the spring seat

P-32592 (Item 2) [Figure 20-110-34].

Figure 20-110-35
Install the springs (Item 1) [Figure 20-110-32].

Figure 20-110-33 1

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1
2

P-32588

P-32590 Install the spool assemblies (Item 1) [Figure 20-110-35]

into the housing.

Install the shim (Item 1) and spring (Item 2) on the spool

(Item 3) [Figure 20-110-33].

20-110-12 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-38

Assembly (Cont'd)
1
Figure 20-110-36

P-32583

Install the plunger assemblies (Item 1) [Figure 20-110-

P-32586 38] into the housing.

Figure 20-110-39
Install the plunger (Item 1) [Figure 20-110-36] into the
bushing.

Figure 20-110-37 1

1
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P-32582

Install the plate (Item 1) [Figure 20-110-39].

P-32584
NOTE: Spring pressure can dislodge the plunger
assemblies until the plate is secured in place.
Install the O-ring (Item 1) [Figure 20-110-37] on the
bushing.

20-110-13 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT Figure 20-110-42

Assembly (Cont'd)
1
Figure 20-110-40

3 2

3
2

P-32574

Align the coupler (Item 1) with the control plate (Item 2)

P-32578 and plate (Item 3) [Figure 20-110-42]. Tighten the
coupler.

Press down on the plate (Item 1) keeping the plunger Figure 20-110-43
assemblies (Item 2) fully seated and install the U-joint
(Item 3) [Figure 20-110-40].
1
Figure 20-110-41 3

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1
2

P-32573
2

Install the connector (Item 1) [Figure 20-110-43].

P-32577
Align the connector with the coupler (Item 2) and tighten
the nut (Item 3) [Figure 20-110-43].
Install the control plate (Item 1) until the plate makes light
contact with all four plungers (Item 2) [Figure 20-110-
41].

20-110-14 E85 Service Manual

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)

Assembly (Cont'd)

Figure 20-110-44

P-32560

Install the tabs of the boot (Item 1) in between the joystick

flange and mounting plate (Item 2) [Figure 20-110-44].

Install the handle. (See Handle Removal And Installation

on Page 20-110-2.)
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20-110-15 E85 Service Manual

20-110-16
E85 Service Manual
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LEFT CONTROL LEVER (JOYSTICK) Figure 20-120-2

Testing
1
The following tools will be needed to do the procedure:

MEL1355 - Hydraulic Test Kit

Stop the engine.

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

Page 10-60-1.)

Figure 20-120-1

P131643

From the test kit install a 3447 kPa (35 bar) (500 psi)
1 gauge (Item 1) [Figure 20-120-2] on the pilot line. Start
the excavator, and warm the hydraulic oil to operating
temperature.

Engage the circuit to be tested. Record the operating

2 pressure.

The operating pressure should be approximately 2799 -

3103 kPa (28 - 31 bar) (406 - 450 psi).
P131642
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If the operating pressure is correct, check the valve

section spool for proper operation. If the operating
At the control valve assembly find the pilot line (Item 1) pressure is incorrect, remove the pressure reducing
[Figure 20-120-1] of the control lever (joystick) that is to valve, clean, install and retest. (See Testing And
be checked. (Boom, Arm, Slew, Bucket) Adjusting on Page 20-33-1.)

Disconnect the hydraulic fitting (Item 1) [Figure 20-120- If the pressure is still incorrect replace the pressure
1] from the control valve. reducing valve. (See Testing And Adjusting on Page 20-
33-1.)

20-120-1 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-120-5

Handle Removal And Installation

Remove the left console cover. (See Console Removal

And Installation on Page 40-50-7.)

Figure 20-120-3

P129225

Raise the joystick and remove the wire harness (Item 1)

[Figure 20-120-5] from the console.
1
Figure 20-120-6
P129220

Disconnect the wire harness (Item 1) [Figure 20-120-3].

Figure 20-120-4

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1
2
1

P129226

Slide the grommet / wire harness (Item 1) [Figure 20-

120-6] out of the joystick body.

P-92043

Raise the boot (Item 1) and remove the bolts (Item 2)

[Figure 20-120-4].

20-120-2 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D)

Handle Removal And Installation (Cont’d)

Figure 20-120-7

P-92044

Pull the boot down and pull the wire harness (Item 1) out
of the boot. Loosen the nut (Item 2) [Figure 20-120-7]
and remove the handle.

Figure 20-120-8
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P-32521

Installation: Align the top of the dust boot (Item 1) with

the groove (Item 2) [Figure 20-120-8].

20-120-3 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-120-11

Joystick Assembly Removal And Installation 1

Remove the left console cover. (See Console Removal

And Installation on Page 40-50-7.)
2
Figure 20-120-9

2
P-92046

Pull the boot (Item 1) [Figure 20-120-11] up from the

mounting plate.
1
Remove the bolts (Item 2) [Figure 20-120-11].
P-92040
Remove the joystick assembly.

Disconnect the wire harness (Item 1) [Figure 20-120-9].

Figure 20-120-10

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P-92045

Mark and remove the hoses [Figure 20-120-10].

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

20-120-4 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D)

Parts Identification

1. Handle
2. Boot
3. Coupler
4. Control Plate 1
5. U-Joint
6. Grommet
7. Plate
8. Plunger
9. Spool
10. Spring
11. Housing
12. Wire Harness
13. Lock 2
14. Connector

5
6

7
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10

11

12

13

14
NA1481

20-120-5 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-120-14

Disassembly

Remove the left handle. (See Handle Removal And 2

Installation on Page 20-120-2.)

Clean the outside of the control lever before disassembly.

Figure 20-120-12

1
1
P-32576

Loosen the nut (Item 1) and remove the connector (Item

2) [Figure 20-120-14].

Figure 20-120-15
1
P-32560
2
Remove the boot (Item 1) [Figure 20-120-12].

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Figure 20-120-13

2 3
3

1 P-32574

Mark the coupler (Item 1), control plate (Item 2), and
plate (Item 3) [Figure 20-120-15] for ease of assembly.

P-32568

Mark the coupler (Item 1), nut (Item 2), and connector
(Item 3) [Figure 20-120-13] for ease of assembly.

20-120-6 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-120-18

Disassembly (Cont’d)
1
Figure 20-120-16

1 2

P-32578

Mark the plate and housing for correct installation.

P-32574 Remove the U-joint (Item 1) [Figure 20-120-18].

NOTE: The plate (Item 2) [Figure 20-120-18] is spring

Remove the coupler (Item 1) from the control plate (Item loaded and will come up as the U-joint is
2) [Figure 20-120-16]. removed.

Figure 20-120-17 Figure 20-120-19

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1 1

P-32577 P-32582

Remove the control plate (Item 1) from the U-joint (Item Remove the plate (Item 1) [Figure 20-120-19].
2) [Figure 20-120-17].

20-120-7 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-120-22

Disassembly (Cont'd)
1
Figure 20-120-20

P-32588

Remove the spool assemblies (Item 1) [Figure 20-120-

P-32583 22].

Figure 20-120-23
Remove the plunger assemblies (Item 1) [Figure 20-120-
20].
1
Figure 20-120-21

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2
3

P-32591

Compress the spring (Item 1) and remove the seat (Item

P-32587 2) [Figure 20-120-23].

Remove the O-ring (Item 1) and plunger (Item 2) from the

bushing (Item 3) [Figure 20-120-21].

20-120-8 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-120-26

Disassembly (Cont'd)
1
Figure 20-120-24 1

2
1

P-32579

Clamp the housing in a vise that is equipped with padded

P-32590 jaws [Figure 20-120-26].

Remove the two bolts (Item 1) [Figure 20-120-26].

Remove the spring (Item 1) and shim (Item 2) from the
spool (Item 3) [Figure 20-120-24]. Figure 20-120-27

Figure 20-120-25
1

1
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P-32593

P-32592
Remove the end cap (Item 1) [Figure 20-120-27].

Remove the springs (Item 1) [Figure 20-120-25] from the

housing.

20-120-9 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D)

Disassembly (Cont'd)

Figure 20-120-28

P-32594

Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

120-28].

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20-120-10 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-120-31

Assembly

Clean all parts in solvent and dry with compressed air.

1
1
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.

Figure 20-120-29

P-32580
1 2

Install the bolts (Item 1) [Figure 20-120-31].

Turn the housing over.

P-32594
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Clamp the housing in a vise equipped with padded jaws.

Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
120-29].

Figure 20-120-30

P-32593

Install the end cap (Item 1) [Figure 20-120-30].

20-120-11 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-120-34

Assembly (Cont’d)

Figure 20-120-32
2

P-32591

Compress the spring (Item 1) and install the spring seat

P-32592 (Item 2) [Figure 20-120-34].

Figure 20-120-35
Install the springs (Item 1) [Figure 20-120-32].
1
Figure 20-120-33

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2

P-32588

P-32590 Install the spool assemblies (Item 1) [Figure 20-120-35]

into the housing.

Install the shim (Item 1) and spring (Item 2) on the spool

(Item 3) [Figure 20-120-33].

20-120-12 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-120-38

Assembly (Cont’d)
1
Figure 20-120-36

P-32583

Install the plunger assemblies (Item 1) [Figure 20-120-

P-32586 38] into the housing.

Figure 20-120-39
Install the plunger (Item 1) [Figure 20-120-36] into the
bushing.
1
Figure 20-120-37

1
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P-32582

Install the plate (Item 1) [Figure 20-120-39].

P-32584
NOTE: Spring pressure can dislodge the plunger
assemblies until the plate is secured in place.
Install the O-ring (Item 1) [Figure 20-120-37] on the
bushing.

20-120-13 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-120-42

Assembly (Cont’d) 1

Figure 20-120-40

3 2

2
3

P-32574

Align the coupler (Item 1) with the control plate (Item 2)

P-32578 and plate (Item 3) [Figure 20-120-42]. Tighten the
coupler.

Press down on the plate (Item 1) keeping the plunger Figure 20-120-43
assemblies (Item 2) fully seated and install the U-joint
(Item 3) [Figure 20-120-40].
1 3
Figure 20-120-41

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1
2

P-32573
2

Install the connector (Item 1) [Figure 20-120-43].

P-32577
Align the connector with the coupler (Item 2) and tighten
the nut (Item 3) [Figure 20-120-43].
Install the control plate (Item 1) until the plate makes light
contact with all four plungers (Item 2) [Figure 20-120-
41].

20-120-14 E85 Service Manual

LEFT CONTROL LEVER (JOYSTICK) (CONT’D)

Assembly (Cont’d)

Figure 20-120-44

P-32560

Install the tabs of the boot (Item 1) in between the joystick

flange and the mounting plate (Item 2) [Figure 20-120-
44].

Install the handle. (See Handle Removal And Installation

on Page 20-120-2.)
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20-120-15 E85 Service Manual

20-120-16
E85 Service Manual
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HYDRAULIC FILTER MOUNT Figure 20-130-2

Removal And Installation

1
Drain the hydraulic reservoir. (See Removing And
Replacing The Hydraulic Fluid on Page 10-130-3.)
1

IMPORTANT
When repairing hydrostatic and hydraulic systems, 1 2
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
P131645
damage the system.
I-2003-0888
Remove the three hoses (Item 1) [Figure 20-130-2].
Remove the right upperstructure cover. (See Removal
And Installation on Page 40-70-1.) Installation: Tighten the hose clamps to 6,21 N•m (55 in-
lb) torque.
Figure 20-130-1
Remove the two bolts (Item 2) [Figure 20-130-2] and
remove the filter mount assembly.
1
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P131644

Loosen the nut and remove the wire harness (Item 1)

[Figure 20-130-1].

Disconnect the wire harness (Item 2) [Figure 20-130-1].

20-130-1 E85 Service Manual

20-130-2
E85 Service Manual
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HYDRAULIC RESERVOIR Figure 20-140-3

Removal And Installation 1

Drain the reservoir. (See Removing And Replacing The

Hydraulic Fluid on Page 10-130-3.) 1

Remove the center cover. (See Removal And Installation

on Page 40-220-1.)

Remove the right side cover. (See Removal And

Installation on Page 40-200-1.)
2
Remove the tailgate. (See Removal And Installation on
Page 40-180-1.)
P131659
Figure 20-140-1

Remove the hoses (Item 1), loosen the hose clamp (Item
2) [Figure 20-140-3] and remove the hose.

1 Installation: Tighten the hose clamp to 6,21 N•m (55 in-

lb) torque.

Figure 20-140-4
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P131974

Figure 20-140-2 1

1
1
1
P131969

Disconnect the wire harness (Item 1) [Figure 20-140-4]

from the pin grabber controller.

P131973

Remove the bolts (Item 1) [Figure 20-140-1] and [Figure

20-140-2] and remove the engine cover.

20-140-1 E85 Service Manual

HYDRAULIC RESERVOIR (CONT’D) Figure 20-140-7

Removal And Installation (Cont’d)

Figure 20-140-5

P131975

Remove the bolts (Item 1) [Figure 20-140-7].

2 P131968
Figure 20-140-8

Disconnect the wire harness (Item 1) and hose (Item 2)

[Figure 20-140-5] from the washer bottle.

Figure 20-140-6

1 2
1

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1 2

P131966

Remove the bolts (Item 1) and the bracket (Item 2)

[Figure 20-140-8].
P131965

Remove the nuts (Item 1) and reposition the fuse panel.

Remove the bolts (Item 2) [Figure 20-140-6].

20-140-2 E85 Service Manual

HYDRAULIC RESERVOIR (CONT’D)

Removal And Installation (Cont’d)

Figure 20-140-9

P131964

Remove the bolts (Item 1) [Figure 20-140-9].

Figure 20-140-10

2
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P131967

Remove the bolts and nuts (Item 1). Remove the center
cover frame (Item 2) [Figure 20-140-10] and remove the
reservoir.

20-140-3 E85 Service Manual

20-140-4
E85 Service Manual
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OIL COOLER

Removal And Installation

The oil cooler and radiator are removed from the

excavator as a unit. (See Oil Cooler / Radiator Removal
And Installation on Page 60-40-1.)
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20-150-1 E85 Service Manual

20-150-2
E85 Service Manual
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BLADE CONTROL LEVER Figure 20-160-3

Handle Removal And Installation

Remove the right console cover. (See Console Cover

Removal And Installation on Page 40-40-1.)

Figure 20-160-1

1 1

P-91896

Remove the connector lock (Item 1) [Figure 20-160-3]

from the connector.

Figure 20-160-4
P-91899

Remove the cable tie strap (Item 1) [Figure 20-160-1].

Figure 20-160-2
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P-91896

Depress the wire terminal tabs and remove the wires

1 from the back of the electrical connector [Figure 20-160-
4].
P-91897

Disconnect the wire harness (Item 1) [Figure 20-160-2].

20-160-1 E85 Service Manual

BLADE CONTROL LEVER (CONT’D) Figure 20-160-7

Handle Removal And Installation (Cont’d)

Figure 20-160-5

1
P-92019

Route the harness (Item 1) [Figure 20-160-7] out

P-21668 through the top of the dust boot.

Figure 20-160-8
Installation: Re-bend the tab (Item 1) [Figure 20-160-5]
on each wire before installing the electrical connector.

Installation: The wires must be installed in the proper 2

locations in the wire connector, listed below:

A Green 1

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B Brown
C Red
D Black
E White

Check each wire to be certain the tab locks into position.

Figure 20-160-6 P-92021

Loosen the locknut (Item 1) and remove the handle (Item

2) [Figure 20-160-8].

P-92022

Cut and remove the cable tie (Item 1) [Figure 20-160-6].

20-160-2 E85 Service Manual

BLADE CONTROL LEVER (CONT’D) Figure 20-160-11

Removal And Installation

Remove the right console cover. (See Console Cover

Removal And Installation on Page 40-40-1.)

Figure 20-160-9

1
1

P-92000

Figure 20-160-12

P-91899

Cut and remove the cable tie (Item 1). Disconnect the
wire harness (Item 2) [Figure 20-160-9].

Figure 20-160-10
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1
1

P-92001

Remove the bolts (Item 1) [Figure 20-160-11] and

1 [Figure 20-160-12].

1
1
P-91894

Mark and remove the four hoses (Item 1) [Figure 20-160-

10].

20-160-3 E85 Service Manual

BLADE CONTROL LEVER (CONT’D)

Removal And Installation (Cont’d)

Figure 20-160-13

1 1

P-92002

Tilt the control away from the console and remove the
two hoses (Item 1) [Figure 20-160-13].

Remove the control.

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20-160-4 E85 Service Manual

BLADE CONTROL LEVER (CONT’D)

Parts Identification

1. Handle
2. Boot
3. Bushing
4. O-ring
5. Push Rod
6. Spring Seat
7. Spring 1
8. Shim
9. Spool
10. Cable Tie
11. Bolt
12. Detent Lock
13. Pivot Assembly
14. Plate
15. Body
16. Lock
17. Connector
3

2 4

4
6
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10
7
3
8
4 11
10
12 9
5
4 11
13 7
6

7 14
10 8

16 15

17

NA2308S

20-160-5 E85 Service Manual

BLADE CONTROL LEVER (CONT’D) Figure 20-160-16

Disassembly And Assembly

1
Figure 20-160-14

P-21668

Installation: Re-bend the tab (Item 1) [Figure 20-160-

P-92005 16] on each wire before installing the electrical
connector.

Remove the connector lock (Item 1) [Figure 20-160-14]. Installation: The wires must be installed in the proper
locations in the wire connector, listed below.
Figure 20-160-15
A Green
B Brown
C Red
D Black

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E White

Check each wire to be certain the tab locks into position.

Figure 20-160-17

1
P-92006

Depress the wire terminal tabs and remove the wires

from the back of the electrical connector [Figure 20-160-
15].

P-92021

Cut and remove the cable tie (Item 1) [Figure 20-160-

17].

20-160-6 E85 Service Manual

BLADE CONTROL LEVER (CONT’D) Figure 20-160-20

Disassembly And Assembly (Cont’d)

Figure 20-160-18
1

P-92010

1
Remove the four bolts (Item 1) [Figure 20-160-20].
P-92008
Figure 20-160-21

Route the harness (Item 1) [Figure 20-160-18] through 1

the top of the dust boot.

Figure 20-160-19
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3
2

1 P-92011

Remove the pivot assembly (Item 1), detent lock (Item 2),
and plate (Item 3) [Figure 20-160-21].
P-92006

Loosen the nut (Item 1) [Figure 20-160-19] and remove

the handle and dust boot.

20-160-7 E85 Service Manual

BLADE CONTROL LEVER (CONT’D) Figure 20-160-24

Disassembly And Assembly (Cont’d)

1
Figure 20-160-22
2

P-92018

Remove the lever (Item 1). Remove the shim (Item 2)

P-92021 [Figure 20-160-24] from both sides of the lever.

Figure 20-160-25
Remove the roll pin (Item 1) [Figure 20-160-22].

Figure 20-160-23
2
1 3

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3

2
1 3

P-92011
1

P-92017 Remove the bushings (Item 1) and push rods (Item 2).
Remove the O-rings (Item 3) [Figure 20-160-25] from the
ID and OD of the bushings.
Remove the pivot pin (Item 1) [Figure 20-160-23].

20-160-8 E85 Service Manual

BLADE CONTROL LEVER (CONT’D) Figure 20-160-28

Disassembly And Assembly (Cont’d)

Figure 20-160-26

1 3

1 2 3

P-92015

2 3
Remove the spring (Item 1) and shims (Item 2) from the
P-92013 spool (Item 3) [Figure 20-160-28].

Remove the blade raise spool assembly (Item 1), blade

lower / float spool assembly (Item 2) and springs (Item 3)
[Figure 20-160-26].

NOTE: The spool assemblies must be installed in the

correct bores or the float function of the blade
will not work correctly.
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Figure 20-160-27

1
2

P-32591

Compress the spring (Item 1) and remove the seat (Item

2) [Figure 20-160-27].

20-160-9 E85 Service Manual

20-160-10
E85 Service Manual
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CASE DRAIN FILTER MOUNT

Removal And Installation

Remove the right upperstructure cover. (See Removal

And Installation on Page 40-70-1.)

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.
I-2003-0888

Figure 20-170-1

2 1

1
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P131646

Remove the two hoses (Item 1) [Figure 20-170-1].

Remove the two bolts (Item 2) [Figure 20-170-1] and

remove the filter mount assembly.

20-170-1 E85 Service Manual

20-170-2
E85 Service Manual
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TRAVEL CONTROL VALVE Figure 20-180-2

Removal And Installation

Remove the travel levers. (See Removal And Installation

on Page 40-90-1.)
1
1
Remove the floor mat and center floorplate. (See
Removal And Installation on Page 40-100-1.)

Figure 20-180-1

1 1

1
P133058

Tip the plate towards the operator’s seat. Mark and

remove the hoses (Item 1) [Figure 20-180-2].
1
If equipped with a sending unit, disconnect the wire
harness.

P133059
IMPORTANT
Remove the bolts (Item 1) [Figure 20-180-1] from the
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When repairing hydrostatic and hydraulic systems,

front floorplate. 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

Remove the valve / floorplate assembly.

20-180-1 E85 Service Manual

TRAVEL CONTROL VALVE (CONT’D)

Parts Identification

1. O-ring
2. Bushing 8
3. Plunger 
4. Spring Seat
5. Spring
1
6. Shim 9
7. Spool
8. Cable Tie 2
9. Dust Boot
10. Screw
11. Pivot Assembly 1
12. Plate
13. Valve Body 8
14. Plug 3
15. Nut
16. Sending Unit
4

10
5
11
6

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7
12

13 14

1
15
7
7
15
1

1 14

7
15
16 NA2307S

20-180-2 E85 Service Manual

TRAVEL CONTROL VALVE (CONT’D) Figure 20-180-5

Disassembly And Assembly

Figure 20-180-3 1

P-92102

1
Remove the dust boot (Item 1) [Figure 20-180-5].
P-92097
Figure 20-180-6

Remove the bolts (Item 1) [Figure 20-180-3] and nuts.

Remove the valve from the floor pan.
3
Installation: Tighten the bolts to 43 - 47 N•m (32 - 35 ft-
lb) torque.
2
NOTE: The procedure is shown on the left travel side
3
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of the valve. The procedure is the same for

both sides of the valve.
1
Figure 20-180-4
2
1
P-92103

Remove the four screws (Item 1) [Figure 20-180-6] and

remove the pivot assembly.
1
Installation: After installing the pivot assembly loosen
the screws (Item 2). Turn the adjustment screws (Item 3)
[Figure 20-180-6] until there is no end play in the pivot
assembly.
1
Tighten the screws (Item 2) [Figure 20-180-6] after the
P-92101 adjustment is complete.

Cut and remove the cable ties (Item 1) [Figure 20-180-

4].

20-180-3 E85 Service Manual

TRAVEL CONTROL VALVE (CONT’D) Figure 20-180-9

Disassembly And Assembly (Cont’d)

Figure 20-180-7

1
1

P-92106

2
Remove the plunger assemblies (Item 1) [Figure 20-180-
P-92019 9].

Figure 20-180-10
Loosen the screw (Item 1) and remove the pivot pin (Item
2) [Figure 20-180-7].
1
Figure 20-180-8
2
3

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1

P-32587

Remove the O-rings (Item 1) and plunger (Item 2) from

P-92105 the bushing (Item 3) [Figure 20-180-10].

Remove the plate (Item 1) [Figure 20-180-8].

20-180-4 E85 Service Manual

TRAVEL CONTROL VALVE (CONT’D) Figure 20-180-13

Disassembly And Assembly (Cont’d)

3
Figure 20-180-11
2
1

P-32590
1

Remove the spring (Item 1) and shim (Item 2) from the

P-92107 spool (Item 3) [Figure 20-180-13].

Figure 20-180-14
Remove the spool assemblies (Item 1) [Figure 20-180-
11].

Figure 20-180-12

1
1
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P-92108

2 Remove the spring (Item 1) [Figure 20-180-14].

P-32591
Repeat the procedure for the right travel side of the valve.

Compress the spring (Item 1) and remove the seat (Item

2) [Figure 20-180-12].

20-180-5 E85 Service Manual

TRAVEL CONTROL VALVE (CONT’D) Figure 20-180-17

Disassembly And Assembly (Cont’d)

Figure 20-180-15

1 P-95287

1
Remove the O-rings (Item 1) [Figure 20-180-17] from the
P-95286 fittings.

Figure 20-180-18
Remove the fittings (Item 1) [Figure 20-180-15].

Figure 20-180-16

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1
1
P-95288

P-95285 Remove the O-rings (Item 1) [Figure 20-180-18] from the

plugs.

Remove the plugs (Item 1) [Figure 20-180-16].

20-180-6 E85 Service Manual

TRAVEL CONTROL VALVE (CONT’D) Figure 20-180-21

Disassembly And Assembly (Cont’d)

Figure 20-180-19

1 1

2 P-95287
1 2

Remove the O-ring (Item 1) [Figure 20-180-21] from

P-95289 both fittings.

Remove the nut (Item 1) [Figure 20-180-19].

Installation: Tighten the nut to 9,8 N•m (7.2 ft-lb) torque.

Remove the spool (Item 2) [Figure 20-180-19].

Figure 20-180-20
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1
P-95290

Remove the fittings (Item 1) [Figure 20-180-20].

20-180-7 E85 Service Manual

20-180-8
E85 Service Manual
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REMOVING AIR FROM THE HYDRAULIC SYSTEM Start the excavator.

Procedure The excavator piston pump has a minimum displacement

stop, approximately 9,6 L/min (2.4 U.S. gpm) which is
Open the right side cover. (See Opening And Closing on being circulated through the valve even when all
Page 10-60-1.) functions are in neutral.

Figure 20-190-1 If additional air has gotten into some of the circuits
(motors or cylinders), the excavator can be operated with
the bleed tool in place.

1 NOTE: When the excavator is operated with bleed

hose in place, the reservoir cap is removed.
The hydraulic system must be protected from
contamination and spill.

P131648

Install a female quick coupler and hose on the male quick

coupler (Item 1) [Figure 20-190-1].

Figure 20-190-2
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P131647

Remove the fill cap from the reservoir. Route the hose
(Item 1) [Figure 20-190-2] into the reservoir.

NOTE: The hydraulic system must be filled with oil

before starting the excavator to prevent
damage to the system.

20-190-1 E85 Service Manual

20-190-2
E85 Service Manual
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MANIFOLD (PIN GRABBER)

Removal And Installation

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

Lower the work group to the ground.

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

Remove the floor mat and floorplate.

Remove the tool box. (See Removal And Installation on

Page 40-210-1.)

Figure 20-200-1

2
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2
1

P131788

Disconnect the wire harness (Item 1) and hoses (Item 2)

[Figure 20-200-1].

Remove the nuts and bolts (Item 3) [Figure 20-200-1].

Remove the manifold.

20-200-1 E85 Service Manual

MANIFOLD (PIN GRABBER) (CONT’D)

Parts Identification

1. Nut 1
2. O-ring
3. Coil  2
4. Spool
5. Back-up Ring
6. Body 3
7. Check Valve
8. Plug
9. Orifice
2

5
2

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5

2
5
6

2 5

7
2

8 8
9
NA13737S

20-200-2 E85 Service Manual

MANIFOLD (PIN GRABBER) (CONT’D) Figure 20-200-4

Disassembly And Assembly

Clean the outside of the manifold before disassembly.

1
Figure 20-200-2

P131897

Remove the O-ring (Item 1) [Figure 20-200-4] from the

2 nut.

P131896 Figure 20-200-5

Remove the nut (Item 1) and coil (Item 2) [Figure 20-

200-2] from the spool assembly. 1
Remove the spool from the body.
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Figure 20-200-3

1
1
1 P131899
1
1
Remove the check valve (Item 1) [Figure 20-200-5].

2 2 2
P131898

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

[Figure 20-200-3] from the spool.

20-200-3 E85 Service Manual

MANIFOLD (PIN GRABBER) (CONT’D) Figure 20-200-8

Disassembly And Assembly (Cont'd)

Figure 20-200-6

P131902

1
Remove the O-rings (Item 1) [Figure 20-200-8] from the
P131900 fittings and plugs.

Figure 20-200-9
Remove the back-up ring (Item 1) and O-rings (Item 2)
[Figure 20-200-6].

Figure 20-200-7 1

2 1

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2

P131904
1

Remove the threaded orifice (Item 1) [Figure 20-200-9]

2 from the P port.
P131901

Clean all parts in solvent and dry with compressed air.

Remove the plugs (Item 1) and fittings (Item 2) [Figure
20-200-7]. Inspect all parts for wear or damage. Replace any worn
or damaged parts.

Always install new back-up rings and O-rings. Lubricate

all O-rings with clean hydraulic fluid before installation.

20-200-4 E85 Service Manual

SECONDARY AUXILIARY VALVE Figure 20-210-2

Removal And Installation

Lower the work group to the ground.

Stop the engine.

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

IMPORTANT P128518

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all Remove the hoses (Item 1) and tubelines from the top of
parts clean. Always use caps and plugs on hoses, the valve [Figure 20-210-2].
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Remove the right upperstructure cover. (See Removal

And Installation on Page 40-70-1.)

Remove the battery. (See Removing And Installing The

Battery on Page 50-20-3.)
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Remove the hydraulic reservoir. (See Removal And

Installation on Page 20-140-1.)

Figure 20-210-1

P131589

Disconnect the harness (Item 1) [Figure 20-210-1].

Mark all hoses for proper installation.

20-210-1 E85 Service Manual

SECONDARY AUXILIARY VALVE (CONT’D)

Removal And Installation (Cont'd)

Figure 20-210-3

P131590

Remove the bolts (Item 1) [Figure 20-210-3].

Figure 20-210-4

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1
1

P-95638

Reposition the valve and remove the hoses (Item 1)

[Figure 20-210-4].

Remove the valve.

20-210-2 E85 Service Manual

SECONDARY AUXILIARY VALVE (CONT’D)

Parts Identification

1. Nut
2. Coil
3. Solenoid
4. O-ring 6 6
1
5. Back-up Ring
6. Plug
7. Spring
8. Spool 2 4
9. Relief Valve 4
10. Body

7
7

3
8
8

4 4
4
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5
4

5
4

10

4
4
4
6
6

NA10136S

20-210-3 E85 Service Manual

SECONDARY AUXILIARY VALVE (CONT’D) Figure 20-210-7

Disassembly And Assembly

Figure 20-210-5 2 2

1 1 1
2

P122687

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

P122684 [Figure 20-210-7].

Figure 20-210-8
Remove the nut (Item 1) and coil (Item 2) [Figure 20-
210-5].

Installation: Tighten the nut to 7 N•m (5 ft-lb) torque.

Figure 20-210-6
1 1

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1

P122686

Remove the relief valves (Item 1) [Figure 20-210-8].

Installation: Tighten the relief valves to 51 - 61 N•m (38 -

P122685 45 ft-lb) torque.

Remove the solenoid (Item 1) [Figure 20-210-6].

Installation: Tighten the solenoid to 24 - 30 N•m (18 - 22

ft-lb) torque.

20-210-4 E85 Service Manual

SECONDARY AUXILIARY VALVE (CONT’D) Figure 20-210-11

Disassembly And Assembly (Cont'd)

Figure 20-210-9

1
P122691

1
Remove the O-ring (Item 1) [Figure 20-210-11].
P122688
Figure 20-210-12

Remove the O-ring (Item 1) [Figure 20-210-9]. 1

Figure 20-210-10

2 2
1 1
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P122695

Remove the springs (Item 1) and spools (Item 2) [Figure

P122689 20-210-12].

Remove the plugs (Item 1) [Figure 20-210-10].

20-210-5 E85 Service Manual

SECONDARY AUXILIARY VALVE (CONT’D)

Disassembly And Assembly (Cont'd)

Figure 20-210-13

1 1

P122692

Remove the plugs (Item 1) [Figure 20-210-13].

Tighten the plugs to 96 - 107 N•m (71 - 79 ft-lb) torque.

Figure 20-210-14

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1

P122693

Remove the O-rings (Item 1) [Figure 20-210-14].

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts.

Always install new O-rings. Lubricate the O-rings with

clean hydraulic fluid before installation.

20-210-6 E85 Service Manual

VALVE (BOOM LOCK) Figure 20-220-2

Removal And Installation

2
Lower the work group to the ground.

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

Figure 20-220-1 1

1
P133216
1

2 Remove the hose (Item 1) [Figure 20-220-2].

Disconnect the tubeline (Item 2) [Figure 20-220-2].

1

P132112

Remove the four bolts (Item 1) and cover (Item 2) [Figure

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20-220-1].

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

20-220-1 E85 Service Manual

VALVE (BOOM LOCK) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-220-3

P133215

Remove the two hoses (Item 1) [Figure 20-220-3].

Figure 20-220-4

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3

P133213

Remove the nuts (Item 1) and bolts. Remove the valve

(Item 2) [Figure 20-220-4].

The lock valve is not serviceable. If the relief valves (Item

3) [Figure 20-220-4] have been tampered with, the
complete valve assembly must be replaced.

20-220-2 E85 Service Manual

VALVE (ARM LOCK)

Removal And Installation

IMPORTANT
Lower the work equipment to the ground.
When repairing hydrostatic and hydraulic systems,
With the engine off, turn the key to the ON position and clean the work area before disassembly and keep all
move both hydraulic control levers to relieve hydraulic parts clean. Always use caps and plugs on hoses,
pressure. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 20-221-1 I-2003-0888

Figure 20-221-3

1
P133184

P133185
Remove the bolts (Item 1) [Figure 20-221-1].
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Figure 20-221-2 Remove the hoses (Item 1) [Figure 20-221-3].

Figure 20-221-4
1
1
1
2

1
P133183

P133186
Remove the bolts (Item 1) and cover (Item 2) [Figure 20-
221-2].
Remove the three hoses (Item 1) [Figure 20-221-4].

20-221-1 E85 Service Manual

VALVE (ARM LOCK) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-221-5

1 1

P133191

Figure 20-221-6

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2 1

P133189A

Loosen the clamps (Item 1) [Figure 20-221-5] and

remove the valve / bracket assembly (Item 1) [Figure 20-
221-6].

The lock valve is not serviceable. If the relief valves (Item

2) [Figure 20-221-6] have been tampered with, the
complete valve assembly must be replaced.

20-221-2 E85 Service Manual

UNDERCARRIAGE

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

TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Track Lug Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Idler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Idler Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-7
Idler Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-8
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-11
Track Tensioner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-16
Track Tensioner Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-17
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-18
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-19
Lower Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-20
Lower Roller Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-21
Lower Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-24
Upper Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-30
Upper Roller Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-31
Sprocket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-34
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TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) . . . . . . . . . . . . . . . . . . 30-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-3
Track Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-4
Track Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-6
Idler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-7
Idler Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-8
Idler Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-9
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-12
Track Tensioner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-17
Track Tensioner Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-18
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-19
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-20
Lower Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-21
Lower Roller Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-22
Lower Roller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-25
Upper Roller Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-31
Upper Roller Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-32
Sprocket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-35
Guide Plate Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-35

30-01 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (SEGMENTED TRACK) . . . . . . . . . . . . . 30-22-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1
Rubber Pad Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1
Guide Plate Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-22-1

TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

SWING CIRCLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2

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30-02 E85 Service Manual

BLADE

Removal And Installation

Lower the work group and blade to the ground.

Remove the blade cylinder. (See Removal And

Installation on Page 20-24-2.)

Figure 30-10-1

P131518

Remove the nuts (Item 1) [Figure 30-10-1] and bolt from

the blade arm pivot pin (both sides).
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Remove the pivot pin (Item 2) [Figure 30-10-1] (both

sides).

Remove the blade.

30-10-1 E85 Service Manual

30-10-2
E85 Service Manual
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TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK)

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 30 mm (1.18 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 23,4 mm (0.92 in)

0.92
1.15 x 100 = 80

80% of the track lug is remaining with 20% wear on the

track lugs.

30-20-1 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Checking Tension WARNING

NOTE: The wear of the pins and bushings on the AVOID INJURY
undercarriage vary with the working Keep fingers and hands out of pinch points when
conditions and the different types of soil checking the track tension.
conditions. It is necessary to inspect track W-2142-0903
tension to maintain the correct tension. See
Service Schedule for the correct service Figure 30-20-3
interval. (See SERVICE SCHEDULE on Page
10-70-1.)

Figure 30-20-2

30 - 45 mm
1
(1.2 - 1.6 in)

P131519

P131422 Figure 30-20-4

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Track Frame

1
30 - 45 mm
(1.2 - 1.6 in)

Track
Roller
P131423

Track
Raise one side of the machine (Approximately four
inches) using the boom and arm. B-14067

Raise the blade fully and install jackstands under the

blade and track frame (Item 1) [Figure 30-20-2]. Raise Measure the clearance at the middle track roller. Do not
the boom until all machine weight is on the jackstands. get fingers into pinch points between the track and the
track roller. Use a bolt or a dowel of the appropriate size
Stop the engine. to check the gap between the contact edge of the roller
and the top edge of the track guide [Figure 30-20-3] and
[Figure 30-20-4].

Rubber Track Clearance - 30 - 45 mm (1.2 - 1.6 in).

30-20-2 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-7
TRACK) (CONT’D)
1
Adjusting Tension

Figure 30-20-5

P131512

The tension removal tool (P/N 7277225) is available and

1 recommended to direct the flow of grease to aid in
cleanup. Always dispose of the grease in an
environmentally friendly manor.
P131514
Use tool 7277225 (Item 1) [Figure 30-20-7] to loosen the
track tension fitting (Item 1) [Figure 30-20-6] to release
Loosen the two bolts on the cover (Item 1) [Figure 30-20- tension from the track.
5]. Pivot the cover downward.
The tool is sized to fit the one piece track tension fitting
(Item 1) [Figure 30-20-6].

WARNING NOTE: Do not loosen the track tension fitting (Item 1)

[Figure 30-20-6] more than 1-1/2 turns.
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HIGH PRESSURE GREASE CAN Installation: Tighten the track tension fitting to 24 - 30
CAUSE SERIOUS INJURY N•m (18 - 22 ft-lb) torque.
• Do not loosen the track tension fitting more than
1 - 1/2 turns. Repeat the procedure for the opposite side.
W-2994-0515

Figure 30-20-6

P131513

Add grease to the track tension fitting (Item 1) [Figure

30-20-6] until the track tension is correct.

30-20-3 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Track Removal And Installation WARNING

Lift and block both sides of the machine as follows: Put jackstands under the blade and rear corners of
the undercarriage before working under the machine.
Raise the blade fully. Failure to block up the machine may allow it to move
or fall and result in injury or death.
Figure 30-20-8 W-2218-1195

Stop the engine.

Release track tension. (See Adjusting Tension on Page

30-20-3.)

Start the engine.

Slowly turn the track in the forward direction.

Figure 30-20-10

1 1
P131515

Use the boom and arm to lift the blade end of the
machine up about 75 mm (3.0 in) and install jackstands
(Item 1) [Figure 30-20-8] under the blade.

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Raise the boom.

Figure 30-20-9

P131517

Insert a steel rod or pipe (Approximately 30 mm [1.250 in]

1 in diameter) between the track and the idler wheel
[Figure 30-20-10].

P133064

Swing the upperstructure 180 degrees and use the boom

and arm to slowly lift the opposite end of the
undercarriage and install jackstands (Item 1) [Figure 30-
20-9] under the undercarriage.

Raise the boom until the weight of the machine is

supported by the jackstands.

30-20-4 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-12
TRACK) (CONT’D)

Track Removal And Installation (Cont’d)

Figure 30-20-11

P131425

Insert a pry bar between the track and the idler wheel
and pry out on the track until the track slides off the idler
P131424 wheel [Figure 30-20-12].

Remove the track.

Insert a second steel rod or pipe, at a distance of two
lugs, between the track and the idler wheel [Figure 30- To install the track:
20-11]. Continue to turn the track until the first pipe
contacts the track frame. Put the track over the rear drive sprocket lugs.

Stop the engine. Put the front of the track onto the front idler wheel.
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Adding grease to the track tensioner. (See Adjusting

Tension on Page 30-20-3.)

30-20-5 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-14
TRACK) (CONT’D)

Idler Removal And Installation

NOTE: Dealer disassembly of the component(s) 1

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check 3
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.
2
1
Remove the track. (See Track Removal And Installation
on Page 30-20-4.)
P131592

Figure 30-20-13
Remove the four bolts (Item 1) and washers. Remove the
idler (Item 2) [Figure 30-20-14].

1 DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY (Item 3) [Figure 30-20-14].

WARNING

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P131591

Install a chain (Item 1) [Figure 30-20-13] and hoist to the

idler and slide the idler out the track frame.
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 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) (CONT’D)

Idler Parts Identification

1. Plug
2. Support
3. Roll Pin
4. Seal Assembly
5. O-ring
7
6. Bushing
7. Idler
8. Shaft

4
3

6
5
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2 3
1

5
4

NA14243S

30-20-7 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-17
TRACK) (CONT’D)

Idler Disassembly

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found 1
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Figure 30-20-15
P-89261

1 Figure 30-20-18

Page 432 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
P-89259

Remove the roll pin (Item 1) [Figure 30-20-15].

P-89263
Figure 30-20-16

Remove the floating seal (Item 1) [Figure 30-20-17] and

[Figure 30-20-18] from the support and idler.
1

P-89260

Pull up on and remove the support (Item 1) [Figure 30-

20-16].

30-20-8 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-21
TRACK) (CONT’D)

Idler Disassembly (Cont’d)

Figure 30-20-19

P-89267

Figure 30-20-22

P-89264

Remove the O-ring (Item 1) [Figure 30-20-19] from the 1

shaft.

Figure 30-20-20
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P-89268

Remove the floating seal (Item 1) [Figure 30-20-21] and

[Figure 30-20-22] from the support and idler.

P-89266

Tip the idler over and remove the support / shaft

assembly (Item 1) [Figure 30-20-20].

30-20-9 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-25
TRACK) (CONT’D)

Idler Disassembly (Cont’d)

Figure 30-20-23 1

P-89270

Remove the O-ring (Item 1) [Figure 30-20-25].

P-89262 Figure 30-20-26

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

four of the steel seals.
1
Figure 30-20-24

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1

P-89271

Remove the bushings (Item 1) [Figure 30-20-26] from

2 both sides of the idler.

P-89269

Remove the roll pin (Item 1). Remove the shaft (Item 2)
[Figure 30-20-24] from the support.

30-20-10 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER NOTE: Inspect the seal ring for damage before
TRACK) (CONT’D) installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
Idler Assembly any twists, gently pull a section of the O-ring
and let it snap back.
Clean all parts in solvent and dry with compressed air.
Figure 30-20-29
The seal assemblies are a matched set and must be
replaced in pairs.
1
Figure 30-20-27

P-40754

Place the seal assembly in the installation tool (Item 1)

P-89271 [Figure 30-20-29].

The O-ring and seal ring assembly have to be lubricated

Install the bushings (Item 1) [Figure 30-20-27] on both with alcohol, so that the O-ring will slip past the housing
sides of the idler.
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retaining ring and seal uniformly in the housing radius.

Figure 30-20-28 Dip the seal assembly in a pan of alcohol.

Figure 30-20-30

1
1

P-89262

P-89276
Install the O-ring (Item 1) [Figure 30-20-28] on the seal
ring. Repeat this procedure on all four seal assemblies.
Shake off the excess alcohol and install the seal
The O-ring and seal ring must be clean and free of any assembly (Item 1) [Figure 30-20-30] in the idler.
dust, oil film and foreign matter.
Use firm, even pressure on the installation tool to pop the
O-ring into the housing.

Remove the installation tool.

30-20-11 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-33
TRACK) (CONT’D)

Idler Assembly (Cont’d) 1

Figure 30-20-31 2

P-89269

Install the shaft (Item 1) in the support. Install the roll pin
(Item 2) [Figure 30-20-33] through the shaft and support
P-89277 assembly.

Figure 30-20-34
The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 30-20-31].
1
Figure 30-20-32

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1
P-40754

Place the seal assembly (Item 1) [Figure 30-20-34] in

P-89270 the installation tool.

The O-ring and seal ring assembly have to be lubricated

Install the O-ring (Item 1) [Figure 30-20-32] onto the with alcohol, so that the O-ring will slip past the housing
shaft. retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

30-20-12 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-37
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-20-35 1

P-89264

Install the idler (Item 1) [Figure 30-20-37] on the shaft /

support assembly.
P-89274
Figure 30-20-38

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-20-35] in the support. 1

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Figure 30-20-36
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P-40754

Place the seal assembly (Item 1) [Figure 30-20-38] in

the installation tool.

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
P-89275 retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 30-20-36].

Apply a light film of oil to both metal seal rings.

NOTE: Do not get any oil on the rubber O-rings.

30-20-13 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-41
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-20-39
1

P-89280

Install the O-ring (Item 1) [Figure 30-20-41] on the shaft.

P-89278 Figure 30-20-42

Shake off the excess alcohol and install the seal 1

assembly (Item 1) [Figure 30-20-39] in the idler.

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Remove the installation tool.

Page 438 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
Figure 30-20-40

P-40754

Place the seal assembly (Item 1) [Figure 30-20-42] in

the installation tool.

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
1 retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

P-89279

The seal assembly stand off height must be equal and

the O-ring (Item 1) [Figure 30-20-40] must not be
twisted.

30-20-14 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-45
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-20-43 1

P-89283

Install the support (Item 1) on the shaft. Press down on

the support and install the roll pin (Item 2) [Figure 30-20-
P-89281 45].

Figure 30-20-46
Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-20-43] in the idler.

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Remove the installation tool.

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1
Figure 30-20-44

89324

Remove the plug (Item 1) [Figure 30-20-46].

Add 0,101 - 0,139 L (3.4 - 4.7 U.S. fl oz) 30W oil to the
1
idler. Install the plug (Item 1) [Figure 30-20-46].

P-89282

The seal stand off height must be equal and the O-ring
(Item 1) [Figure 30-20-44] must not be twisted.

Apply a light film of oil to both metal seal rings.

NOTE: Do not get any oil on the rubber O-rings.

30-20-15 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-49
TRACK) (CONT’D)

Track Tensioner Removal And Installation

DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY.

Figure 30-20-47

P131596

1
Figure 30-20-50

P131593

Remove the shaft (Item 1) [Figure 30-20-47] from the

tube.

NOTE: Add grease to the track tension fitting to push

Page 440 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
the shaft out of the tube. 1

Figure 30-20-48
P131597

The flat sides (Item 1) [Figure 30-20-49] of the recoil

spring grease cylinder must engage the mount (Item 1)
[Figure 30-20-50] of the track frame.
1

P131594

Lower the tube (Item 1) [Figure 30-20-48] out the bottom

of the track frame.

30-20-16 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) (CONT’D)

Track Tensioner Parts Identification

1. Coil Spring Assembly

2. Shaft
3. Wiper seal
4. Wear Ring
5. O-ring
6. Seal
7. Tube
8. Bleed/Grease Fitting

1
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NA14241S

30-20-17 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Track Tensioner Disassembly And Assembly WARNING

Figure 30-20-51

P-62574
1
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
P131600

DO NOT DISASSEMBLE OR REPAIR THE COIL

Remove the O-ring (Item 1) [Figure 30-20-51] from the SPRING ASSEMBLY.
cylinder.

Installation: Apply oil to the O-ring before installation.

Figure 30-20-52

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2
3 4
1

P131595

Remove the wiper seal (Item 1), wear ring (Item 2), seal
(Item 3) and O-ring (Item 4) [Figure 30-20-52].

30-20-18 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-55
TRACK) (CONT’D)

Roller Removal And Installation

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
1
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Figure 30-20-53
P-89286

Remove the bottom roller (Item 1) [Figure 30-20-55].

2
1
NOTE: The procedure is shown on a lower roller used
with the steel track. The photos may appear
different, the procedure is the same.
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P-98302

Loosen the bolt (Item 1) and nut. Remove the top roller
(Item 2) [Figure 30-20-53].

Figure 30-20-54

2 2

P-89285

Loosen the bolts (Item 1) [Figure 30-20-54] on the track

roller on both sides of the track frame.

Installation: Tighten the bolts to 160 - 180 N•m (118 -

133 ft-lb) torque.

30-20-19 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) (CONT’D)

Lower Roller Parts Identification

1. Collar
2. Plug
3. Roll Pin
4. Seal Assembly
5. O-ring
6. Bushing
7. Roller
8. Shaft
7

6
1
5

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4
2

2
3

5
6 4

NA14244S

30-20-20 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-58
TRACK) (CONT’D)

Lower Roller Disassembly

1
NOTE: The procedure is shown on a lower roller used
with the steel track. The photos may appear
different, the procedure is the same.

Figure 30-20-56

P-89289
1

Remove the seal assembly (Item 1) [Figure 30-20-58].

2
Figure 30-20-59

P-89287

Drive the pin (Item 1) towards the top of the collar (Item
Page 445 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off

2) [Figure 30-20-56]. 2

NOTE: The pin bore in the collar is stepped. 1

Figure 30-20-57
P-89290

Remove the seal assembly (Item 1). Remove the O-ring

1 (Item 2) [Figure 30-20-59].

P-89288

Remove the collar (Item 1) [Figure 30-20-57].

30-20-21 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-62
TRACK) (CONT’D)

Lower Roller Disassembly (Cont’d)

Figure 30-20-60

P-89293

1
Remove the seal assembly (Item 1) [Figure 30-20-62]
from the collar.
P-89291
Figure 30-20-63

Remove the shaft assembly (Item 1) [Figure 30-20-60]

from the roller.

Figure 30-20-61 1

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1

P-89262

Remove the O-ring (Item 1) [Figure 30-20-63] from all

four seal rings.
P-89292

Remove the seal assembly (Item 1) [Figure 30-20-61]

from the roller.

30-20-22 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-66
TRACK) (CONT’D)

Lower Roller Disassembly (Cont’d)

1
Figure 30-20-64

P-89296

1
Remove the O-ring (Item 1) [Figure 30-20-66].

P-87924 Figure 30-20-67

Remove the pin (Item 1) [Figure 30-20-64].

Figure 30-20-65
1
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1
P-89297

Remove the bushing (Item 1) [Figure 30-20-67] from

both sides of the roller.
P-87925

Remove the shaft (Item 1) [Figure 30-20-65].

30-20-23 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-70
TRACK) (CONT’D)

Lower Roller Assembly

1
Clean all parts in solvent and dry with compressed air.

The seal assemblies are a matched set and must be

replaced in pairs.

Figure 30-20-68

1
P-89295

Install the shaft (Item 1) [Figure 30-20-70] in the collar.

Figure 30-20-71

P-89297

Install the bushing (Item 1) [Figure 30-20-68] on both

sides of the roller.

Page 448 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
Figure 30-20-69

P-89294

Install the pin (Item 1) [Figure 30-20-71] in the collar and

through the shaft.

P-89296

Install the O-ring (Item 1) [Figure 30-20-69] on the shaft.

30-20-24 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Dip the seal assembly in a pan of alcohol.
TRACK) (CONT’D)
Figure 30-20-74
Lower Roller Assembly (Cont’d)

Figure 30-20-72

1
P-89298

P-89262 Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-20-74] in the collar.

Install the O-ring (Item 1) [Figure 30-20-72] on the seal Use firm, even pressure on the installation tool to pop the
ring. Repeat this procedure on all four seal assemblies. O-ring in to the collar.

The O-ring and seal ring must be clean and free of any Remove the installation tool.
dust, oil film and foreign matter.
Figure 30-20-75
NOTE: Inspect the seal ring for damage before
Page 449 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off

installing the O-ring. Make sure that the O-ring

is not twisted when installing it. To remove
any twists, gently pull a section of the O-ring
and let it snap back.

Figure 30-20-73

P-89299

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-20-75].

P-40754

Place the seal assembly in the installation tool (Item 1)

[Figure 30-20-73].

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.

30-20-25 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-78
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-76

P-89301

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-20-78].
P-40754
Apply a light film of oil to both metal seal rings.

Place the seal assembly (Item 1) [Figure 30-20-76] in NOTE: Do not get any oil on the rubber O-rings.
the installation tool.
Figure 30-20-79
The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.
1

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Dip the O-ring and seal assembly in a pan of alcohol.

Figure 30-20-77

P-89302

Install the roller (Item 1) [Figure 30-20-79] on the shaft.

P-89300

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-20-77] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

30-20-26 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-82
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-80

P-89304

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-20-82].
P-40754
Figure 30-20-83

Place the seal assembly in the installation tool (Item 1)

[Figure 30-20-80].

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
1
retaining ring and seal uniformly in the housing radius.
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Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-20-81

P-89305

Install the O-ring (Item 1) [Figure 30-20-83].

P-89303

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-20-81] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

30-20-27 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-86
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-84

P-89307

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-20-86].
P-40754
Apply a light film of oil to both metal seal rings.

Place the seal assembly in the installation tool (Item 1) NOTE: Do not get any oil on the rubber O-rings.
[Figure 30-20-84].
Figure 30-20-87
The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius. 1

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Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-20-85

P-89308

Install the collar (Item 1) on the shaft. Install the pin (Item
1 2) [Figure 30-20-87] in the collar.

P-89306

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-20-85] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

30-20-28 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-20-88

P-89309

Push down on the collar until the pin bore of the collar is
aligned with the pin bore of the shaft. Fully seat the pin
(Item 1) [Figure 30-20-88].

Remove the plug (Item 2) [Figure 30-20-88]. Add 0,121 -

0,160 L (4.1 - 5.4 U.S. fl oz) of 30W oil to the roller.
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Install the plug.

30-20-29 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER TRACK) (CONT’D)

Upper Roller Parts Identification

1. Snap Ring
2. Pipe Plug
3. Cover
4. O-ring
5. Bearing
6. Roller
7. Seal
8. Shaft


4 1

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2

NA14245S

30-20-30 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-91
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly

Figure 30-20-89
1

P-87918

Install a 50,8 mm (2.0 in) long 3,175 mm (1/8 in) NPT

pipe (Item 1) into the cover. Pull up on the pipe to remove
P-87915 the cover (Item 2) [Figure 30-20-91].

Figure 30-20-92
Remove the snap ring (Item 1) [Figure 30-20-89].

Figure 30-20-90
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1
1

P-87919

P-87916 Remove the O-ring (Item 1) [Figure 30-20-92].

Remove the pipe plug (Item 1) [Figure 30-20-90].

30-20-31 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER Figure 30-20-95
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly (Cont’d)

1
Figure 30-20-93

1 P-87922

Remove the seal (Item 1) [Figure 30-20-95] from the

shaft.
P-87920
Figure 30-20-96

Remove the snap ring (Item 1) [Figure 30-20-93].

Turn the roller over and drain the oil.

1
Assembly: Add 0,133 - 0,169 L (4.5 - 5.7 U.S. fl oz) of
30W oil to the roller before installing the cover.

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Figure 30-20-94

P-87923

1
Remove the seal (Item 1) [Figure 30-20-96] from the
roller.

P-87921

Remove the shaft (Item 1) [Figure 30-20-94] from the

roller.

30-20-32 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly (Cont’d)

Figure 30-20-97

P-87924

Remove the snap ring (Item 1) [Figure 30-20-97].

Figure 30-20-98
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P-87925

Remove the bearings (Item 1) [Figure 30-20-98] from

both ends of the roller.

30-20-33 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (RUBBER
TRACK) (CONT’D)

Sprocket Removal And Installation

Figure 30-20-99

P131427

Remove the drive sprocket bolts [Figure 30-20-99].

Installation: Put thread adhesive (Loctite® 242) on the

bolts and tighten to 245 N•m (181 ft-lb) torque.

Remove the drive sprocket from the travel motor.

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30-20-34 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK)

Description

The track undercarriage components consist of the front

idler, top roller, bottom rollers, drive motor sprocket,
tension cylinder and track frame.
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30-21-1 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Checking Tension WARNING

NOTE: The wear of the pins and bushings on the AVOID INJURY
undercarriage vary with the working Keep fingers and hands out of pinch points when
conditions and the different types of soil checking the track tension.
conditions. It is necessary to inspect track W-2142-0903
tension to maintain the correct tension. See
Service Schedule for the correct service Figure 30-21-2
interval. (See SERVICE SCHEDULE on Page
10-70-1.)
Track Frame
Figure 30-21-1

Track
40 - 60 mm
1 (1.6 - 2.4 in)

B-15022

P131422 Measure the clearance at the middle track roller. Do not

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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 30-21-2].

Steel Track Clearance - 40 - 60 mm (1.6 - 2.4 in).

P131423

Raise the side of the machine (approximately 102 mm [4

in]) using the boom and arm.

Raise the blade fully and install jackstands (Item 1)

[Figure 30-21-1] and [Figure 30-21-2] under the blade
and track frame. Raise the boom until all machine weight
is on the jackstands.

Stop the engine.

30-21-2 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-5
TRACK) (CONT’D)

Adjusting Tension

Figure 30-21-3
1

P131512

The tension removal tool (P/N 7277225) is available and

recommended to direct the flow of grease to aid in
1 cleanup. Always dispose of the grease in an
environmentally friendly manor.
P131511
Use tool 7277225 (Item 1) [Figure 30-21-5] to loosen the
track tension fitting (Item 1) [Figure 30-21-4] to release
Loosen the two bolts on the cover (Item 1) [Figure 30-21- tension from the track.
3]. Pivot the cover downward.
The tool is sized to fit the one piece track tension fitting
(Item 1) [Figure 30-21-4].

WARNING NOTE: Do not loosen the track tension fitting (Item 1)

[Figure 30-21-4] more than 1-1/2 turns.
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HIGH PRESSURE GREASE CAN Installation: Tighten the track tension fitting to 24 - 30
CAUSE SERIOUS INJURY N•m (18 - 22 ft-lb) torque.
• Do not loosen the track tension fitting more than
1 - 1/2 turns. Repeat the procedure for the opposite side.
W-2994-0515

Figure 30-21-4

P131513

Add grease to the track tension fitting (Item 1) [Figure

30-21-4] until the track tension is correct.

30-21-3 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Track Removal WARNING

Lift and block both sides of the machine as follows: Put jackstands under the blade and rear corners of
the undercarriage before working under the machine.
Raise the blade fully. Failure to block up the machine may allow it to move
or fall and result in injury or death.
Figure 30-21-6 W-2218-1195

Stop the engine.

Release track tension. (See Adjusting Tension on Page

30-21-3.)

With the excavator raised and the bleed fitting loosened,

start the excavator. (See Adjusting Tension on Page 30-
21-3.)

Slowly turn the track. This will force more grease out of
1 the grease spring.

1 Stop the engine.

P131515

Use the boom and arm to lift the blade end of the
machine up about 75 mm (3.0 in) and install jackstands WARNING
(Item 1) [Figure 30-21-6] under the blade.

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AVOID INJURY OR DEATH
Raise the boom. Keep fingers and hands out of pinch points when
removing the track.
Figure 30-21-7 W-2173-0195

P133064

Swing the upperstructure 180 degrees and use the boom

and arm to slowly lift the opposite end of the
undercarriage and install jackstands under the
undercarriage (Item 1) [Figure 30-21-7].

Raise the boom until the weight of the machine is

supported by the jackstands.

30-21-4 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-10
TRACK) (CONT’D)

Track Removal (Cont’d)

Figure 30-21-8

1
1

P-87906

Remove the pin (Item 1) [Figure 30-21-10] and any

washers (if equipped).
P-87904
Figure 30-21-11

Rotate the track until the master link and cotter pin (Item
1) [Figure 30-21-8] are at the bottom of the track frame,
between the drive motor and rear lower roller.

Stop the engine.

Remove the cotter pin (Item 1) [Figure 30-21-8].

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Figure 30-21-9

P-87907

Start the excavator and run it at low idle. Slowly engage

the travel motor in the reverse direction. Continue to
engage the travel motor in the reverse direction until the
track has been driven off the track frame [Figure 30-21-
1 11].

Stop the engine.

P-87905

Drive the master pin (Item 1) [Figure 30-21-9] towards

the inside of the track frame.

30-21-5 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-13
TRACK) (CONT’D)

Track Installation

Figure 30-21-12

3
2 2
1
1
P-87906

1 Rotate the track until the track links (Item 1) are located
on the bottom of the track frame, between the drive motor
P-87907 and rear lower roller. Install the master pin (Item 2)
[Figure 30-21-13] from the inside of the track frame.

Place the steel track (Item 1) under the track frame and in Figure 30-21-14
line with the travel motor. Place the opposite end of the
track (Item 2) [Figure 30-21-12] over the drive sprocket.

WARNING

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AVOID INJURY OR DEATH
Drive motor must be operated slowly to avoid any
sudden movements that could cause injury or death.
W-2174-0195
1

With the help of a second person, start the excavator.

Use the travel lever (on the side of the excavator the track
P-87904
in being installed) to slowly turn the drive motor in the
forward direction. Guide the track over the upper roller
(Item 3) [Figure 30-21-12] and on to the front idler. Install the cotter pin (Item 1) [Figure 30-21-14].

30-21-6 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-16
TRACK) (CONT’D)

Idler Removal And Installation

NOTE: Dealer disassembly of the component(s) 1

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check 3
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.
2
1
Remove the track. (See Track Removal on Page 30-21-
4.)
P131592

Figure 30-21-15
Remove the four bolts (Item 1) and washers. Remove the
idler (Item 2) [Figure 30-21-16].

DO NOT DISASSEMBLE OR REPAIR THE COIL

1 SPRING ASSEMBLY (Item 3) [Figure 30-21-16].

WARNING
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2
P131591

Install a chain (Item 1) [Figure 30-21-15] and hoist to the

idler. P-62574

Slide the idler (Item 2) [Figure 30-21-15] out of the track

AVOID INJURY OR DEATH
frame.
• Spring loaded components under pressure can
cause serious injury or death.
• Do not disassemble the coil spring assembly
W-2617-1004

30-21-7 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) (CONT’D)

Idler Parts Identification

1. Plug
2. Support
3. Roll Pin
4. Seal Assembly
5. O-ring
6. Bushing 7
7. Idler
8. Shaft

3
6
5

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3
2
1

4
5

NA14243S

30-21-8 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-19
TRACK) (CONT’D)

Idler Disassembly

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found 1
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Figure 30-21-17
P-89261

1 Figure 30-21-20

1
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P-89259

Remove the roll pin (Item 1) [Figure 30-21-17].

P-89263
Figure 30-21-18

Remove the floating seal (Item 1) [Figure 30-21-19] and

[Figure 30-21-20] from the support and idler.
1

P-89260

Pull up on and remove the support (Item 1) [Figure 30-

21-18].

30-21-9 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-23
TRACK) (CONT’D)

Idler Disassembly (Cont’d)

Figure 30-21-21

P-89267

Figure 30-21-24

P-89264

Remove the O-ring (Item 1) [Figure 30-21-21] from the 1

shaft.

Figure 30-21-22

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1

P-89268

Remove the floating seal (Item 1) [Figure 30-21-23] and

[Figure 30-21-24] from the support and idler.

P-89266

Tip the idler over and remove the support / shaft

assembly (Item 1) [Figure 30-21-22].

30-21-10 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-27
TRACK) (CONT’D)

Idler Disassembly (Cont’d)

Figure 30-21-25 1

P-89270

Remove the O-ring (Item 1) [Figure 30-21-27].

P-89262 Figure 30-21-28

Remove the O-ring (Item 1) [Figure 30-21-25] from all

four of the steel seals.
1
Figure 30-21-26
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P-89271

Remove the bushings (Item 1) [Figure 30-21-28] from

2 both sides of the idler.

P-89269

Remove the roll pin (Item 1). Remove the shaft (Item 2)
[Figure 30-21-26] from the support.

30-21-11 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL NOTE: Inspect the seal ring for damage before
TRACK) (CONT’D) installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
Idler Assembly any twists, gently pull a section of the O-ring
and let it snap back.
Clean all parts in solvent and dry with compressed air.
Figure 30-21-31
The seal assemblies are a matched set and must be
replaced in pairs.
1
Figure 30-21-29

P-40754

Place the seal assembly in the installation tool (Item 1)

P-89271 [Figure 30-21-31].

The O-ring and seal ring assembly have to be lubricated

Install the bushings (Item 1) [Figure 30-21-29] on both with alcohol, so that the O-ring will slip past the housing
sides of the idler.

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retaining ring and seal uniformly in the housing radius.

Figure 30-21-30 Dip the seal assembly in a pan of alcohol.

Figure 30-21-32

1
1

P-89262

P-89276
Install the O-ring (Item 1) [Figure 30-21-30] on the seal
ring. Repeat this procedure on all four seal assemblies.
Shake off the excess alcohol and install the seal
The O-ring and seal ring must be clean and free of any assembly (Item 1) [Figure 30-21-32] in the idler.
dust, oil film and foreign matter.
Use firm, even pressure on the installation tool to pop the
O-ring into the housing.

Remove the installation tool.

30-21-12 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-35
TRACK) (CONT’D)

Idler Assembly (Cont’d) 1

Figure 30-21-33 2

P-89269

Install the shaft (Item 1) in the support. Install the roll pin
(Item 2) [Figure 30-21-35] through the shaft and support
P-89277 assembly.

Figure 30-21-36
The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 30-21-33].
1
Figure 30-21-34
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1
P-40754

Place the seal assembly (Item 1) [Figure 30-21-36] in

P-89270 the installation tool.

The O-ring and seal ring assembly have to be lubricated

Install the O-ring (Item 1) [Figure 30-21-34] onto the with alcohol, so that the O-ring will slip past the housing
shaft. retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

30-21-13 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-39
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-21-37 1

P-89264

Install the idler (Item 1) [Figure 30-21-39] on the shaft /

support assembly.
P-89274
Figure 30-21-40

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-21-37] in the support. 1

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Figure 30-21-38

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P-40754

Place the seal assembly (Item 1) [Figure 30-21-40] in

the installation tool.

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
P-89275 retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 30-21-38].

Apply a light film of oil to both metal seal rings.

NOTE: Do not get any oil on the rubber O-rings.

30-21-14 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-43
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-21-41
1

P-89280

Install the O-ring (Item 1) [Figure 30-21-43] on the shaft.

P-89278 Figure 30-21-44

Shake off the excess alcohol and install the seal 1

assembly (Item 1) [Figure 30-21-41] in the idler.

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Remove the installation tool.

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Figure 30-21-42

P-40754

Place the seal assembly (Item 1) [Figure 30-21-44] in

the installation tool.

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
1 retaining ring and seal uniformly in the housing radius.

Dip the seal assembly in a pan of alcohol.

P-89279

The seal assembly stand off height must be equal and

the O-ring (Item 1) [Figure 30-21-42] must not be
twisted.

30-21-15 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-47
TRACK) (CONT’D)

Idler Assembly (Cont’d)

Figure 30-21-45 1

P-89283

Install the support (Item 1) on the shaft. Press down on

the support and install the roll pin (Item 2) [Figure 30-21-
P-89281 47].

Figure 30-21-48
Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-21-45] in the idler.

Use firm, even pressure on the installation tool to pop the

O-ring into the housing.

Remove the installation tool.

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1
Figure 30-21-46

89324

Remove the plug (Item 1) [Figure 30-21-48].

Add 0,101 - 0,139 L (3.4 - 4.7 U.S. fl oz) 30W oil to the
1
idler. Install the plug (Item 1) [Figure 30-21-48].

P-89282

The seal stand off height must be equal and the O-ring
(Item 1) [Figure 30-21-46] must not be twisted.

Apply a light film of oil to both metal seal rings.

NOTE: Do not get any oil on the rubber O-rings.

30-21-16 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-51
TRACK) (CONT’D)

Track Tensioner Removal And Installation

Figure 30-21-49

1
1
P131596

Figure 30-21-52

P131593

Remove the shaft (Item 1) [Figure 30-21-49] from the

tube.

NOTE: Add grease to the track tension fitting to push

the shaft out of the tube.

Figure 30-21-50
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P131597

The flat sides (Item 1) [Figure 30-21-51] of the recoil

1
spring grease cylinder must engage the mount (Item 1)
[Figure 30-21-52] of the track frame.

P131594

Lower the tube (Item 1) [Figure 30-21-50] out the bottom

of the track frame.

30-21-17 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) (CONT’D)

Track Tensioner Parts Identification

1. Coil Spring Assembly

2. Shaft
3. Wiper Seal
4. Wear Ring
5. O-ring
6. Seal
7. Tube
8. Bleed / Grease Fitting

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8

6
5

NA14241S

30-21-18 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Track Tensioner Disassembly And Assembly WARNING

Figure 30-21-53

P-62574
1
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
P131600

DO NOT DISASSEMBLE OR REPAIR THE COIL

Remove the O-ring (Item 1) [Figure 30-21-53] from the SPRING ASSEMBLY.
cylinder.

Installation: Apply oil to the O-ring before installation.

Figure 30-21-54
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2
3 4
1

P131595

Remove the wiper seal (Item 1), wear ring (Item 2), back-
up ring (Item 3), and O-ring (Item 4) [Figure 30-21-54].

30-21-19 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-57
TRACK) (CONT’D)

Roller Removal And Installation

NOTE: Dealer disassembly of the component(s)

shown here may not be recommended under
Bobcat’s “Do Not Disassemble Policy”, found 1
in the Warranty Policy and Procedure Manual
or by clicking here. Please click here to check
the list of affected part numbers in IRW before
proceeding. This only affects machines sold
in the US and Canada.

Figure 30-21-55
P-89286

Remove the bottom roller (Item 1) [Figure 30-21-57].

2
1

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P-98302

Loosen the bolt (Item 1) and nut. Remove the top roller
(Item 2) [Figure 30-21-55].

Figure 30-21-56

2 2

P-89285

Loosen the bolts (Item 1) [Figure 30-21-56] on the track

roller on both sides of the track frame.

Installation: Tighten the bolts to 160 - 180 N•m (118 -

133 ft-lb) torque.

30-21-20 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) (CONT’D)

Lower Roller Parts Identification

1. Collar
2. Plug
3. Roll Pin
4. Seal Assembly
5. O-ring
6. Bushing
7. Roller
8. Shaft 7

4 5

3
2
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2 3
1
4

NA13728S

30-21-21 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-60
TRACK) (CONT’D)

Lower Roller Disassembly

1
Figure 30-21-58

P-89289

Remove the seal assembly (Item 1) [Figure 30-21-60].

P-89287 Figure 30-21-61

Drive the pin (Item 1) towards the top of the collar (Item
2) [Figure 30-21-58].

NOTE: The pin bore in the collar is stepped.

Figure 30-21-59

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2

1
1

P-89290

Remove the seal assembly (Item 1). Remove the O-ring

(Item 2) [Figure 30-21-61].

P-89288

Remove the collar (Item 1) [Figure 30-21-59].

30-21-22 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-64
TRACK) (CONT’D)

Lower Roller Disassembly (Cont’d)

Figure 30-21-62

P-89293

1
Remove the seal assembly (Item 1) [Figure 30-21-64]
from the collar.
P-89291
Figure 30-21-65

Remove the shaft assembly (Item 1) [Figure 30-21-62]

from the roller.

Figure 30-21-63 1
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P-89262

Remove the O-ring (Item 1) [Figure 30-21-65] from all

four seal rings.
P-89292

Remove the seal assembly (Item 1) [Figure 30-21-63]

from the roller.

30-21-23 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-68
TRACK) (CONT’D)

Lower Roller Disassembly (Cont’d)

1
Figure 30-21-66

P-89296

1
Remove the O-ring (Item 1) [Figure 30-21-68].

P-87924 Figure 30-21-69

Remove the pin (Item 1) [Figure 30-21-66].

Figure 30-21-67
1

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1
P-89297

Remove the bushing (Item 1) [Figure 30-21-69] from

both sides of the roller.
P-87925

Remove the shaft (Item 1) [Figure 30-21-67].

30-21-24 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-72
TRACK) (CONT’D)

Lower Roller Assembly

1
Clean all parts in solvent and dry with compressed air.

The seal assemblies are a matched set and must be

replaced in pairs.

Figure 30-21-70

1
P-89295

Install the shaft (Item 1) [Figure 30-21-72] in the collar.

Figure 30-21-73

P-89297

Install the bushing (Item 1) [Figure 30-21-70] on both

sides of the roller.
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Figure 30-21-71

P-89294

Install the pin (Item 1) [Figure 30-21-73] in the collar and

through the shaft.

P-89296

Install the O-ring (Item 1) [Figure 30-21-71] on the shaft.

30-21-25 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Dip the seal assembly in a pan of alcohol.
TRACK) (CONT’D)
Figure 30-21-76
Lower Roller Assembly (Cont’d)

Figure 30-21-74

1
P-89298

P-89262 Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-21-76] in the collar.

Install the O-ring (Item 1) [Figure 30-21-74] on the seal Use firm, even pressure on the installation tool to pop the
ring. Repeat this procedure on all four seal assemblies. O-ring in to the collar.

The O-ring and seal ring must be clean and free of any Remove the installation tool.
dust, oil film and foreign matter.
Figure 30-21-77
NOTE: Inspect the seal ring for burrs before

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installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
any twists, gently pull a section of the O-ring
and let it snap back.

Figure 30-21-75

P-89299

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-21-77].

P-40754

Place the seal assembly in the installation tool (Item 1)

[Figure 30-21-75].

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.

30-21-26 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-80
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-21-78

P-89301

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-21-80].
P-40754
Apply a light film of oil to both metal seal rings.

Place the seal assembly (Item 1) [Figure 30-21-78] in NOTE: Do not get any oil on the rubber O-rings.
the installation tool.
Figure 30-21-81
The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius.
1
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Dip the O-ring and seal assembly in a pan of alcohol.

Figure 30-21-79

P-89302

Install the roller (Item 1) [Figure 30-21-81] on the shaft.

P-89300

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-21-79] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

30-21-27 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-84
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-21-82

P-89304

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-21-84].
P-40754
Figure 30-21-85

Place the seal assembly in the installation tool (Item 1)

[Figure 30-21-82].

The O-ring and seal ring assembly have to be lubricated

with alcohol, so that the O-ring will slip past the housing
1
retaining ring and seal uniformly in the housing radius.

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Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-21-83

P-89305

Install the O-ring (Item 1) [Figure 30-21-85].

P-89303

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-21-83] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

30-21-28 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-88
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-21-86

P-89307

The seal assembly stand off height must be equal and

the O-ring must not be twisted [Figure 30-21-88].
P-40754
Apply a light film of oil to both metal seal rings.

Place the seal assembly in the installation tool (Item 1) NOTE: Do not get any oil on the rubber O-rings.
[Figure 30-21-86].
Figure 30-21-89
The O-ring and seal ring assembly have to be lubricated
with alcohol, so that the O-ring will slip past the housing
retaining ring and seal uniformly in the housing radius. 1
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Dip the O-ring and seal ring assembly in a pan of alcohol.

Figure 30-21-87

P-89308

Install the collar (Item 1) on the shaft. Install the pin (Item
1 2) [Figure 30-21-89] in the collar.

P-89306

Shake off the excess alcohol and install the seal

assembly (Item 1) [Figure 30-21-87] in the roller.

Use firm, even pressure on the installation tool to pop the

O-ring in to the collar.

Remove the installation tool.

30-21-29 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Lower Roller Assembly (Cont’d)

Figure 30-21-90

P-89309

Push down on the collar until the pin bore of the collar is
aligned with the pin bore of the shaft. Fully seat the pin
(Item 1) [Figure 30-21-90].

Remove the plug (Item 2) [Figure 30-21-90]. Add 0,121 -

0,160 L (4.1 - 5.4 U.S. fl oz) of 30W oil to the roller.

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Install the plug.

30-21-30 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL TRACK) (CONT’D)

Upper Roller Parts Identification

1. Snap Ring
2. Pipe Plug
3. Cover
4. O-ring
5. Bearing
6. Roller
7. Seal
8. Shaft


1
4

1
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NA14245S

30-21-31 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-93
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly

Figure 30-21-91
1

P-87918

Install a 50,8 mm (2.0 in) long 1/8 in NPT pipe (Item 1)

into the cover. Pull up on the pipe to remove the cover
P-87915 (Item 2) [Figure 30-21-93].

Figure 30-21-94
Remove the snap ring (Item 1) [Figure 30-21-91].

Figure 30-21-92

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1
1

P-87919

P-87916 Remove the O-ring (Item 1) [Figure 30-21-94].

Remove the pipe plug (Item 1) [Figure 30-21-92].

30-21-32 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Figure 30-21-97
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly (Cont’d)

1
Figure 30-21-95

1 P-87922

Remove the seal (Item 1) [Figure 30-21-97] from the

shaft.
P-87920
Figure 30-21-98

Remove the snap ring (Item 1) [Figure 30-21-95].

Turn the roller over and drain the oil.

1
Assembly: Add 0,133 - 0,169 L (4.5 - 5.7 U.S. fl oz) of
30W oil to the roller before installing the cover.
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Figure 30-21-96

P-87923

1
Remove the seal (Item 1) [Figure 30-21-98] from the
roller.

P-87921

Remove the shaft (Item 1) [Figure 30-21-96] from the

roller.

30-21-33 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL
TRACK) (CONT’D)

Upper Roller Disassembly And Assembly (Cont’d)

Figure 30-21-99

P-87924

Remove the snap ring (Item 1) [Figure 30-21-99].

Figure 30-21-100

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1

P-87925

Remove the bearings (Item 1) [Figure 30-21-100] from

both ends of the roller.

30-21-34 E85 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (STEEL Guide Plate Removal And Installation
TRACK) (CONT’D)
Figure 30-21-102
Sprocket Removal And Installation

Figure 30-21-101

1 1 1

2
P-89284

P131427 Remove the bolts (Item 1) and guide plates (Item 2)

[Figure 30-21-102] from the track frame.

Remove the drive sprocket bolts [Figure 30-21-101]. NOTE: Photos may appear different but the procedure
is the same.
Installation: Put thread adhesive (Loctite® 242) on the
bolts and tighten to 245 N•m (181 ft-lb) torque.

Remove the drive sprocket from the travel motor.

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30-21-35 E85 Service Manual

30-21-36
E85 Service Manual
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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:
Steel Cords
The following preventions should be taken to minimize
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 E85 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 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Embedded metals are adhered between the steel cords
and the rubber body. The following cases generate
Separation Of Embedded Metals external forces greater than the adhesion strength,
causing separation of the embedded metals:
Figure 30-30-6
Figure 30-30-7

Idler

Rubber
Track

P-4379

PI-13039

Damage:
When the idler continually rides on the projections of
Extraordinary outer forces applied to embedded embedded metals, the embedded metals will eventually
metals cause their separation from the rubber track's peel off [Figure 30-30-7].
body [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 E85 Service Manual

TRACK MAINTENANCE (CONT’D)

Track Damage Identification (Cont’d)

Separation Of Embedded Metals (Cont’d)

Figure 30-30-9

Abrasion

PI-13041

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 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Figure 30-30-11

Separation Of Embedded Metals Due To Corrosion Embedded metal

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 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Figure 30-30-13

Cuts On The Lug Side Rubber

Figure 30-30-12 Cuts

PI-13045

When rubber tracks drive over projections or sharp

P-4377 stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface
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 Machine operators are requested to drive with great
repaired 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 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue 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.

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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 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Causes of the damage:

Track Damage Identification (Cont’d) Lug abrasion is inevitable. Even if lug abrasion is
proceeding, the rubber track can 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 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Figure 30-30-19

Track Damage Identification (Cont’d)

Cracks And Cuts On The Lug Side Rubber

Crack at the edge of Cut on lug side
Figure 30-30-18
embedded metal rubber

PI-13051

Causes of the damage:

When rubber tracks drive over sharp projections,

PI-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals
Damage: [Figure 30-30-19].

Sometimes cracks and cuts on the lug side rubber at the Prevention:
edges of the embedded metals can be observed [Figure
30-30-18]. To avoid extensive stress applied to the lug root where
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metals are embedded, machine operators are requested

Replacement: 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 E85 Service Manual

TRACK MAINTENANCE (CONT’D) Figure 30-30-21

Track Damage Identification (Cont’d)

Abrasion Of The Track Roller Side Track roller

Figure 30-30-20 Abrasion

PI-13053

Causes of the damage:

The abrasion of the track roller side rubber surface

P-4383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against
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 E85 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 E85 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.

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30-30-12 E85 Service Manual

SWING CIRCLE GEAR

Swing Bearing Removal

Remove the upperstructure. (See Removal on Page 40-

10-1.)

Mark the swing bearing to track frame.

Figure 30-40-1

P128194

Remove the twenty four bolts (Item 1) [Figure 30-40-1]

and nuts that hold the swing bearing to the track frame.
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Remove the swing bearing.

Clean and inspect the grease cover for damage. Replace

as necessary.

30-40-1 E85 Service Manual

SWING CIRCLE GEAR (CONT’D) Figure 30-40-4

Swing Bearing Installation

Figure 30-40-2

9 3 10
8 11
1 7 12

6 13

5 14

1 2

2 24 15

23 16
P128193
22 17
21 18
If reusing the existing swing bearing, use the alignment 20 4 19
marks to put the swing bearing in the correct location. If
installing a new swing bearing find the inner race soft
zone (Item 1) and outer race soft zone area (Item 2)
[Figure 30-40-2].

Install the swing bearing so the inside soft zone (Item 1) NA13612

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is at the right hand side of the excavator and the outside
soft zone (Item 2) [Figure 30-40-2] to the left side of the
excavator. Tighten the bolts in the correct sequence (#1 to #24) to
345 - 385 N•m (255 - 285 ft-lb) torque [Figure 30-40-4].
NOTE: Do not put the soft zone to the front or rear of
the excavator. Retorque bolts (#1 to #4) after all bolts have been
torqued.
Figure 30-40-3
Put lubriplate grease or equivalent on the swing bearing
gear.
1

P128194

Install the swing bearing bolts (Item 1) [Figure 30-40-3],

washers, and nuts.

30-40-2 E85 Service Manual

UPPERSTRUCTURE AND SWING SECTION

UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-3

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-5
Front Window Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-6
Front Window Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-7
Front Window Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
Glass Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13

SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

RIGHT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

LEFT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Lower Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Upper Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Compression Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-5
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Lock Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-7

Console Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-7

LEFT UPPERSTRUCTURE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

RIGHT UPPERSTRUCTURE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

TRAVEL LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-2

FLOOR MAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1
Fuel Tank Fitting Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-2

HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1

40-01 E85 Service Manual

SWING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1
Boom Swing Frame Hose Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-4
Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-5
Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-6

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1

ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
Arm To Boom Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-2
Arm To Bucket And Bucket Link Bushing Removal And Installation . . . . . . . . . . . . 40-150-3

BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Bucket Teeth Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Bucket Side Cutting Edge Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-160-2

CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1

TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-2

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QUICK COUPLER (PIN GRABBER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-4
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-5

RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-2

TOOL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1

CENTER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220-1

40-02 E85 Service Manual

UPPERSTRUCTURE Figure 40-10-2

Removal

Lower the blade all the way.

Put all the control levers in NEUTRAL.

Remove the boom. (See Removal And Installation on

Page 40-140-1.)
1
Remove the boom swing cylinder. (See Removal And
Installation on Page 20-22-2.)

Remove the right side cover. (See Removal And

Installation on Page 40-200-1.) P133399

Remove the counterweight. (See Removal And

Installation on Page 40-80-1.) Mark the upperstructure to swing bearing and to the track
frame for assembly (Item 1) [Figure 40-10-2].
Remove the cab. (See Removal And Installation on Page
40-20-1.) Figure 40-10-3

Remove the hydraulic control valve. (See Removal And

Installation on Page 20-40-1.)

Remove the fuel tank. (See FUEL TANK on Page 40-110-

1.)
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Remove the engine. (See Engine Removal And 1

Installation on Page 60-10-14.)

Figure 40-10-1

NA1948

Fasten a chain through the front of the excavator frame

(Item 1) [Figure 40-10-3].

P131657

Remove the hoses from the top of the swivel joint [Figure
40-10-1].

Remove the swing motor. (See Removal And Installation

on Page 20-90-1.)

Remove the swing motor drive carrier. (See Removal And

Installation on Page 20-91-1.)

40-10-1 E85 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-5

Removal (Cont’d)

Figure 40-10-4

1
1

P128203

Partially disassemble the upperstructure from the swing

bearing by removing all but four bolts which are spaced
NA13800
at 90° from each other (Item 1) [Figure 40-10-5].

NOTE: For disassembly safety a minimum of four

Fasten chains to the counterweight mounts (Item 1) evenly spaced bolts must remain installed, to
[Figure 40-10-4]. be removed later.
Install the front and rear lifting chains to a lifting fixture Apply a small amount of lifting pressure to the
above the canopy / cab. upperstructure with the lift sling. Remove the four
remaining bolts holding the upperstructure to the swing

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bearing.

Lift the upperstructure off of the swing bearing. Put the

upperstructure on suitable supporting stands or blocks.

40-10-2 E85 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-7

Installation
2
NOTE: Some images may appear different but the
procedure is the same.

Figure 40-10-6

1 1

1
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NA5582

Install the dowel pins (Item 1) [Figure 40-10-7].

NA5581 Install the bolts (Item 2) [Figure 40-10-7] and washers.

Tighten the bolts to 345 - 385 N•m (255 - 285 ft-lb)
torque.
Rotate the swing bearing so the outside soft zone (Item
1) [Figure 40-10-6] is to the left hand side as shown.

Use a tap in the holes of the swing bearing to remove any

dried thread lock adhesive.

Install the upperstructure onto the swing bearing using

the alignment marks.

40-10-3 E85 Service Manual

UPPERSTRUCTURE (CONT’D)

Installation (Cont’d)

Install the swing motor drive carrier. (See Removal And

Installation on Page 20-91-1.)

Check the backlash between the gears by moving the

frame back and forth at several points throughout 360 of
frame rotation. There must be some backlash present.

Install the swing motor. (See Removal And Installation on

Page 20-90-1.)

Figure 40-10-8

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P131657

Install the hoses [Figure 40-10-8] on the swivel joint.

Remove the chains and lifting fixture.

Install the engine. (See Engine Removal And Installation

on Page 60-10-14.)

Install the fuel tank. (See FUEL TANK on Page 40-110-

1.)

Install the hydraulic control valve. (See Removal And

Installation on Page 20-40-1.)

Install the travel control valve. (See Removal And

Installation on Page 20-180-1.)

Install the counterweight. (See Removal And Installation

on Page 40-80-1.)

Install the right side cover. (See Removal And Installation

on Page 40-200-1.)

Install the boom. (See Removal And Installation on Page

40-140-1.)

40-10-4 E85 Service Manual

CAB

Removal And Installation

Build the service lifting bracket used to remove and install the cab. Use the dimensions shown [Figure 40-20-1] to build
the service lifting bracket.

Figure 40-20-1

777 mm
(30.58 in)

584 mm
(23.00 in)

66 mm 51 mm
66 mm
(2.58 in) (2.58 in) (2.00 in) 76 mm
(3.00 in)

25 mm Ø10 mm (0.19 in TYP)

(1.00 in) (Ø0.40 in TYP) (0.19 in TYP) 279 mm
(11.00 in)
(0.19 in TYP) 13 mm
(0.19 in TYP)
(0.50 in)

6 mm R10 mm
(0.25 in TYP) (R0.38 in)
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76 mm
(3.00 in TYP)

25 mm
80°
(1.00 in)

76 mm
(3.00 in)

161 mm 369 mm
(6.32 in) (14.52 in)

1175 mm
(46.27 in)
52 mm
(2.03 in)

152 mm
(6.00 in)

80°
25 mm
Material: 2 X 2 - 0.25 in wall hot rolled steel 
(1.00 in)
tubing 0.25 in hot rolled steel plate

MS1933A

40-20-1 E85 Service Manual

CAB (CONT’D) Figure 40-20-3

Removal And Installation (Cont’d)

1
Remove the floor mat. (See Removal And Installation on
Page 40-100-1.)

Remove the cab door. (See Door Removal And

Installation on Page 40-20-5.)

Figure 40-20-2

P133271

Adjust the lifting bracket to the proper width by moving

2 the bracket (Item 1) [Figure 40-20-3].

Figure 40-20-4

1
P133274

Install the chain hoist (Item 1) on the lifting bracket

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

Install the cab / canopy service lifting bracket on the cab

[Figure 40-20-2].

NOTE: Use a chain hoist of sufficient capacity.

P128715

WARNING Pull up on and remove the rear tray (Item 1) [Figure 40-
20-4].
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 E85 Service Manual

CAB (CONT’D) Figure 40-20-7

Removal And Installation (Cont’d)

Figure 40-20-5

1 2

P131878

Disconnect the wiper washer hose (Item 1) and harness

P133088 (Item 2) [Figure 40-20-7] and guide through the
upperstructure.

Remove the bolts and washers (Item 1) [Figure 40-20-5] Remove the telematics antenna from the rear window (if
from the rear of the cab. equipped).

Installation: Tighten the bolts to 255 - 285 N•m (188 - Figure 40-20-8
210 ft-lb) torque.

Figure 40-20-6 1
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1 1

1 1

2 P133341

P133086 Remove the radio (if equipped) and disconnect the three
harnesses (Item 1) and antenna (Item 2) [Figure 40-20-
8].
Remove the bolts and washers (Item 1) [Figure 40-20-6]
from the front of the cab. Slowly raise the cab making sure all harnesses and
hoses are completely removed. Remove the cab.
Installation: Tighten the bolts to 255 - 285 N•m (188 -
210 ft-lb) torque.

40-20-3 E85 Service Manual

CAB (CONT’D)

Removal And Installation (Cont’d)

Figure 40-20-9

P133297

Installation: Install the cab mounts (Item 1) [Figure 40-

20-9] on the four corners of the cab.

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40-20-4 E85 Service Manual

CAB (CONT’D) Figure 40-20-11

Door Removal And Installation

Figure 40-20-10

P133089

Remove the two screws (Item 1) and center hinge (Item

2) [Figure 40-20-10].
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P133090

The door can be removed from the cab by slowly

swinging the door back and forth while lifting up on the
door [Figure 40-20-11].

Installation: Align the hinges and swing the door back

and forth until the door weight settles the hinges to full
engagement.

40-20-5 E85 Service Manual

CAB (CONT’D) Figure 40-20-14

Front Window Removal And Installation

Figure 40-20-12

1
1

P128836

Close the window and remove the bolts (Item 1) [Figure

P128834 40-20-13] and [Figure 40-20-14] and nuts.

Figure 40-20-15
With the window open and latched, remove the nut (Item
1) [Figure 40-20-12] and remove the gas spring bolt from
the cab.

Figure 40-20-13

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1
P133371

Tilt the window and remove the rollers (Item 1) [Figure

40-20-15] from both roller mounts. Remove the window.
P128835

40-20-6 E85 Service Manual

CAB (CONT’D) Figure 40-20-18

Front Window Disassembly And Assembly

Figure 40-20-16

4
3
2
1 4
1
2 3
3 2
4
1
1
2
3
4
P128844

Figure 40-20-19
P128841

Figure 40-20-17

5
1 2 3 4
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P128845
1
2 3 4 5 7
6
Remove the bolts (Item 1), washers (Item 2), gasket
P128842 washers (Item 3), and spacer (Item 4) [Figure 40-20-18]
and [Figure 40-20-19].

Remove the bolts (Item 1), washers (Item 2), gasket Remove the handle (Item 5) [Figure 40-20-19].
washers (Item 3), and spacers (Item 4) [Figure 40-20-
16] and [Figure 40-20-17] from the window. Installation: Tighten the bolts to 6,8 - 7,8 N•m (60 - 69
in-lb) torque.
Remove the gasket (Item 5), mount (Item 6), and nuts
(Item 7) [Figure 40-20-17].

Repeat the procedure for the opposite mount.

Installation: Tighten the bolts to 6,8 - 7,8 N•m (60 - 69

in-lb) torque.

40-20-7 E85 Service Manual

CAB (CONT’D) Figure 40-20-22

Front Window Disassembly And Assembly (Cont’d)

Figure 40-20-20

4
3 1
2
1

P133364

Pull down and remove the seal (Item 1) [Figure 40-20-

P133365 22] from the bottom of the window.

Figure 40-20-21

3 4 5
1 2

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6
P133366

Remove the bolts (Item 1), washers (Item 2), gasket

washers (Item 3) and spacers (Item 4) [Figure 40-20-20]
and [Figure 40-20-21].

Remove the gasket (Item 5), roller mount (Item 6), and
nuts (Item 7) [Figure 40-20-21].

NOTE: The rollers (Item 1) [Figure 40-20-15] will be

installed when the window is in the cab.

Installation: Tighten the nuts to 6,8 - 7,8 N•m (60 - 69 in-

lb) torque.

Repeat the procedure for the opposite roller mount.

40-20-8 E85 Service Manual

CAB (CONT’D) Figure 40-20-24

Front Window Adjustment

Figure 40-20-23
1

P133372
2

Loosen the nuts (Item 1) and adjust the roller bracket

(Item 2) [Figure 40-20-24] so the window will roll freely
through the full range of travel. Tighten the nuts to 6,8 -
545,5 mm 7,8 N•m (60 - 69 in-lb) torque.
(21.48 in)
1 1

818 mm
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(32.2 in)
NA13506

Before installing the window, adjust the bottom roller

brackets (Item 1) and left roller bracket (Item 2) [Figure
40-20-23] to the dimensions shown. Tighten the bolts to
6,8 - 7,8 N•m (60 - 69 in-lb) torque.

Install the front window. (See Front Window Removal And

Installation on Page 40-20-6.)

40-20-9 E85 Service Manual

CAB (CONT’D)

Front Window Adjustment (Cont’d)

Figure 40-20-25

1
2
1

P128851

Figure 40-20-26

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1
2

P128852

Loosen the bolts (Item 1) and nuts. Move the striker latch
(Item 2) [Figure 40-20-25] and [Figure 40-20-26] as
needed. Tighten the bolts to 6,8 - 7,8 N•m (60 - 69 in-lb)
torque.

40-20-10 E85 Service Manual

CAB (CONT’D)

Front Window Adjustment (Cont’d)

Fully raise the front window.

Figure 40-20-27

P128854

Figure 40-20-28

1
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P128853

Loosen the bolts (Item 1) and nuts. Move the striker latch
(Item 2) [Figure 40-20-27] and [Figure 40-20-28] as
needed to engage the latch and not interfere with
opening / closing the front window. Tighten the bolts to
6,8 - 7,8 N•m (60 - 69 in-lb) torque.

40-20-11 E85 Service Manual

CAB (CONT’D)

Glass Removal

Figure 40-20-29

P133091

Push a small diameter wire through the adhesive (Item 1)

[Figure 40-20-29]. 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

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will be destroyed when removed.

40-20-12 E85 Service Manual

CAB (CONT’D) Figure 40-20-31

Glass Installation
1
NOTE: Some images may appear different but the
procedure is the same.

Top Polycarbonate Window And Rear Glass

Remove the majority of the old urethane adhesive from

the perimeter of the cab.
1
NOTE: Leave a thin film (0,79 mm (0.03 in) thick) of
the old urethane on the cab frame, fresh
urethane will bond to the remaining film.
MS1993
Prime and paint any bare metal or scratches.

Clean the metal surfaces with 3M surface cleaner. Clean Apply a 6,4 X 9,5 mm (0.25 X 0.375 in) bead of urethane
the glass surface with glass cleaner adhesive (Item 1) [Figure 40-20-31] to the perimeter of
the cab.
Cut the tip of the adhesive tube to the desired shape and
size to provide a bead height sufficient to give good Install the polycarbonate window (Item 1) [Figure 40-20-
contact with the polycarbonate window around the entire 30]. Press the polycarbonate window into the cab to
perimeter. make complete contact with the adhesive. Tape the glass
in place.
Figure 40-20-30
Allow the adhesive to cure for a minimum of eight hours
at 24°C (75°F) and 20% relative humidity.
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1 1 Remove the tape after the adhesive is cured.

NA13485

NOTE: Use only Bobcat approved top Polycarbonate

glass to maintain the FOPS rating.

40-20-13 E85 Service Manual

CAB (CONT’D) Figure 40-20-33

Glass Installation (Cont’d)

Right And Left Side Glass

1
Remove the majority of the old urethane adhesive from
the perimeter of the cab.
1
Prime and paint any bare metal or scratches.

Clean the metal surfaces with 3M surface cleaner. Clean

the glass surface with glass cleaner.

Figure 40-20-32

1
1

NA13486
1

Install the glass (Item 1) [Figure 40-20-33]. Press the

glass into the cab to make complete contact with the
adhesive. Tape the glass in place.

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MS1993

Allow the adhesive to cure for a minimum of eight hours

Apply a 6,4 X 9,5 mm (0.25 X 0.375 in) bead of urethane at 24°C (75°F) and 25% relative humidity.
adhesive (Item 1) [Figure 40-20-32] to the perimeter of
the cab. Remove the tape after the adhesive is cured.

IMPORTANT
If the glass has direct contact with the metal frame,
the glass may break due to machine vibration.
I-2236-0105

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.

40-20-14 E85 Service Manual

CAB (CONT’D) Figure 40-20-36

Glass Installation (Cont’d)

Door Glass

Remove the door from the excavator.

1
NOTE: Some images may appear different but the
procedure is the same.

Figure 40-20-34

P-61224

Apply a 6,4 X 9,5 mm (0.25 X 0.375 in) bead of urethane

adhesive (Item 1) [Figure 40-20-36] around the door
frame.
1
Apply the adhesive directly on top of the old adhesive.

P-61216
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Remove the broken glass (Item 1) [Figure 40-20-34].

Figure 40-20-35

P-61218

Cut and remove the old urethane adhesive (Item 1) and

leaving less than a 0,79 mm (0.03 in) thick layer (Item 2)
[Figure 40-20-35] for the new adhesive to bond to.

NOTE: Use care not to scratch the paint on the frame.

Clean the metal surfaces with 3M surface cleaner. Clean

the glass surface with glass cleaner.

40-20-15 E85 Service Manual

CAB (CONT’D) Figure 40-20-38

Glass Installation (Cont’d)

Door Glass (Cont’d)

Figure 40-20-37

1 1

P128952

Install both gaskets onto the frame.

Center the glass on the frame using the latch cutout (Item
P128951 1) [Figure 40-20-38].

Figure 40-20-39
Place the glass (Item 1) [Figure 40-20-37] on the frame.
The glass must be centered on the frame, and the glass
must not have direct contact with the door frame.

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IMPORTANT
If the glass has direct contact with the metal frame,
the glass may break due to machine vibration.
I-2236-0105

NA13507

Center the glass on the frame [Figure 40-20-39].

Place the clamps over the frame.
Allow the adhesive to cure for a minimum of eight hours
at 24°C (75°F) and 25% relative humidity before
removing the clamps.
Allow thirty-six hours for the adhesive to fully cure.

40-20-16 E85 Service Manual

CAB (CONT’D) Figure 40-20-42

Glass Installation (Cont’d)

1
Door Glass (Cont’d)
2
Figure 40-20-40

P133392

Install the door handle (Item 1) and bolt (Item 2) [Figure

40-20-42]. Tighten the nut to 3,4 - 3,9 N•m (30 - 35 in-lb)
torque.
P128953
Figure 40-20-43

Install the door handle grommet (Item 1) and striker bolt /

latch (Item 2) [Figure 40-20-40].
2
Figure 40-20-41
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1
1

3
P128958

Turn the door over and install the bracket (item 1) and nut
(Item 2) [Figure 40-20-43].
P128956
Install the nuts (Item 3) [Figure 40-20-43].

If equipped, install the keypad or keypad delete cover

(Item 1) [Figure 40-20-41].

40-20-17 E85 Service Manual

CAB (CONT’D)

Glass Installation (Cont’d)

Door Glass (Cont’d)

Figure 40-20-44

2
1

P128959

Install the linkage bars (Item 1). Snap the connectors

(Item 2) [Figure 40-20-44] over the linkage.

Figure 40-20-45

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1
2

2
P128960

Install the cover (Item 1) and screws (Item 2) [Figure 40-

20-45].

Install the door. (See Door Removal And Installation on

Page 40-20-5.)

40-20-18 E85 Service Manual

SEAT

Removal And Installation

Figure 40-30-1

P128757

Tip the seat forward and disconnect the wire harness

(Item 1) [Figure 40-30-1]. (If equipped with heated seat.)

Figure 40-30-2
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P128758

Remove the four nuts (Item 1) [Figure 40-30-2] from the

seat rails.

Remove the seat.

40-30-1 E85 Service Manual

40-30-2
E85 Service Manual
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RIGHT CONSOLE Figure 40-40-2

Console Cover Removal And Installation

Remove the operator cab. (See Removal And Installation

on Page 40-20-1.). 1

Remove the instrument panel / controller. (See Removal

And Installation on Page 50-100-1.)

Figure 40-40-1

P112814

P112815

Remove the screw (Item 1) [Figure 40-40-1].

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Pull the side cover (Item 1) away from the front cover
(Item 2) [Figure 40-40-2].

Pull the front cover (Item 2) [Figure 40-40-2] towards the

front of the excavator and remove the cover.

40-40-1 E85 Service Manual

RIGHT CONSOLE (CONT’D) Figure 40-40-5

Console Cover Removal And Installation (Cont’d)

Figure 40-40-3
1 2

P112818

Pull up on and remove the storage containers (Item 1)

P112816 and (Item 2) [Figure 40-40-5].

Note: The excavator may be equipped with a radio

Installation: Install the tab (Item 1) [Figure 40-40-3] of instead of the storage container (Item 2)
the side cover into the front cover. [Figure 40-40-5]. Pull up on and remove the
radio.
Figure 40-40-4

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2
1

P112817

Remove the two bolts (Item 1) and nuts. Remove the

armrest (Item 2) [Figure 40-40-4].

40-40-2 E85 Service Manual

RIGHT CONSOLE (CONT'D) Figure 40-40-8

Console Cover Removal And Installation (Cont’d)

Figure 40-40-6

1 1
1 1

P112823

Remove the pin assembly (Item 1). Remove the nut (Item
P112820 2) [Figure 40-40-8] from the key switch. Lower the switch
into the console.

Disconnect the wire harness (Item 1) [Figure 40-40-6] Installation: Tighten the nut to 5,6 N•m (50 in-lb) torque.
from the engine speed control, switches and auxiliary
power outlet. Figure 40-40-9

Figure 40-40-7
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1
1 1

P112825

P112822
Pull up on the center pin (Item 1) [Figure 40-40-9].

Pull up on the center pin (Item 1) [Figure 40-40-7].

40-40-3 E85 Service Manual

RIGHT CONSOLE (CONT'D) Figure 40-40-12

Console Cover Removal And Installation (Cont’d)

Figure 40-40-10

P112828

1
1 1
Remove the pin assembly (Item 1) [Figure 40-40-12].
P112826
Figure 40-40-13

Remove the pin assembly (Item 1) [Figure 40-40-10].

Figure 40-40-11

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1
1

P112829

Pull up on the center pin (Item 1) [Figure 40-40-13].

P112827

Pull up on the center pin (Item 1) [Figure 40-40-11].

40-40-4 E85 Service Manual

RIGHT CONSOLE (CONT'D)

Console Cover Removal And Installation (Cont’d)

Figure 40-40-14

1
P112830

Remove the pin assembly (Item 1) [Figure 40-40-14].

Figure 40-40-15
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P112831

Loosen the nut (Item 1) [Figure 40-40-15] and bolt

located under the console cover. Remove the cover.

40-40-5 E85 Service Manual

40-40-6
E85 Service Manual
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LEFT CONSOLE

Lower Console Cover Removal And Installation

Figure 40-50-1

2
P-92485

Pull out on the center of the plastic fastener assembly

(Item 1) [Figure 40-50-1] (both sides).

Remove the fastener assembly and cover (Item 2)

[Figure 40-50-1].
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40-50-1 E85 Service Manual

LEFT CONSOLE (CONT'D) Figure 40-50-4

Upper Console Cover Removal And Installation

Figure 40-50-2

P-92473

Pull up on the center of the plastic fastener (Item 1)

P-92471 [Figure 40-50-4].

Figure 40-50-5
Remove the screw (Item 1) [Figure 40-50-2] and lower
the console.

Figure 40-50-3 3
2

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1

P-92474

Remove the fastener assembly (Item 1). Remove the

P-92472 bolts (Item 2) and nuts. Remove the armrest (Item 3)
[Figure 40-50-5].

Remove the screw (Item 1) [Figure 40-50-3] from the

rear of the cover.

40-50-2 E85 Service Manual

LEFT CONSOLE (CONT'D) Figure 40-50-8

Upper Console Cover Removal And Installation

(Cont’d)

Figure 40-50-6

1
2
2

P-92478

Pull up on the rear of the top cover (Item 1) [Figure 40-

50-8].
P-92475
Figure 40-50-9

Pull down on the front of the bottom cover (Item 1)

[Figure 40-50-6].

Figure 40-50-7 1 1
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2 2

P-92479

Installation: Push down on the top cover until the lock

tabs (Item 1) engage the slots (Item 2) [Figure 40-50-9].
P-92476

Installation: Push up on the bottom cover until the lock

tabs (Item 1) [Figure 40-50-7] engage the slots (Item 2)
[Figure 40-50-6].

40-50-3 E85 Service Manual

LEFT CONSOLE (CONT'D)

Upper Console Cover Removal And Installation

(Cont’d)

Figure 40-50-10

P-92477

Disconnect the wire harness from the switches and

remove the top cover (Item 1) [Figure 40-50-10].

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40-50-4 E85 Service Manual

LEFT CONSOLE (CONT'D) Figure 40-50-13

Compression Spring Removal And Installation

Remove the lower console cover. (See Lower Console

Cover Removal And Installation on Page 40-50-1.)

Lower the console.

Figure 40-50-11
1

P-92506

Remove the nut (Item 1) [Figure 40-50-13].

1 Figure 40-50-14

P-92311
2

Install a pin (Item 1) [Figure 40-50-11] in the bottom of

the compression spring rod.
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Figure 40-50-12

3
1

P-92508

Remove the bolt (Item 1) and bushing (Item 2). Remove

the spring assembly (Item 3) [Figure 40-50-14] from the
console.
1

P-92507

Support the console in the raised position. Remove the

bolt and roller (Item 1) [Figure 40-50-12].

Lower the console and remove the pin from the rod.

Raise and support the console.

40-50-5 E85 Service Manual

LEFT CONSOLE (CONT'D) Figure 40-50-17

Compression Spring Removal And Installation

(Cont’d)

Figure 40-50-15

3
P-52264

1
Remove the sleeve (Item 1) and washer (Item 2) from the
shaft (Item 3) [Figure 40-50-17].
P-92315

Remove the bushing (Item 1) [Figure 40-50-15] from the

bottom of the console.

Figure 40-50-16

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1

P-52263

Remove the spring (Item 1) from the shaft (Item 2)

[Figure 40-50-16].

40-50-6 E85 Service Manual

LEFT CONSOLE (CONT'D) Console Removal And Installation

Lock Lever Removal And Installation Remove the upper console cover. (See Upper Console
Cover Removal And Installation on Page 40-50-2.)
Remove the lower console cover. (See Console Removal
And Installation on Page 40-50-7.) Remove the lower console cover. (See Lower Console
Cover Removal And Installation on Page 40-50-1.)
Remove the compression spring assembly from the
console. (See Compression Spring Removal And Remove the left control lever (Joystick). (See Joystick
Installation on Page 40-50-5.) Assembly Removal And Installation on Page 20-120-4.)

Figure 40-50-18 Remove the lock lever. (See Lock Lever Removal And
Installation on Page 40-50-7.)
1
Figure 40-50-20

P-92312
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Remove the nut (Item 1) and bolt. Remove the lock lever
P-92511
(Item 2) [Figure 40-50-18].

Figure 40-50-19 Remove the nut (Item 1) [Figure 40-50-20] and bolt.

Remove the console.

1 Figure 40-50-21

P-92509

Remove the bushing (Item 1) [Figure 40-50-19] from

both sides of the lever.
P-92510

Remove the bushings (Item 1) [Figure 40-50-21].

40-50-7 E85 Service Manual

40-50-8
E85 Service Manual
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LEFT UPPERSTRUCTURE COVER

Removal And Installation

Figure 40-60-1

P133101

Remove the bolts (Item 1) and remove the cover (Item 2)

[Figure 40-60-1].
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40-60-1 E85 Service Manual

40-60-2
E85 Service Manual
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RIGHT UPPERSTRUCTURE COVER

Removal And Installation

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

Page 10-60-1.)

Figure 40-70-1

2 1

P133103

Remove the bolts (Item 1). Remove the cover (Item 2)

[Figure 40-70-1].
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40-70-1 E85 Service Manual

40-70-2
E85 Service Manual
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COUNTERWEIGHT Figure 40-80-3

Removal And Installation

Remove the left upperstructure cover. (See Removal And

Installation on Page 40-60-1.)

Remove the right upperstructure cover. (See Removal

And Installation on Page 40-70-1.)
1
Remove the tailgate. (See Removal And Installation on
Page 40-180-1.)

Figure 40-80-1

P133069

Remove the plugs and install lifting brackets (Item 1)

1 [Figure 40-80-1], [Figure 40-80-2], and [Figure 40-80-
3].

Figure 40-80-4

P133067
2
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2
Figure 40-80-2

P133068

P133070

Attach the lifting bracket (Item 1) and chains (Item 2)

[Figure 40-80-4].

40-80-1 E85 Service Manual

COUNTERWEIGHT (CONT'D) Figure 40-80-7

Removal And Installation (Cont'd)

Figure 40-80-5

1
1 P133075

Remove the bolts (Item 1) [Figure 40-80-5], [Figure 40-

P133080 80-6] and [Figure 40-80-7].

Installation: Tighten the bolts to 370 - 410 N•m (275 -

Figure 40-80-6 300 ft-lb) torque.

Remove the counterweight.

1 WARNING

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AVOID INJURY OR DEATH
Never get under the counterweights during the
installation or removal procedure.
W-2383-1000

P133074

40-80-2 E85 Service Manual

TRAVEL LEVERS AND PEDALS

Removal And Installation

Figure 40-90-1

1 1

P128631

Remove the bolts (Item 1) [Figure 40-90-1].

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

lb) torque.
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40-90-1 E85 Service Manual

TRAVEL LEVERS AND PEDALS (CONT’D)

Disassembly And Assembly

Figure 40-90-2

P128751

Remove the bolts (Item 1) [Figure 40-90-2].

Figure 40-90-3

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2

P128750

Remove the screw (Item 1) and remove the handle

(Item 2) [Figure 40-90-3].

40-90-2 E85 Service Manual

FLOOR MAT Figure 40-100-3

Removal And Installation

Figure 40-100-1

1
1
1

1
1

P131239

Remove the bolts (Item 1) [Figure 40-100-3] and remove

P133077 the floorplate.

Lift up on and remove the floor mat (Item 1) [Figure 40-

100-1].

Figure 40-100-2
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P133078

Lift up on and remove the front floor mat (Item 1) [Figure

40-100-2].

40-100-1 E85 Service Manual

40-100-2
E85 Service Manual
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FUEL TANK Figure 40-110-3

Removal And Installation

2
Remove the floor mat and center floorplate. (See
Removal And Installation on Page 40-100-1.)
3
Remove the left upperstructure cover. (See Removal And
Installation on Page 40-60-1.)

Drain the fuel tank. (See FUEL SYSTEM on Page 10- 1

110-1.)

Figure 40-110-1

P133234

Remove the fuel fill hose (Item 1) and vent hose (Item 2)
[Figure 40-110-3] from the fuel tank.
2
Disconnect the fuel sender wire harness (Item 3) [Figure
40-110-3].

Figure 40-110-4

P133072
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Remove the bolts (Item 1) and rear fuel tank bracket

(Item 2) [Figure 40-110-1].

Figure 40-110-2

1
P133082
2 2
1
Remove the fuel tank (Item 1) [Figure 40-110-4].

P133079

Disconnect the fuel sender wire harness (Item 1) [Figure

40-110-2].

Mark and remove the fuel lines (Item 2) [Figure 40-110-

2].

40-110-1 E85 Service Manual

FUEL TANK (CONT’D)

Fuel Tank Fitting Removal And Installation

Remove the fuel tank. (See Removal And Installation on

Page 40-110-1.)

Remove the sending units if the tank is being replaced.

(See Lower Fuel Level Sender Removal And Installation
on Page 50-70-1.)

Figure 40-110-5

1
1

2 2

P128521

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Pull up and remove the fittings (Item 1), bushings (Item 2)
[Figure 40-110-5] and tube from the tank.

Installation: Lubricate the bushings with clean fuel for

ease of installation.

40-110-2 E85 Service Manual

HORN

Removal And Installation

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

Page 10-60-1.)

Remove the right side upperstructure cover (See

Removal And Installation on Page 40-70-1.)

Figure 40-120-1

1
1

P131587

Disconnect the wire harness (Item 1) [Figure 40-120-1].

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Remove the nut (Item 2) [Figure 40-120-1] and remove

the horn.

40-120-1 E85 Service Manual

40-120-2
E85 Service Manual
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SWING FRAME Figure 40-130-2

Removal And Installation

Rotate the upperstructure so the blade is to the rear of 3

the excavator.

Remove the arm. (See Removal And Installation on Page

40-150-1.)

Remove the boom. (See Removal And Installation on

Page 40-140-1.) 1

Figure 40-130-1
2
P133245
2
Install the boom pin (Item 1) using spacers (Item 2) to
position a lifting clevis (Item 3) [Figure 40-130-2] in the
center of the boom pin.

NOTE: The spacers will prevent the clevis from

sliding on the boom pin causing the swing
frame to tip from side to side.

1
P133244
IMPORTANT
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Remove the snap ring (Item 1), washer, and pin (Item 2) Do Not use a porta-power to press out the swing
[Figure 40-130-1] from the rod end of the swing cylinder. frame pivot pins without the lower pin being
supported. Excess pressure can cause the swing
frame casting to crack.
I-2092-1204

40-130-1 E85 Service Manual

SWING FRAME (CONT’D) Figure 40-130-5

Removal And Installation (Cont’d)

Figure 40-130-3 1

P133248

Remove the two bolts (Item 1) [Figure 40-130-5].

P133247
Figure 40-130-6

Support the bottom pin with a jack [Figure 40-130-3].

Figure 40-130-4

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1

P133249

Install a porta-power between the top and bottom pins

P133251 and press the top pin out [Figure 40-130-6].

Remove the cotter pin and retaining pin (Item 1) [Figure

40-130-4].

40-130-2 E85 Service Manual

SWING FRAME (CONT’D)

Removal And Installation (Cont’d)

Figure 40-130-7

P133253

Install a spacer tube (Item 1) [Figure 40-130-7] and jack

under the swing frame to support the casting. The spacer
tube must be large enough to allow the pin to be driven in
the center of the spacer tube for pin removal.

Use a large punch (Item 2) [Figure 40-130-7] and drive

the bottom swing frame pin out.
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NOTE: Do not use a porta-power to press out the

bottom pin because the top casting cannot be
supported and possible damage to the
casting could occur.

Remove the swing frame.

Inspect the bushings for damage. Replace damaged

bushings as necessary. (See Bushing Removal on Page
40-130-5.)

40-130-3 E85 Service Manual

SWING FRAME (CONT’D)

Boom Swing Frame Hose Routing

Figure 40-130-8

5 4
3

6
1

P-92038

Route the hoses through the swing frame as follows

[Figure 40-130-8]:

1. Female Quick Coupler

2. Male Quick Coupler
3. Arm Rod End Hose
4. Arm Base End Hose

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5. Bucket Rod End Hose
6. Bucket Base End Hose

40-130-4 E85 Service Manual

SWING FRAME (CONT’D) Figure 40-130-9

Bushing Removal

IMPORTANT
1
Do Not point (hammer) on the boom swing bracket. 2
Excess pressure can cause the casting to crack.
I-2095-1195

The following parts will be needed for removal and

installation of the swing frame bushings: 3 5
P-91831
1. Bolt - 19 x 190 mm or (3/4 x 7-1/2 in) long.

2. Nut - 19 mm or (3/4 in). Install the spacer (Item 1) and washer (Item 2) [Figure
40-130-9] over the flanged end of the bushing.
3. Washer - 22 mm I.D. x 100 mm O.D. x 13 mm thick or
(7/8 I.D. x 3-5/16 O.D. x 1/2 in thick). The spacer (Item 1) [Figure 40-130-9] must be centered
over the bushing to avoid contact between the bushing
4. Washer - 22 mm I.D. x 144 mm O.D. x 13 mm thick or and the spacer during removal.
(7/8 I.D. x 4-1/2 O.D. x 1/2 in thick).
Install the washer (Item 3) [Figure 40-130-9] onto the
5. Washer - 22 mm I.D. 114 mm O.D. x 13 mm thick or opposite end of the bushing. This washer must be
(7/8 I.D. x 4-1/2 O.D. x 1/2 in thick). centered on the bushing and must not contact the
casting.
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6. Spacer - 114 mm I.D. x 133 mm O.D. x 70 mm thick

or (4-1/2 I.D. x 5-1/4 O.D. x 2-3/4 in thick). Install the bolt (Item 4) and the nut (Item 5) [Figure 40-
130-9] through the washers and the spacer.

Tighten the bolt and nut to remove the bushing from the
casting.

40-130-5 E85 Service Manual

SWING FRAME (CONT’D) Figure 40-130-11

Bushing Installation

NOTE: Some photos may appear different but the

procedure is the same.

Apply a film of grease to the outer diameter of the

bushing and to the inner diameter of the casting.

Center the bushing on the casting hole.

NOTE: Make sure that the bushing is centered into

the casting hole and that it starts in the hole
evenly and square.
P-91827
Figure 40-130-10

Figure 40-130-12

5
1

2
3

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4
P-91830

P-91829
Put the washer (Item 1) [Figure 40-130-10] over the
flanged end of the bushing.
The same procedure is used to remove and install the
Put the spacer (Item 2) and the washer (Item 3) [Figure bushings in the frame castings [Figure 40-130-11] and
40-130-10] over the bushing hole casting. Center the [Figure 40-130-12].
spacer and the washer over the bushing hole.

Install the bolt (Item 4) through the washers, the spacer

and the bushing. Install the nut (Item 5) [Figure 40-130-
10].

Tighten the bolt and nut until the bushing is seated in the
casting.

40-130-6 E85 Service Manual

BOOM Figure 40-140-2

Removal And Installation

Remove the arm. (See Removal And Installation on Page

40-150-1.)
1
Remove the boom cylinder. (See Removal And
Installation on Page 20-20-3.)

Lower the boom.

Figure 40-140-1

P128220

1 Mark and remove the hoses (Item 1) [Figure 40-140-2].

Figure 40-140-3

P133099 3
4
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Disconnect the wire harness (Item 1) [Figure 40-140-1]

from the left and right boom lights. Cut and remove the
cable ties from the wiring harness.
1
Remove the cable tie straps.
P133242

IMPORTANT Remove the nuts (Item 1), bolt (Item 2) and pin (Item 3)
[Figure 40-140-3].

When repairing hydrostatic and hydraulic systems, Remove the boom (Item 4) [Figure 40-140-3].
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

40-140-1 E85 Service Manual

BOOM (CONT’D)

Removal And Installation (Cont’d)

Figure 40-140-4

P128523

Remove the seals (Item 1) [Figure 40-140-4] from both

sides of the boom.

Remove the bushings from both sides of the boom.

Install the new bushings in the boom.

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Figure 40-140-5

6 mm (0.236”)

TS-1614A

Install the bushings until they are seated 6 mm (0.236 in)

in the pin boss [Figure 40-140-5] on both sides of the
boom.

Install new seals on both sides of the boom.

40-140-2 E85 Service Manual

ARM Figure 40-150-3

Removal And Installation

Remove the arm cylinder. (See Removal And Installation

on Page 20-22-2.) 1

Figure 40-150-1

1 P133102

Remove the hydraulic hoses (Item 1) [Figure 40-150-2]

and [Figure 40-150-3].

Figure 40-150-4
P-98444

2
Support the arm with a chain hoist (Item 1) [Figure 40-
150-1].
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IMPORTANT 3

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
P133106
damage the system.
I-2003-0888
Remove the nuts (Item 1) and bolt (Item 2) [Figure 40-
Figure 40-150-2 150-4].

Remove the pin (Item 3) [Figure 40-150-4].

1
Remove the arm from the boom.

P133100

40-150-1 E85 Service Manual

ARM (CONT’D)

Arm To Boom Bushing Removal And Installation

Figure 40-150-5

P128223

Remove the seals (Item 1) [Figure 40-150-5] from both

sides of the arm.

Remove the bushings (Item 2) [Figure 40-150-5] from

both sides of the arm.

Install the new bushings in the arm.

Page 572 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
Figure 40-150-6

7,2 mm (0.283”)
TS-1614A

Install the bushings until they are seated 7,2 mm (0.283

in) in the pin boss [Figure 40-150-6] (both sides).

Install new seals on both sides of the arm.

40-150-2 E85 Service Manual

ARM (CONT’D) Figure 40-150-9

Arm To Bucket And Bucket Link Bushing Removal

And Installation

Figure 40-150-7

7,2 mm (0.283”)
TS-1614A

1 1
Install the bushings until they are seated 7,2 mm (0.283
in) in the pin boss [Figure 40-150-9] (both sides).
P128221
Install new seals on both sides of the arm.

Remove the seals (Item 1) [Figure 40-150-7] from both

sides of the arm.

Figure 40-150-8
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1
1
P128224

Remove the bushings (Item 1) [Figure 40-150-8] from

both sides of the arm.

40-150-3 E85 Service Manual

40-150-4
E85 Service Manual
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BUCKET Figure 40-160-2

Bucket Teeth Removal And Installation

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. 2
• Engine is running.
• Tools are being used.
W-2505-0604 P-23376

Position the bucket so the bucket teeth are at a 30 degree Remove the two nuts (Item 1) and bolts from the tooth
angle up from the ground for accessibility to the teeth. shank (Item 2) [Figure 40-160-2]. Remove the tooth
shank.
Lower the boom until the bucket is fully on the ground.
Installation: Tighten the nuts to 125 - 135 N•m (90 - 100
Stop the engine and exit the excavator. ft-lb) torque.

Figure 40-160-1 Figure 40-160-3

1
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1
2

1 2
2

3 3
P-23374 P-69201A

Remove the retaining pin (Item 1) from the tooth point The retaining pin (Item 1) must be installed as shown
(Item 2) [Figure 40-160-1]. [notch (Item 2) to the front] for proper fit and tooth
retention. The side of the tooth point (Item 3) [Figure 40-
Remove the tooth point (Item 2) from the shank (Item 3) 160-3] also shows the correct orientation of the retaining
[Figure 40-160-1]. pin.

Installation: Position the new tooth point on the shank

and install a new retaining pin. Install the retaining pin
until it is flush with the top of the point.

40-160-1 E85 Service Manual

BUCKET (CONT’D)

Bucket Side Cutting Edge Removal And Installation

Figure 40-160-4

P-23377

The bucket side cutting edges (Item 1) [Figure 40-160-4]

are reversible.

Figure 40-160-5

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1 2

P-23373

Remove the two bolts and nuts (Item 1) [Figure 40-160-

5].

Installation: Tighten the nuts to 125 - 135 N•m (90 - 100

ft-lb) torque.

Remove the cutting edge (Item 2) [Figure 40-160-5].

40-160-2 E85 Service Manual

CLAMP Figure 40-170-3

Removal And Installation

1
Lower the clamp to the ground.
1
Figure 40-170-1

P131637

Install a lifting device (Item 1) [Figure 40-170-3] on the

clamp.

P131632 Figure 40-170-4

Remove the snap ring (Item 1) [Figure 40-170-1] and

washer from the rod end of the clamp cylinder.

Figure 40-170-2
1
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2 P131638

1 Remove the nuts and bolt (Item 1) [Figure 40-170-4].

Remove the pin (Item 2) [Figure 40-170-4] and clamp.

P131636

Remove the pin (Item 1) [Figure 40-170-2].

40-170-1 E85 Service Manual

40-170-2
E85 Service Manual
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TAILGATE Figure 40-180-2

Removal And Installation

1
Figure 40-180-1

1 P131797

Figure 40-180-3
P131796

1
Support the tailgate and remove the nuts (Item 1).
Remove the gas strut (Item 2) [Figure 40-180-1].
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P131798

Remove the clip (Item 1) [Figure 40-180-2] and [Figure

40-180-3] and washer from both hinges.

Remove the tailgate.

40-180-1 E85 Service Manual

TAILGATE (CONT’D)

Latch Removal And Installation

Figure 40-180-4

P131906

Remove the bolt (Item 1), nuts (Item 2), and latch (Item 3)
[Figure 40-180-4].

Figure 40-180-5

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1

P131905

Remove push button latch (Item 1) [Figure 40-180-5].

40-180-2 E85 Service Manual

QUICK COUPLER (PIN GRABBER)

Troubleshooting

System errors are indicated by the green light on the switch flashing and/or repeating buzzer chirps. Refer to the error
indicator table.

PIN GRABBER ERROR INDICATORS

CHIRP FLASHES FAULT POSSIBLE CAUSE
1 1 SOLENOID • SOLENOID
• SOLENOID CONNECTOR
• CONTROLLER CONNECTOR
• HARNESS
2 2 PRESSURE SENSOR • PRESSURE SENSOR
• PRESSURE SENSOR CONNECTOR
• CONTROLLER CONNECTOR
• HARNESS
3 BUZZER • BUZZER
• BUZZER CONNECTORS
• CONTROLLER CONNECTOR
• HARNESS
1,2,3 SWITCH LED • SWITCH
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If the coupler is not functioning properly, and there are no system errors, refer to the table.

PIN GRABBER
PROBLEM CAUSE CORRECTION
Safety locks not releasing. Low hydraulic pressure Check pressure.
Faulty pressure switch. Replace pressure switch.
Faulty check valve. Clean or replace check valve.
Faulty cylinder. Replace cylinder.
Safety locks releasing during Faulty seals in cylinder. Repair cylinder.
operation. Faulty check valve. Clean or replace check valve.
Faulty cylinder. Replace cylinder.
Safety locks close when changing Faulty check valve or pilot valve. Clean or replace check valve or pilot
attachments. valve.
Faulty cylinder. Replace cylinder.

40-190-1 E85 Service Manual

QUICK COUPLER (PIN GRABBER) (CONT'D) Removal And Installation

Daily Inspection

Figure 40-190-1
WARNING
1
AVOID INJURY OR DEATH
2 Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
3 • Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907

Remove the bucket. (See Operation & Maintenance

Manual for correct removal procedure.)

P113075 Figure 40-190-2

Remove all dirt and debris from the quick coupler. Inspect
the fixed hook (Item 1), safety lock (Item 2), and sliding
hook (Item 3) [Figure 40-190-1] for wear or damage.

Repair or replace damaged parts.

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P-91726

Support the boom with a hoist [Figure 40-190-2].

Figure 40-190-3

P116264

Mark and remove the coupler hydraulic hoses (Item 1)

and (Item 2) [Figure 40-190-3] from the manifold.

40-190-2 E85 Service Manual

QUICK COUPLER (PIN GRABBER) (CONT'D)

Removal And Installation (Cont’d)

Figure 40-190-4

2
P116262

Remove the two nuts (Item 1) and bolt (Item 2) from the
bucket link pin boss (Item 3) and quick coupler pin boss
(Item 4) [Figure 40-190-4].

Remove the bucket link and coupler pins.

Remove the coupler assembly.

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Figure 40-190-5

1 1

P-93433A

Remove the O-rings (Item 1) [Figure 40-190-5].

40-190-3 E85 Service Manual

QUICK COUPLER (PIN GRABBER) (CONT'D)

Parts Identification

1. Sliding Hook
2. Roll Pin
3. Spring Assembly
4. Hydraulic Cylinder
5. Link
6. Safety Lock
7. Lock Pin
8. Lock Link Pin
9. Rubber Block
10. Guide Assembly
10

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5

4
2 6

2
8

NA8361S

40-190-4 E85 Service Manual

QUICK COUPLER (PIN GRABBER) (CONT’D) Figure 40-190-8

Disassembly And Assembly

1
Figure 40-190-6

2
1

P116321

Remove the spring assembly (Item 1) [Figure 40-190-8].

P116318
Figure 40-190-9

Insert a flat blade screwdriver (Item 1) at the end of the

guide assembly (Item 2) [Figure 40-190-6]. Pry to 1
compress the spring and remove the guide assembly
from the frame.

Figure 40-190-7
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P116322

Remove safety lock pivot pin (Item 1) [Figure 40-190-9].

2 Figure 40-190-10

P116320

Tighten the spring assembly bolt (Item 1) and nut (Item 2)

[Figure 40-190-7] until the spring assembly is free from
the housing.

NOTE: Keep the flats of the spring retainers in line 2

with the mounts for reassembly.
1

P11632

Remove the safety lock link pin (Item 1) and the safety
lock (Item 2) [Figure 40-190-10].

40-190-5 E85 Service Manual

QUICK COUPLER (PIN GRABBER) (CONT’D) Figure 40-190-13

Disassembly And Assembly (Cont’d)

Figure 40-190-11

1
P116317

Rotate the cylinder (Item 1) [Figure 40-190-13] up and

P116315 lift it from the frame.

Inspect and replace parts as necessary.

Remove the cylinder retaining pins (Item 1) from the
sliding hook (Item 2) [Figure 40-190-11]. Reverse procedures for reassembly.

Figure 40-190-12

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1

P116316

Pry out the rubber blocks (Item 1) [Figure 40-190-12].

40-190-6 E85 Service Manual

RIGHT SIDE COVER Figure 40-200-3

Removal And Installation

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

Page 10-60-1.) 1

Figure 40-200-1

P131799

Support the cover and remove the gas struts (Item 1)

[Figure 40-200-3].

Slide the cover to the right and remove the cover from the
P131800 excavator.

Figure 40-200-2
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P131801

Remove the clips (Item 1) [Figure 40-200-1] and [Figure

40-200-3] and washers.

40-200-1 E85 Service Manual

RIGHT SIDE COVER (CONT’D) Figure 40-200-6

Latch Removal And Installation

Figure 40-200-4

2
1

P133109

2
Loosen the nut (Item 1), remove the cotter pin / pin (Item
P133107 2) [Figure 40-200-6]. Remove the cable from the
bracket.

Loosen the nut (Item 1) and remove the knob / cable NOTE: Mark the location of the nut for correct latch
(Item 2) [Figure 40-200-4]. adjustment.

NOTE: Mark the location of the nut for correct latch Figure 40-200-7
adjustment.

Figure 40-200-5 2

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1

2
1

P133110

P133108 Remove the two bolts (Item 1) and remove the latch pin /
bracket (Item 2) [Figure 40-200-7].

Remove the bolts / nuts (Item 1) and remove the bracket

(Item 2) [Figure 40-200-5].

40-200-2 E85 Service Manual

TOOL BOX Figure 40-210-3

Removal And Installation

Remove the floor mat and floor panel. (See Removal And
Installation on Page 40-100-1.)

Figure 40-210-1

1
1

P128771

Remove the screws (Item 1) [Figure 40-210-3].

1 Figure 40-210-4

P131238

Open the tool box and remove the floor mat (Item 1)
[Figure 40-210-1]. Close the tool box.

Figure 40-210-2
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P128772

1 Remove the cover (Item 1) [Figure 40-210-4].

1
Figure 40-210-5

P131240

Remove the screws (Item 1) [Figure 40-210-2].

1
1

2
P131241

Remove the bolts (Item 1) and floorplate (Item 2) [Figure

40-210-5].

40-210-1 E85 Service Manual

40-210-2
E85 Service Manual
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CENTER COVER

Removal And Installation

Figure 40-220-1

1
2

2 1

3 P131795

Loosen the bolts (Item 1) [Figure 40-220-1].

Remove the bolts (Item 2) and remove the cover (Item 3)

[Figure 40-220-1].
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40-220-1 E85 Service Manual

40-220-2
E85 Service Manual
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ELECTRICAL SYSTEM AND ANALYSIS

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Shut-Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-4

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Removing And Installing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-3

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-7

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Page 593 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2

Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
Boom Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2

MAGNETIC LOCKOUT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Lower Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Upper Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2

DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2

50-01 E85 Service Manual

CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Panel Setup (Deluxe Instrument Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Password Setup (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-7
Password Setup (Deluxe Instrument Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-8
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-9
Maintenance Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-10

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

CONTROLLER (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Gateway Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Auxiliary Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-2

CONTROLLER (PIN GRABBER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1

ENGINE CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-3

KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

Page 594 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

MOTION ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-2

SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1

Connecting The Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1

SHUT-OFF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1

TRAVEL MOTOR AUTO-SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

Auto-Shift Drive System (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-2

AUTO IDLE PRESSURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-2

50-02 E85 Service Manual

CONNECTED MACHINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-200-1
Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-200-1
Page 595 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off

50-03 E85 Service Manual

50-04
E85 Service Manual
Page 596 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
INDEX TABLE GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
S. NO DIAGRAM
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
1 SH01 - INDEX
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
2 SH02 - POWER
3 SH03 - GROUND BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT LEGEND
4 SH04 - CAN BUS 01 BATTERY GROUND 2000 THROUGH 2999 BLACK BLK CONNECTOR
5 SH05 - CAN BUS 02
CONTROLLER GROUND 2000 THROUGH 2999 BROWN BRN 1 1
6 SH06 - ENGINE
7 SH07 - HYDRAULICS 01 MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
PARTIAL CONNECTOR
8 SH08 - HYDRAULICS 02 HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
9 SH09 - FRAME
CONTROLLER SUPPLY (5V, 8V) 5000 THROUGH 5999 YELLOW YEL 1 1
10 SH10 - LIGHTS,BEACON
11 SH11 - RADIO,WIPER,FUEL LIGHTS 6000 THROUGH 6999 PINK PNK
1 1
12 SH12 - HEATER,HVAC OTHER FUNCTIONS 7000 THROUGH 7999 WHITE WHT
13 SH13 - OPTIONS SHEET 01
ENGINE 8000 THROUGH 8999 TAN TAN WIRE BREAK
14 SH14 - OPTIONS SHEET 02
COMMUNICATION CAN LO 90XX, 92XX, 94XX, 96XX, 98XX PURPLE PUR SHT1/E2 SHT1/E2
15 SH15 - AUTO HVAC BOX
SHT1/F2 SHT1/F2
16 SH16 - MANUAL HVAC BOX COMMUNICATION CAN HI 91XX, 93XX, 95XX, 97XX, 99XX PURPLE/WHITE PUR/WHT

17 SH17 - DEPTH CHECK

HARNESS PART NUMBER

Page 597 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off

COUPLER 7320117
WIPER 7171777
BEACON / STROBE 7332515
MOTION ALARM 7306988
RH CONSOLE 7306915
LH CONSOLE 7306901
ENGINE 2.4 7306921
BOOM LIGHT 7287258
DELUXE 7234121
SECONDARY 7236409

DEPTH CHECK 7333116

BOOM LONG 7314093
BLR2 7246903
CAB H69162
SEAT 7301033

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
Click Here For Interactive PDF AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 1 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 1 / 17
7221961
Printable Version Click Here
GATEWAY CONTROLLER
3120 LBL
21
S22
8000 TAN
4
J1A
9335 PUR
SHT9/F1

FUSE AND RELAY MODULE

8010 TAN
FUSE 4
1320 RNG
FUSE AND RELAY MODULE 4A 4B SHT5/E6
25.0A 1325 RNG
SHT5/E4
SW PW RELAY

E1 FUSE 1
1050 RNG 1460 RNG
E4 1A 1B SHT11/B4
10.0A
1750 RNG
2000 BLK SHT11/H3
SHT3/F5 E2 E5
FUSE 3
2010 BLK 1800 RNG
SHT10/H8 P7 P7 3A 3B SHT6/E4
25.0A 1900 RNG
SHT7/C7
1730 RNG
SHT7/F7
FUSE 2

1330 RED
1470 RNG 1780 RNG
2A 2B SHT8/C2
20.0A S11 7130 WHT
SHT14/G7
7400 WHT
SHT8/D2
1770 RNG
SHT8/E6
1775 RNG
SHT8/F6

1110 RED
SHT9/G6
S3 FUSE 9
1150 RED 1155 RED 1120 RED
9A 9B SHT9/G6
25.0A S24 1115 RED
SHT9/F1
1125 RED
SHT9/F1

FUSE 10

Page 598 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
1140 RED
10A 10B SHT5/D6
25.0A
1145 RED
SHT5/D4

FUSE 5
1075 RED
5A 5B SHT6/B5
25.0A
1040 RED

FUSE 6
1310 RED 1180 RED
6A 6B SHT12/F3
40.0A

FUSE 7
9400 PUR
7A 7B SHT9/D4
5.0A
1035 RED
SHT6/C5
1146 RED
SHT6/D5

FUSE 11
6300 PNK
11A 11B SHT10/D5
20.0A
1370 RED
SHT10/H8

BATTERY BATT PWR

RH CONS S4 FUSE 12
BATT-CABLE BLK B+ CABLE RED 1030 RED 1360 RED 7210 WHT
SHT3/F1 12A 12B SHT9/C1
T12 15.0A

C113
FUSE 8
1500 RNG 1505 RNG
SHT6/B5 8A 8B 1 1
15.0A
P7 P7

GLOW PLUG FUSE 50A

1065 RED 1060 RED
A B SHT6/D5
50.0A
C160 C160
1070 RED
SHT6/G2

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 2 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 2 / 17
7221961
Printable Version Click Here
2470 BLK
SHT7/E3
2115 BLK
SHT9/F1
2105 BLK
SHT9/F1
2145 BLK
SHT5/E4
2650 BLK
SHT14/H7
2820 BLK
SHT11/B2
S6
2940 BLK
SHT10/G5
2200 BLK
SHT9/D1
2000 BLK
SHT2/G6
2710 BLK
SHT5/E6
2550 BLK
SHT6/F5
2375 BLK BATT-CABLE BLK

2310 BLK
SHT6/G6 SHT2/C8

BATTERY FRAME GND

RH CONS
2110 BLK
SHT9/C6
2430 BLK
SHT8/D6
2030 BLK 2740 BLK
SHT10/F1 SHT12/G4
2020 BLK 2930 BLK
SHT10/F2
2010 BLK 2555 BLK S7 2300 BLK
SHT10/F2 SHT5/F4
Page 599 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off

2870 BLK C463 2840 BLK

SHT10/E5 SC1 DOME LIGHT CONN SHT9/C1
2975 BLK 2950 BLK 2950 BLK
SHT11/H6 B B T11
2880 BLK 2100 BLK
SHT10/B6 SHT9/C6
2610 BLK
SHT9/C6
2302 BLK
SHT5/C2

2970 BLK C461

SHT10/C5
S14 RH CONSOLE CONNECTOR 1
2960 BLK 2790 BLK 2790 BLK
SHT11/C5 E E
2985 BLK
SHT11/C6

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 3 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863
CHG NOTICE DWN
GLM
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 3 / 17
7221961
Printable Version Click Here
CAN BUS 1 CONNECTIONS

C453 C611
ACD CONNECTOR S38 S36 S32 S30 S28 DISPLAY CONNECTOR
9520 PUR/WHT 9535 PUR/WHT 9505 PUR/WHT S42 9503 PUR/WHT 9515 PUR/WHT 9570 PUR/WHT 9540 PUR/WHT
A A 3 3

120.0
Ohms

S39 S37 S43 S33 S31

9620 PUR 9635 PUR 9605 PUR 9603 PUR 9615 PUR 9670 PUR 9640 PUR
B B 4 4
TP-04 TP-04 TP-05 TP-05 TP-06 TP-06 TP-14 TP-14 TP-07 TP-07 TP-08 TP-08 TP-09 TP-09
S29

9500 PUR/WHT
TP-15 TP-11 TP-12
TP-10

9600 PUR

9550 PUR/WHT

9502 PUR/WHT

9530 PUR/WHT
C612
GATEWAY CONTROLLER

9650 PUR

9602 PUR

9630 PUR
9560 PUR/WHT
2 2
TP-12
J1B 9660 PUR
4 4
9
CAN OPTIONS CONNECTOR
8
C454B
9530 PUR/WHT
2 2
TP-11
9630 PUR
4 4
DELUXE DISPLAY OPTION CONN

C420
9502 PUR/WHT
2
TP-15
9602 PUR
4

Page 600 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
TELEMATICS OPTION CONN

SECONDARY CONTROLLER
C170
SECONDARY CONTROLLER BREAKOUT J2B
9550 PUR/WHT 9550 PUR/WHT
J J 9
TP-10 TP-01 TP-01
9650 PUR 9650 PUR
H H 8

GATEWAY CONTROLLER ELECTRONIC ENGINE CONTROLLER

9690 PUR
S34 9695 PUR
20 47
TP-13 TP-13
S35
9590 PUR/WHT 9595 PUR/WHT
14 48
J1B J7

C350
9675 DGN
4 4

9575 YEL
3 3
ENGINE ECU CAN 1

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 4 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863
CHG NOTICE DWN
GLM
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHTPrintable
4 / 17
7221961
Version Click Here
C611
DISPLAY CONNECTOR

1355 RNG
5 5

2355 BLK
2 2

1195 RED
1 1

SEE SHEET 4 4
CAN BUS 01
FOR PINS 3&4
3 3

C612
CAN OPTIONS CONNECTOR

2555 BLK 6 6
SHT3/E5
C453 1365 RNG
ACD CONNECTOR 5 5
C615
2575 BLK 2365 BLK
A A 10 10 3 3
SEE CAN S18
GATEWAY CONTROLLER SPLICE
1185 RED
B B 1 1
J1A
9700 PUR SEE SHEET 4 4
23 C C CAN BUS 01
FOR PINS 2&4
2 2
J1B

1355 RNG

1365 RNG

1195 RED

1185 RED
9800 PUR
21 D D
C454B
1375 RNG DELUXE DISPLAY OPTION CONN
2710 BLK SHT6/G6
SHT3/F5 G G
1325 RNG 1335 RNG
SHT2/G1 5 5
S26
Page 601 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off

1320 RNG
SHT2/G1 E E 2145 BLK 2145 BLK
SHT3/F5 3 3

1140 RED 1145 RED 1165 RED

SHT2/E1 F F SHT2/E1 1 1
S27
4 4
SEE SHEET
CAN BUS 01

1302 RNG
FOR PINS 2&4
2 2

1102 RED
C420
TELEMATICS OPTION CONN

1102 RED
1
1302 RNG
5
2302 BLK
SHT3/D5 3

OPEN 6

SEE SHEET 4
CAN BUS 01
FOR PINS 2&4
2

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 5 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863
CHG NOTICE DWN
GLM
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 5 / 17
7221961
Printable Version Click Here
ELECTRONIC ENGINE CONTROLLER GATEWAY CONTROLLER THROTTLE
3610 LBL
SHT9/E5 C
8150 TAN 2520 BLK
19 4 SHT9/G4 B
3510 LBL
11 A
J1B
C473

C350
STARTER RELAY
1375 RNG

ENGINE ECU CAN 1

SHT5/E4 1 1 P7 P7
2070 BLK SHT12/F3
2375 BLK 9370 PUR 2050 BLK
SHT3/F5 2 2 7 J2 J5 SHT10/H8

9645 DGN
54 6 6 J1 1070 RED
J4 SHT2/B1
9545 YEL
5

8200TAN
53 5
FUSE AND RELAY MODULE

ENGINE HARNESS
STARTER

INTERCONNECT
C113
8013 TAN
28 2 2 8200 TAN
G G
8250 TAN 8250 TAN T3
8014 TAN 22 F F
35 3 3
ALTERNATOR

2075 BLK S17 2550 BLK T2

4 SHT3/F5

2080 BLK
6 T17 E E

1080 RED
2090 BLK

2085 BLK
2

WIF SENSOR
8012 TAN D D

C110

T7

T6
34 2

S
L
8011 TAN
9 1
1800 RNG 1800 RNG 1090 RED
C120 SHT2/F1 C C

Page 602 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
GLOW PLUG RELAY
P7 P7
2060 BLK

8510 TAN 1146 RED T1

56 H5 H2 SHT2/C1
ENGINE AIR
FILTER SWITCH
H1 1060 RED 3210 LBL 3210 LBL
H4 SHT2/B1 SHT9/G4 B B B
3150 LBL 3150 LBL
16 A A A
FUSE AND RELAY MODULE RH CONSOLE CONN 2 C159
J1A C116
C117
GLOW PLUG CONNECTOR
8500 TAN 8500 TAN
1 1
T8 GLOW PLUG
8550 TAN
4 4
C113
ENGINE HARNESS
INTERCONNECT

ENGINE ECU RELAY

P7 P7

8005 TAN 1035 RED

45 C2 C5 SHT2/C1

1084 RNG S19 1076 RNG

1 C4 1075 RED
C1 SHT2/D1
1085 RNG
3
1086 RNG FUSE AND RELAY MODULE
5
1500 RNG
SHT2/B5
J7

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 6 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863
CHG NOTICE DWN
GLM
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHTPrintable
6 / 17
7221961
Version Click Here
GATEWAY CONTROLLER
C501 C502 C503
3375 LBL BROWN
SHT9/F4 B B A
P
LOAD MOMENT
3710 LBL GREEN C170
20 C C C PRESSURE
SECONDARY CONTROLLER BREAKOUT
3675 LBL YELLOW SENSOR
SHT9/E5 A A B 2670 BRN 2670 BRN
10 B B

2660 BRN
2900 BLK 2 A A
SHT10/E2

2660 BRN
J2A

CW SOLENOID
ANGLE BLADE
3700 LBL 3700 LBL
19 J J 2

C621
J1A

LOAD MOMENT
4670 LGN 4670 LGN

6
7 G G 1
C477

CCW SOLENOID
ANGLE BLADE
4660 LGN 4660 LGN
5 F F 1

C621
J2B

2
SECONDARY CONTROLLER 2
1730 RNG 1730 RNG
SHT2/F1 A A C478

3900 LBL CONSOLE SENSOR SIGNAL 3900 LBL

11 H H B
J1B C CONSOLE SENSOR
4300 LGN 4300 LGN

2SPEED SOLENOID
SHT9/G6 F F A
C471 2470 BLK
GATEWAY CONTROLLER SHT3/G5 2

9200 PUR 9200 PUR 4970 LGN

SHT9/D1 G G 6 1

3920 LBL
J1B C414

1720 RNG

WRKGRP SOLENOID
Page 603 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off

2500 BRN
26 2
J1A
4500 LGN
4995 LGN 4995 LGN 26 1
28 K K G
2ND AUX SWITCH INPUT C415
J1B
J1A 4370 LGN 4370 LGN F
SHT9/G4 E E

LEFT HANDLE
S12
D

2nd AUX SOLENOID

4830 LGN 4830 LGN
10 D D A
LH POT SIGNAL (OFFSET)
4400 LGN 2990 BLK
J1B E 27 B
RH CONSOLE CONNECTOR 2
C457 J1A
C 4990 LGN
25 A
3665 LBL 3665 LBL B 2ND AUX SOLENOID PWR
SHT9/E5 A A J1B C701
1900 RNG 1900 RNG C467
SHT2/F1 G G
RH CONSOLE CONNECTOR 1
C461

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 7 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
Printable
SHT 7 / 17
7221961
Version Click Here
GATEWAY CONTROLLER
GATEWAY CONTROLLER
J1B C412
7 4890 LGN OFFSET B
1
J1A
2890 BRN
10 2

17
C411
2880 BRN OFFSET A
2 2
J1B
4880 LGN
5 1

C456
AUX BASE
RH JOYSTICK J1A C418 SOLENOID
1775 RNG 2340 BRN
SHT2/F1 F 18 2
7500 WHT
31 G J1B
4340 LGN
19 1
4350 LGN
SHT9/G4 E AUX ROD
4320 LGN
J1A C419 SOLENOID
12 A 2330 BRN
3670 LBL
1 2
SHT9/E5 D
J1B
4330 LGN
4920 LGN
13 1
29 B
1770 RNG
SHT2/F1 C
J1A
C479

Page 604 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
7410 WHT
C108 33 B
3300 LBL HYD TEMP TRAVEL SWITCH
32 A 7400 WHT
13 SHT2/F1 A
T
3320 LBL
SHT9/G4 B

3430 LBL
C103
34
C102 HYD BYPASS SWITCH
J1A 2430 BLK C476
SHT3/E5
ANGLE BLADE JOYSTICK
SECONDARY CONTROLLER
4960 LGN
B
1780
RNG
SHT2/F1 C

J2B 4620 LGN

M 4620 LGN
E
17 M
J2A 4600 LGN 4600 LGN
A
12 C C
J2B 3660 LBL 3660 LBL
24 R R D

DELUXE DISPLAY OPTION CONN

J2A 4005 LGN
P 4005 LGN
3 P 7 7

4010 LGN 4010 LGN

7 S S 8 8

SECONDARY CONTROLLER BREAKOUT C454B

C170

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 8 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHTPrintable
8 / 17
7221961
Version Click Here
GATEWAY CONTROLLER

J1B

1110 RED 2520 BLK

3 SHT2/E1 SHT6/H4
4350 LGN
1120 RED SHT8/F6
2 SHT2/E1 4370 LGN
SHT7/D7
S1
4310 LGN 3810 LBL
17 SHT9/F6
3320 LBL
SHT8/D6
3310 LBL
SHT11/D5 SECONDARY CONTROLLER SECONDARY CONTROLLER BREAKOUT
3210 LBL C170
4300 LGN SHT6/D4 J2B
23 SHT7/E7 3375 LBL 9335 PUR 9335 PUR
SHT7/H7 22 N N SHT2/H1

1115 RED 1115 RED

3 E E SHT2/E1

3820 LBL 1125 RED 1125 RED

B 2 D D SHT2/E1

3800 LBL P
1 C LOAD SENSE SENSOR
2105 BLK 2105 BLK
3810 LBL
15 K K SHT3/G5
SHT9/G4 A
C156 2115 BLK 2115 BLK
16 L L SHT3/G5

3675 LBL
SHT7/H7
3670 LBL
SHT8/E6
3825 LBL S40 3610 LBL
24 SHT6/H4
3665 LBL
SHT7/C7
Page 605 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off

DELUXE DISPLAY OPTION CONN FORWARD HORN

9331 PUR T102 9200 PUR
6 6 1 SHT7/E7
2200 BLK
C454B 1 SHT3/F5
T103

9333 PUR S41 IGNITION SWITCH

22 9400 PUR
1 SHT2/D1
9330 PUR
J1A 4
C455
9340 PUR
24 2
C455
T10
BUZZER ACC POWER PLUG C465
9320 PUR 2840 BLK
8 1 SHT3/E5

2610 BLK
T9 7210 WHT
SHT3/D5 2 SHT2/C1

6400 PNK
SHT10/B6
J1B
2100 BLK
15 SHT3/D5

2110 BLK
16 SHT3/E5

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 9 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHTPrintable
9 / 17
7221961
Version Click Here
FUSE AND RELAY MODULE GATEWAY CONTROLLER
6010 PNK
2050 BLK P7 P7 A
SHT6/G2
2010 BLK 6210 PNK LEFT BOOM LIGHT
SHT2/F6 G5 G2 5
6200 PNK J1A B
1370 RED
G1
SHT2/C1 G4

2010 BLK
C626

LIGHT RELAY
C460
6220 PNK 6015 PNK , 6020 PNK
S10 A A A
RIGHT BOOM LIGHT

2940 BLK 2015 BLK . 2020 BLK

SHT3/F5 B B B
C625
C627
C469
CAB TO LH CONSOLE CONNECTOR 2 6030 PNK

6240 PNK 6240 PNK SC2 6010 PNK

A A

SHT3/E8

SHT3/E8

SHT3/E8
6020 PNK

2020 BLK

2010 BLK

2030 BLK
C219

C627

C626

C629
6310 PNK
B B A A

1
2

1
2

1
2
BEACON/STROBE

6230 PNK
OPTION
2870 BLK CONNECTOR
SHT3/E8 B B

FRONT LEFT FRONT RIGHT REAR CAB

CAB LIGHT CAB LIGHT LIGHT
OPTION

6310 PNK
C619

Page 606 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
2900 BLK
6 SHT7/G6
C461
RH CONSOLE CONNECTOR 1 C619
2935 BLK

6300 PNK 6300 PNK

SHT2/C1 C C 2
1
BEACON SWITCH

6310 PNK
B B

C470
6230 PNK HOUSE LIGHT
K K A

2970 BLK
SHT3/D8 B

DOME LIGHT
T18
2880 BLK
SHT3/D8 1
C463
DOME LIGHT CONN
6400 PNK 6400 PNK
SHT9/C1 A A 1
T19

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 10 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT Printable
10 / 17
7221961
Version Click Here
C220 C469
RADIO CAB TO LH CONSOLE CONNECTOR 2
1750 RNG 1750 RNG
1 C C SHT2/G1
2975 BLK
2

LEFT SPEAKER
SHT3/D8
7980 WHT T15
3 1
2980 BLK
4 T16 1
7990 WHT
5
2990 BLK
6

T14

RIGHT SPEAKER
1
T13
1

C157
A
UPPER FUEL LEVEL
SENDER

C157
B
GATEWAY CONTROLLER

3110 LBL
3100 LBL 3100 LBL
12 B B

C158
J1B

A
LOWER FUEL LEVEL
SENDER
Page 607 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off

C158
B
3310 LBL 3310 LBL
SHT9/G4 C C
RH CONSOLE CONNECTOR 2
C457

C464
WIPER SWITCH C468 CONNECTOR LH CONSOLE C628 MOTOR WIPER
7100 WHT 7100 YEL
2 A A A
7120 DGN
2985 BLK C C C

PARK
3 SHT3/C8 2960 BLK 2960 BRN
7110 WHT SHT3/C8 B B B
4
7120 WHT
5

WASHER MOTOR
7110 WHT 2820 BLK
F F 1 M 2 SHT3/F5

C462 C462
1460 RNG 1460 RNG
D D SHT2/G1

RH CONSOLE CONNECTOR 1
C461

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 11 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
Printable
SHT 11 / 17
7221961
Version Click Here
C161
HVAC PWR
1190 RED
A
2740 BLK
SHT3/E5 B

HVAC RELAY
GATEWAY CONTROLLER
1180 RED
D1 SHT2/D1
D4
7010 WHT 2070 BLK
9 D5 D2 SHT6/G2

J1A P7 P7
FUSE AND RELAY MODULE

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C623
HVAC BOX CONNECTOR C635
7040 WHT
A A B
PRESSURE SWITCH
2810 BLK 7020 WHT
B B A

C C
C631 C632 C633
7020 WHT 7030 WHT AC CLUTCH
1 1 1

COMPRESSOR DIODE
2810 BLK BLK BLK
2830
2 2 2

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 12 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHTPrintable
12 / 17
7221961
Version Click Here
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Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 13 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHTPrintable
13 / 17
7221961
Version Click Here
7329832 HARNESS BEACON/STROBE

C706 C705
BEACON CONNECTOR CAB HARNESS BEACON POWER CONNECTOR
6310 PNK
C458 A A 1 1
TRAVEL ALARM PWR
2650 BLK
SHT3/F5 B B
2870 BLK
B B 2 2
7130 WHT
SHT2/F1 A A

P2
2650 BLK
B B
7301033 HARNESS SEAT
MOTION ALARM POWER CONNECTOR
C161A C001
7130 WHT
A A HVAC POWER CONNECTOR POWER SPLICE SEAT FUSE
1190 RED SP1 1193 RED
A A A
2740 BLK 1192 RED
B B B
P1 RED
7420 WHT
SP4 A C161C
P1 PRESSURE SWITCH SEAT CONNECTOR

1191
7140 WHT
2650 BLK

B C161B
HVAC PASS THROUGH CONNECTION OPEN 6
1191 RED 1191 RED 1192 RED
A A 5
2741 BLK 2742 BLK
P5 B B 4
7400 WHT SP2
A A GROUND SPLICE OPEN 3
MACHINE HARNESS CONNECTOR OPEN
7410 WHT 2
B B
OPEN 1

P3
SP2
LATCHING RELAY
2670 BLK
B
7150 WHT
A

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7190 WHT
E
7220 WHT 7234121 HARNESS DELUXE
D
7140 WHT

C614
DISPLAY CONNECTOR MACHINE HARNESS
7410

2660 BLK
WHT

12 12

11 11
SP1 C620
MOTION ALARM DISABLE SW
7160 WHT 10 10
2
7210 WHT
SP3 4 9 9

2660 BLK 8 8
6
C613
7220 WHT
1 DELUXE DISPLAY
7200 WHT

7 7
CONNECTOR
7170 WHT

6 6 6 6
2680 BLK

P4 P4 RELAY P4
1355 RNG
5 5 5 5
86 85 9640 PUR
4 4 4 4
87 ALARM 9540 PUR/WHT
30 7180 WHT
TM2 3 3 2 2
87A
2355 BLK
2 2 3 3
2690 BLK TM1
1195 RED
1 1 1 1

7306988 HARNESS MOTION ALARM

Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 14 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863
CHG NOTICE DWN
GLM
SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
Printable
SHT 14 / 17
7221961
Version Click Here
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Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 15 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
Printable
SHT 15 / 17
7221961
Version Click Here
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Wiring Schematic E85 S/NWARNING
B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 16 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
SHT 16 / 17
7221961
Printable Version Click Here
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Wiring Schematic E85 S/NWARNING

B48411001 & Above PROPRIETARY NOTICE TOLERANCES: ECN 68863 Printed On October 2017
csf

THIS DOCUMENT CONTAINS CONFIDENTIAL AND TRADE SECRET INFORMATION,

THE EXPORT OR REEXPORT OF THIS DRAWING OR A IS THE PROPERTY OF BOBCAT COMPANY, AND IS GIVEN TO THE RECEIVER IN
WEST FARGO, NORTH DAKOTA, USA
7221961
PRODUCT PRODUCED BY THIS DRAWING IS SUBJECT CONFIDENCE. THE RECEIVER, BY RECEPTION AND RETENTION OF THE
TO U.S. EXPORT ADMINISTRATION REGULATIONS TITLE
AND OTHER APPLICABLE GOVERNMENTAL RESTRICTIONS DOCUEMENT, ACCEPTS THE DOCUMENTS IN CONFIDENCE AND AGREES THAT,
OR REGULATIONS. EXCEPT AS AUTHORIZED IN WRITING BY BOBCAT COMPANY, IT WILL (1) NOT
SCHEMATIC ELECTRIC
Sheet 17 of 17
USE THE DOCUMENT OR ANY COPY THEREOF OR THE CONFIDENTIAL OR TRADE UNLESS OTHERWISE SPECIFIED
COPYRIGHT C SECRET INFORMATION THEREIN; (2) NOT COPY THE DOCUMENT, (3) NOT
X ± 13 MAT
DISCLOSE TO OTHERS EITHER THE DOCUMENT OR THE CONFIDENTIAL OR DWG. NO.
0
REV
SEE SHEET 1
DESCRIPTION
68863 GLM
CHG NOTICE DWN SHEET
ORIGINALLY CREATED AND REVISED IN THE YEARS AS
IDENTIFIED IN THE RELEASING ECN. BOBCAT COMPANY
RESERVES ALL RIGHTS.
TRADE SECRET INFORMATION THEREIN; AND (4) UPON COMPLETION OF THE
NEED TO RETAIN THE DOCUMENT, OR UPON DEMAND, RETURN THE DOCUMENT,
ALL COPIES THEREOF, AND ALL MATERIALS COPIED THEREFROM.
Printable
SHT 17 / 17
7221961
Version Click Here
ELECTRICAL SYSTEM INFORMATION

Troubleshooting Chart
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. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.

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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.

50-10-1 E85 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
relays.

The location and sizes are shown in [Figure 50-10-2].

1 Always replace fuses using the same type and capacity.

P132034

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

50-10-2 E85 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Fuse And Relay Location / Identification (Cont’d)

Figure 50-10-2

F5 F1 F9
A C E G
F6 F2 F10

F7 F3 F11
B D F H

F8 F4 F12

The location and sizes 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
F1 Wiper / Washer 10 F9 Controller 25 A Switched Power R

F2 Switched Power 20 F10 ACD 25 B NOT USED R

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F3 Alternator Excite / 25 F11 Lights 20 C HVAC R
Heater

F4 ACD 25 F12 Power Port 15 D Lights R

F5 Controller 25 E Fuel Shutoff R

(ECU)

F6 HVAC 40 F Glow Plugs R

F7 Start Key 5 G NOT USED R

F8 Fuel Pull 15 H Starter R

50-10-3 E85 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Shut-Off Switch

Open the tailgate and the right side cover. (See

TAILGATE on Page 10-50-1.) and (See RIGHT SIDE
COVER on Page 10-60-1.)

Figure 50-10-3

P132052

The shut-off switch (Item 1) [Figure 50-10-3] (if

equipped) is located under the right side cover below the
fuse panel.
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Rotate the switch (Item 1) [Figure 50-10-3]

counterclockwise to turn the switch to the OFF position,
clockwise to turn to the ON position.

50-10-4 E85 Service Manual

BATTERY Figure 50-20-2

Servicing

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

Page 10-60-1.).

Figure 50-20-1

P9589 P9590

The battery cables must be clean and tight [Figure 50-

20-2]. Remove acid or corrosion from the battery and
cables using a sodium bicarbonate and water solution.
Cover the battery terminals and cable ends with battery
P131588 saver grease to prevent corrosion.

Check for broken or loose connections.

The battery (Item 1) [Figure 50-20-1] is located in the
front of the right side upperstructure. 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 (-)

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cable to the battery.

The original equipment battery is maintenance free. If a

replacement battery is installed, check the electrolyte
level in the battery.

If the electrolyte level is lower than 13 mm (0.50 in) above

the plates, add distilled water only.

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

50-20-1 E85 Service Manual

BATTERY (CONT’D) Start the engine. After the engine has started, remove
the ground (-) cable first (Item 2) [Figure 50-20-3].
Using A Booster Battery (Jump Starting)
Disconnect the cable from the excavator starter (Item 1)
[Figure 50-20-3].

IMPORTANT
If jump starting the excavator from a second IMPORTANT
machine:
Damage to the alternator can occur if:
When jump starting the excavator from a battery • Engine is operated with battery cables
installed in a second machine, make sure the engine disconnected.
is NOT running while using the glow plugs. High • Battery cables are connected when using a fast
voltage spikes from a running machine can burn out charger or when welding on the excavator.
the glow plugs. (Remove both cables from the battery.)
I-2060-0906 • Extra battery cables (booster cables) are
connected wrong.
If it is necessary to use a booster battery to start the I-2223-0903
engine, BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and
disconnect the battery cables.

Be sure the key switch is OFF. The booster battery must

be 12 volt.
WARNING
AVOID INJURY OR DEATH
Open the tailgate. (See TAILGATE on Page 10-50-1.)
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
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Figure 50-20-3
rubber gloves to keep acid off body.

In case of acid contact, wash immediately with water.

2 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

P132071

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 50-20-3] of the excavator starter.

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 starter mounting bolt (Item 2)
[Figure 50-20-3].

50-20-2 E85 Service Manual

BATTERY (CONT’D)

Removing And Installing The Battery

WARNING
Open the right side cover. (See RIGHT SIDE COVER on
Page 10-60-1.) AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
Remove the right side upperstructure cover. (See RIGHT contact. Wear goggles, protective clothing and
UPPERSTRUCTURE COVER on Page 40-70-1.) rubber gloves to keep acid off body.

Figure 50-20-4 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.
4 1
If electrolyte is taken internally drink large quantities
3
of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
2 W-2065-0807

P131588

Disconnect the negative (-) cable (Item 1) [Figure 50-20-

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4] first.

Disconnect the positive (+) cable (Item 2) [Figure 50-20-

4].

Remove the nuts (Item 3) and remove the hold-down

clamp (Item 4) [Figure 50-20-4].

Remove the battery.

Always clean the terminals and the cable ends, even

when installing a new battery.

Install the battery. Install the hold-down clamp and tighten

the nuts.

Connect the battery cables. Connect the negative (-)

cable (Item 1) [Figure 50-20-4] last to prevent sparks.

50-20-3 E85 Service Manual

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50-20-4
E85 Service Manual
ALTERNATOR

Belt Adjustment

The alternator / fan belt is a special maintenance free

type that is pretensioned over the pulleys. This belt
eliminates the need for a tensioning device and does not
require periodic adjustment.

Belt Replacement

Stop the engine and open the tailgate. (See TAILGATE

on Page 10-50-1.)

Figure 50-30-1

1
5

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3
P132072

Remove the three bolts (Item 1) securing the fan guard to

the radiator shroud and remove the fan guard (Item 2)

Loosen the lower alternator mounting nut (Item 3)

[Figure 50-30-1].

Remove the nut (Item 4) from the top alternator mounting

bolt (Item 5) [Figure 50-30-1].

Use a pry bar to take the pressure off of the bolt (Item 5)
[Figure 50-30-1] and remove the top bolt.

Remove and replace the alternator belt.

Use the pry bar to position the alternator and install the
bolt (Item 5) [Figure 50-30-1].

Install the nut (Item 4) and tighten the top bolt (Item 5)
and bottom alternator mounting nut (Item 3) [Figure 50-
30-1].

Close the tailgate.

50-30-1 E85 Service Manual

ALTERNATOR (CONT’D)

Charging System Inspection

WARNING
AVOID INJURY OR DEATH

IMPORTANT Batteries contain acid which burns eyes and skin on

contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
Damage to the alternator can occur if:
• Engine is operated with battery cables In case of acid contact, wash immediately with water.
disconnected. In case of eye contact get prompt medical attention
• Battery cables are connected when using a fast and wash eye with clean, cool water for at least 15
charger or when welding on the excavator. minutes.
(Remove both cables from the battery.)
• Extra battery cables (booster cables) are If electrolyte is taken internally drink large quantities
connected wrong. of water or milk! DO NOT induce vomiting. Get
I-2223-0903 prompt medical attention.
W-2065-0807

If the charging system malfunctions check the following:

Check the condition and tension of the engine accessory

drive belt. If belt is worn or deteriorated replace the belt.
(See Belt Replacement on Page 50-30-1.) WARNING
Inspect the alternator wiring harness and connectors at BATTERY GAS CAN EXPLODE AND CAUSE
alternator. Harness and connectors must be clean and SERIOUS INJURY OR DEATH
tight. Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
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Check the fuse for the alternator in the fuse panel. If the make final connection (negative) at machine frame.
fuse is burned, find the cause and repair / replace. If the
fuse is in doubt, remove and check the fuse for continuity. Do not jump start or charge a frozen or damaged
battery. Warm battery to 16°C (60°F) before
Check the electrolyte level in the battery. Add distilled connecting to a charger. Unplug charger before
water as needed. (Does not apply to maintenance free connecting or disconnecting cables to battery. Never
batteries.) lean over battery while boosting, testing or charging.
W-2066-0910
Verify the charge of the battery. Make sure battery is fully
charged.

Disconnect the battery cables (negative first, then

positive). Inspect the cable clamps and battery posts for
corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
prevent corrosion. Reconnect the cable to the positive
terminal.

50-30-2 E85 Service Manual

ALTERNATOR (CONT’D) Low Voltage Testing

Alternator Voltage Testing Figure 50-30-3

Open the tailgate. (See Opening And Closing on Page

10-50-1.)

Figure 50-30-2
1

P131762

Turn engine OFF and remove the L and S terminal

connector (Item 1) [Figure 50-30-3] from the alternator.
P133235
Turn the key to the ON position.

Start the engine and run at low idle. With a voltmeter, Figure 50-30-4
check the voltage between the B+ terminal and ground
[Figure 50-30-2].

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The voltage must be higher than 13.5 volts but lower than
14.7 volts at 21°C (70°F) (Alternator Temperature).

If the voltage is higher than 14.7 volts, proceed to the

high voltage test.

If the voltage is lower than 13.5 volts, run the engine at

high idle and recheck voltage. If voltage is still below 13.5
volts, proceed to the low voltage test.

P133236

Check the voltage across the “L” terminal (Item 1) [Figure

50-30-4]. The voltage should be what the battery voltage
is. If not, check the wire harness, relay, and fuses. If the
wire harness, relay, and fuses are okay, remove the
alternator for replacement or repair.

50-30-3 E85 Service Manual

ALTERNATOR (CONT’D) Figure 50-30-6

High Voltage Testing

Figure 50-30-5

P133238

Figure 50-30-7
P131762

Turn the engine OFF and remove the L and S Terminal

connector (Item 1) [Figure 50-30-5] from the alternator.

1
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P131765

Check the continuity between the “S” terminal (Item 1)

[Figure 50-30-6] and the positive (+) terminal on the
battery terminal (Item 1) [Figure 50-30-7]. There should
be continuity. If there is no continuity, replace the wire
harness.

NOTE: The upperstructure cover is removed for

photo clarity.

If the voltage is still above 14.7 volts at 21°C (70°F)

(alternator temperature), then remove the alternator for
replacement or repair.

50-30-4 E85 Service Manual

ALTERNATOR (CONT’D) Figure 50-30-10

Removal And Installation

Open the tailgate. (See Opening And Closing on Page

10-50-1.)

Disconnect the battery. (See Removing And Installing 1

The Battery on Page 50-20-3.)

Remove the belt. (See Belt Replacement on Page 50-30-

1.)

Figure 50-30-8

P131769

Remove the nut (Item 1) [Figure 50-30-10] and bolt.

1

P131762

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Disconnect the wire harness (Item 1) [Figure 50-30-8]
from the alternator.

Figure 50-30-9

P131766

Remove the nut (Item 1) [Figure 50-30-9] and wire.

50-30-5 E85 Service Manual

ALTERNATOR (CONT’D)

Removal And Installation (Cont’d)

Figure 50-30-11

1
3

P131770

Remove the bolt (Item 1) and ground wire (Item 2)

[Figure 50-30-11].

Remove the bolt (Item 3) [Figure 50-30-11] and remove

the alternator.
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50-30-6 E85 Service Manual

ALTERNATOR (CONT’D)

Parts Identification

1. Nut
2. Washer
3. Pulley 6
4. Spacer
5. Bolt 5
6. Case Half
7. Bearings
8. Retainer
9. Rotor 3
10. Stator
11. Case half
12. Sleeve
13. Regulator
14. Rectifier
1 4 5
15. Cover
16. Spacer 11 12

2
10 5

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9

15 1

14
13

16

C-3529

50-30-7 E85 Service Manual

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50-30-8
E85 Service Manual
STARTER Figure 50-40-2

Testing

Figure 50-40-1 Bat

S
M

Bat
S
M Cranking
Motor

Cranking
Motor
A-1991

Connect a jumper wire (of at least 4 gauge in size)

A-1992 between the M terminal and the BAT terminal [Figure 50-
40-2].

The key switch must be in the OFF position. If the starter turns, the defect is in the solenoid.

The battery must be at full charge. If the starter does not turn, the starter is defective.

The cable connections on the battery must be clean and

tight.

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Connect a jumper wire between S terminal and BAT
terminal [Figure 50-40-1].

If the starter turns but does not turn the engine, the
starter drive has a defect.

50-40-1 E85 Service Manual

STARTER (CONT’D) Figure 50-40-5

Removal And Installation

Disconnect the negative (-) cable from the battery. (See 1

Removing And Installing The Battery on Page 50-20-3.)

Figure 50-40-3

2
1
P133113

Remove the top bolt (Item 1) [Figure 50-40-5].

Remove the starter (Item 2) [Figure 50-40-5].

1
P133112

Disconnect the wires (Item 1) [Figure 50-40-3] from the

starter.

Figure 50-40-4
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P128240

Remove the bottom bolt (Item 1) and ground cable (Item

2) [Figure 50-40-4].

50-40-2 E85 Service Manual

STARTER (CONT’D)

Parts Identification

1. Screw
2. Bolt
3. Brush Cover
4. Brush Holder
5. Bearing
6. Armature 1
2
7. O-ring
8. Frame
4
9. Bolt
10. Cover
5
6 11. Gasket
12. Switch
3 13. Nut
5
7 14. Housing
15. Idler Gear
8 16. Roller
17. Retainer
7 18. Spring
19. Ball
20. Pinion Shaft

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10 9
11

13 12

13
18
15
13 19
17 16 20

14 18 21. Clutch
21 22. Washer
23. Bolt
24. Housing
24 25. Spring Seat
26. Pinion Gear
27. Collar
18 28. Snap Ring
26
7
28
22

25
7
27
23
D-2396

50-40-3 E85 Service Manual

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50-40-4
E85 Service Manual
LIGHTS Figure 50-50-3

Removal And Installation

Figure 50-50-1

P-22943

Remove the light bulb assembly (Item 1) [Figure 50-50-

P133114 3] from the lens.

Figure 50-50-4
To remove the upperstructure light, pivot the light (Item 1)
[Figure 50-50-1] back inside the frame.
1
Figure 50-50-2

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2

P133231

Disconnect the wire harness (Item 1) remove the nut

P133115 (Item 2) and remove the light (Item 3) [Figure 50-50-3].

Disconnect the wire harness (Item 1) [Figure 50-50-2].

50-50-1 E85 Service Manual

LIGHTS (CONT’D) Boom Light Bulb Replacement

Boom Light Removal And Installation Figure 50-50-7

NOTE: The procedure is shown on the left boom

light. The procedure is the same for the right 3
boom light.
1
Figure 50-50-5

2
P131758

Disconnect the wire harness (Item 1) [Figure 50-50-7].

Rotate light bulb assembly (Item 2) counterclockwise and

P131758 pull straight out from the boom light (Item 3) [Figure 50-
50-7].

Disconnect the wire harness (Item 1) [Figure 50-50-5]. Figure 50-50-8

Figure 50-50-6
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3
1
P131760

P131759
NOTE: Do not touch the halogen bulb with your
fingers or allow bulb to come in contact with
Remove the nut (Item 1) and bolt (Item 2). Remove the oils. If contaminated, the bulb should be
boom light (Item 3) [Figure 50-50-6] from the boom light cleaned with mild alcohol and a clean cloth
guard. [Figure 50-50-8].

50-50-2 E85 Service Manual

MAGNETIC LOCKOUT SENSOR Figure 50-60-3

Removal And Installation

Remove the lower console cover. (See Lower Console

Cover Removal And Installation on Page 40-50-1.)

Figure 50-60-1

1
2

P-92228

Remove the switch (Item 1) [Figure 50-60-3] from the

wire harness.
1
Figure 50-60-4
P-92226

Loosen the screws (Item 1) and remove the switch (Item

2) [Figure 50-60-1].

Figure 50-60-2

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1 2

P-92229

1
Loosen the screws (Item 1) and remove the magnet (Item
2) [Figure 50-60-4].

P-92227

Route the switch and wire harness (Item 1) [Figure 50-

60-2] out the back of the console.

50-60-1 E85 Service Manual

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50-60-2
E85 Service Manual
FUEL LEVEL SENDER Upper Fuel Level Sender Removal And Installation

Lower Fuel Level Sender Removal And Installation Figure 50-70-3

Remove the negative battery cable. (See Removing And

Installing The Battery on Page 50-20-3.)

Remove the floor mat and floor panel. (See Removal And
Installation on Page 40-100-1.)
1
Figure 50-70-1

P131261

Remove the left side cover. (See Opening And Closing

on Page 10-60-1.)

Disconnect the wire harness and remove the sending

unit (Item 1) [Figure 50-70-3].
P131242
Installation: Tighten the fuel level sender to 7 N•m (5 ft-
lb) torque.
Disconnect the harness connector (Item 1) [Figure 50-

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70-1] from the fuel sender.

Figure 50-70-2

P131243

Remove the fuel sender (Item 1) [Figure 50-70-2]. The

sender threads into the tank, use a wrench to remove the
sender.

Installation: Tighten the fuel level sender to 7 N•m (5 ft-

lb) torque.

50-70-1 E85 Service Manual

FUEL LEVEL SENDER (CONT’D) The resistance for the upper fuel level sender should
read as followed.:
Testing
FULL: 22 ohm
Use an ohmmeter to check the resistance of the fuel HALF: 92 ohm
sender. EMPTY: 242 ohm

Figure 50-70-4 Figure 50-70-6

1
1

P131244 P131245

Insert one of the ohm tester leads into each of the fuel Inspect the gasket (Item 1) [Figure 50-70-6] and replace
sender electrical connectors (Item 1) [Figure 50-70-4] in as needed.
the end of the fuel sender.
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Figure 50-70-5

P131246

With the fuel sender in the position shown [Figure 50-70-

5], read the ohm in the empty position. Slide the float
upwards and the ohm reading will decrease. See
resistance chart below.

The resistance for the upper fuel level sender should

read as follows:

FULL: 33 ohm
HALF: 91 ohm
EMPTY: 233 ohm

50-70-2 E85 Service Manual

DIAGNOSTIC SERVICE CODES Deluxe Instrument Panel

Viewing Service Codes The last 40 codes stored in history can also be viewed
using the Deluxe Instrument Panel.
The Service Codes will aid your dealer in diagnosing
conditions that can damage your machine.

Standard Instrument Panel

Press a scroll button (Item
Figure 50-80-1 1) repeatedly until the
Active Warnings screen
icon (Inset) is highlighted.

1 1
1
The ACTIVE WARNINGS
screen displays active
service codes. Press [9]
to view the next service
code if more than one is
present. Press [4] to
2 display a history of service
codes.
The WARNINGS
P-97989
HISTORY screen will list
the Service Code Number
Press the Information button (Item 2) to cycle the data (CODE), Hourmeter
display (Item 1) [Figure 50-80-1] until the service code reading when the error
screen is displayed. If more than one service code is occurred (HOUR), and the
User (USER) who was

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present, the codes will scroll on the data display.
logged in to operate the
When no service code is present, [NONE] is displayed machine when the error
[Figure 50-80-1]. occurred.
Press [9] to view the next eight service codes.
NOTE: Corroded or loose grounds can cause 
multiple service codes and / or abnormal A total of 40 codes can be stored. When more than 40
symptoms. All instrument panel lights codes occur, the oldest code will disappear and the
flashing, alarm sounding, headlights and newest code will be in the number 1 position.
taillights flashing, can indicate a bad ground.
The same symptoms can apply if the voltage
Press the list number next
is low, such as loose or corroded battery
to the service code for
cables. If you observe these symptoms, check
more detail.
grounds and positive leads first.

Press the left scroll button
to back up one screen.

50-80-1 E85 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List

CODE CODE

E00065131 Injector #1 Fault H0104 Boom Angle Sensor, No Communication

E00065231 Injector #2 Fault H0204 Arm Angle Sensor, No Communication
E00065331 Injector #3 Fault H0304 Bucket Angle Sensor, No Communication
E00065431 Injector #4 Fault H0405 Arm Sensor Supply, Short to Battery
E00122111 ECU Safety Monitoring Fault H0406 Arm Sensor Supply, Short to Ground
E00122119 ECU Safety Monitoring Fault
E00122126 ECU Safety Monitoring Fault
E00122127 ECU Safety Monitoring Fault M0116 Air Filter Not Connected
E00122128 ECU Safety Monitoring Fault M0117 Air Filter Not Connected
E00122129 ECU Safety Monitoring Fault
M0216 Hydraulic Filter Not Connected
H2521 Angle Blade Control Switch Out of Range High M0217 Hydraulic Filter Plugged
H2522 Angle Blade Control Switch Out of Range Low
H2524 Angle Blade Control Switch Out of NEUTRAL M0309 Battery Voltage Low
M0310 Battery Voltage High
H2605 Angle Blade Base Solenoid Short to Battery M0311 Battery Voltage Extremely High
H2606 Angle Blade base Solenoid Short to Ground M0314 Battery Voltage Extremely Low
H2607 Angle Blade Base Solenoid Open Circuit M0322 Battery Voltage Out of Range Low
H2632 Angle Blade Base Solenoid Overcurrent

H2705 Angle Blade Rod Solenoid Short to Battery M0610 Engine Speed High
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H2706 Angle Blade Rod Solenoid Short to Ground M0611 Engine Speed Extremely High
H2707 Angle Blade Rod Solenoid Open Circuit M0613 Engine Speed No Signal
H2732 Angle Blade Rod Solenoid Overcurrent M0615 Engine Speed Shutdown
M0618 Engine Speed Out of Range
H3128 Interrupted Power Failure M0634 Engine Speed Invalid Data from ECU

H4423 Secondary Controller Not Programmed

H4497 Secondary Controller Programmed M0710 Hydraulic Oil Temperature High
M0711 Hydraulic Oil Temperature Extremely High
H4621 5V Sensor Supply Out of Range High M0715 Hydraulic Oil Temperature Shutdown
H4622 5V Sensor Supply Out of Range Low M0721 Hydraulic Oil Temperature Out of Range High
M0722 Hydraulic Oil Temperature Out of Range Low

H7404 Main Controller No Communication M0810 Engine Coolant Temperature High

H7604 Display No Communication M0811 Engine Coolant Temperature Extremely High
M0815 Engine Coolant Temperature Shutdown

L0102 Lights Button Error On

L0202 High Flow Button Error On M0909 Fuel Level Low
L0302 Auxiliary Button Error On M0921 Fuel Level Out of Range High
L0402 Information Button Error On M0922 Fuel Level Out of Range Low

L7404 Gateway Controller No Communication M1121 Console Sensor Out of Range High
M1122 Console Sensor Out of Range Low
L7672 Display Panel programming Error M1128 Console Sensor Failure

50-80-2 E85 Service Manual

DIAGNOSTICS SERVICE CODE (CONT’D)

Service Codes List (Cont’d)

CODE CODE

M1705 Hydraulics Enable Solenoid Short to Battery M4721 8V Sensor Supply Out of Range High
M1706 Hydraulics Enable Solenoid Short to Ground M4722 8V Sensor Supply Out of Range Low
M1707 Hydraulics Enable Solenoid Open Circuit
M1732 Hydraulics Enable Solenoid Overcurrent M5002 Light Output Error On
M5003 Light Output Error Off
M2005 Two Speed Solenoid Short to Battery
M2006 Two Speed Solenoid Short to Ground M5205 Offset Base Solenoid Short to Battery
M2007 Two Speed Solenoid Open Circuit M5206 Offset Base Solenoid Short to Ground
M5207 Offset Base Solenoid Open Circuit
M5232 Offset Base Solenoid Overcurrent
M2202 Starter Output Error On
M2203 Starter Output Error Off
M2207 Starter Output Open Circuit M5305 Offset Rod Solenoid Error On
M2228 Starter Output Failure M5306 Offset Rod Solenoid Short to Ground
M5307 Offset Rod Solenoid Open Circuit
M5332 Offset Rod Solenoid Overcurrent
M2302 Starter Relay Error On
M2303 Starter Relay Error Off

M2521 Load Sense Sensor Out of Range High M5421 Offset Control Switch Out of Range High
M2522 Load Sense Sensor Out of Range Low M5422 Offset Control Switch Out of Range Low

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M5424 Offset Control Switch Out of NEUTRAL
M2721 Throttle Sensor Out of Range High
M2722 Throttle Sensor Out of Range Low M5505 Auxiliary Base Solenoid Short to Battery
M5506 Auxiliary Base Solenoid Short to Ground
M3128 Interrupted Power Failure M5507 Auxiliary Base Solenoid Open Circuit
M5532 Auxiliary Base Solenoid Overcurrent
M3304 Deluxe Panel No Communication
M5605 Auxiliary Rod Solenoid Short to Battery
M3404 RFID Key Controller No Communication M5606 Auxiliary Rod Solenoid Short to Ground
M5607 Auxiliary Rod Solenoid Open Circuit
M3702 Hyd Exchange Output Error On M5632 Auxiliary Rod Solenoid Overcurrent
M3703 Hyd Exchange Output Error Off
M5721 Auxiliary Control Switch Out of Range High
M4028 Wrong ECU Detected M5722 Auxiliary Control Switch Out of Range Low
M5724 Auxiliary Control Switch Out of NEUTRAL
M4109 Alternator Low
M4110 Alternator High M5810 Fuel Temperature High
M5811 Fuel Temperature Extremely High
M4304 Keyless Start Panel No Communication M5815 Fuel Temperature Shutdown

M4404 Secondary Controller No Communication M6204 Load Moment Sensor In Error

M4621 5V Sensor Supply Out of Range High

M4622 5V Sensor Supply Out of Range Low M6402 Switched Power Relay Error On
M6403 Switched Power Relay Error Off

50-80-3 E85 Service Manual

DIAGNOSTICS SERVICE CODE (CONT’D)

Service Codes List (Cont’d)

CODE CODE

M6505 ECU Power Short to Battery P0100 MAF sensor fault

M6506 ECU Power Short to Ground P0102 MAF sensor fault
M6507 ECU Power Open Circuit P0103 MAF sensor fault
P0105 Manifold pressure sensor fault
M6604 ECU No Communication P0107 Manifold pressure sensor fault
P0108 Manifold pressure sensor fault
M6702 HVAC Output Error On P0110 Intake manifold temperature sensor fault
M6703 HVAC Output Error Off P0111 Intake manifold temperature fault
P0112 Intake manifold temperature sensor fault
M7002 Switched Power Output Error On P0113 Intake manifold temperature sensor fault
M7003 Switched Power Output Error Off P0114 Intake manifold temperature sensor fault
M7007 Switched Power Output Open Circuit P0116 Engine coolant temperature fault
M7028 Switched Power Output Failure P0117 Water temperature sensor fault
P0118 Water temperature sensor fault
M7423 Main Controller Not Programmed
M7497 Main Controller Software Updated P0180 Fuel temperature sensor fault
P0181 Fuel temperature fault
M7748 Key Switch Multiple P0182 Fuel temperature sensor fault
P0183 Fuel temperature sensor fault
M7839 Hourmeter Changed
P0190 Rail pressure sensor fault
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P0191 Rail pressure fault

M8615 Engine Speed Derate Shutdown P0192 Rail pressure sensor fault
M8625 Engine Speed Derate Unresponsive P0193 Rail pressure sensor fault
P0195 Engine oil temperature sensor fault
P0196 Engine oil temperature fault
P00BC Intake air volume fault P0197 Engine oil temperature sensor fault
P00BD Intake air volume fault P0198 Engine oil temperature sensor fault

P0002 Rail pressure control fault P0200 Injector fault

P0003 Rail pressure control fault P0201 Injector #1 fault
P0004 Rail pressure control fault P0202 Injector #2 fault
P0006 Rail pressure control fault P0203 Injector #3 fault
P0007 Rail pressure control fault P0204 Injector #4 fault

P0016 Cam or crank sensor fault P0217 Engine temperature extremely high
P0219 Engine speed extremely high
P0070 Intake air temperature sensor fault
P0072 Intake air temperature sensor fault P0237 Engine oil pressure sensor fault
P0073 Intake air temperature sensor fault P0238 Engine oil pressure sensor fault
P0074 Intake air temperature sensor fault P0241 Boost control fault
P0242 Boost control fault
P0087 Rail pressure fault
P0088 Rail pressure control fault P0251 Rail pressure control fault
P0089 Rail pressure control fault P0252 Rail pressure control fault
P0093 Intake air temperature fault P0253 Rail pressure control fault

50-80-4 E85 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE CODE

P0258 Rail pressure control fault P0371 Crank position sensor fault
P0259 Rail pressure control fault P0372 Crank position sensor fault
P0374 Crank position sensor fault
P025A Inlet metering valve fault
P025B Inlet metering valve fault
P025C Inlet metering valve fault P037E Glow plug signal fault
P025D Inlet metering valve fault P037F Glow plug signal fault

P0261 Injector #1 fault

P0262 Injector #1 fault P0380 Glow plug relay / intake heater fault
P0264 Injector #2 fault P0383 Glow plug relay fault
P0265 Injector #2 fault P0384 Glow plug relay fault
P0267 Injector #3 fault
P0268 Injector #3 fault
P0401 EGR control fault
P0270 Injector #4 fault P0402 EGR control fault
P0271 Injector #4 fault P0403 EGR actuator fault
P0404 EGR position fault
P0405 EGR fault
P029A Injector #1 fault P0406 EGR actuator position fault
P029B Injector #1 fault P0407 EGR actuator position fault

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P029E Injector #2 fault P0409 EGR actuator position fault
P029F Injector #2 fault

P02A2 Injector #3 fault P046D EGR actuator position fault

P02A3 Injector #3 fault
P02A6 Injector #4 fault P0524 Engine oil pressure low
P02A7 Injector #4 fault
P0543 Exhaust gas temperature sensor fault
P02EE Injector #1 fault P0544 Exhaust gas temperature sensor fault
P02EF Injector #2 fault P0545 Turbo temperature sensor fault
P02F0 Injector #3 fault P0546 Turbo temperature sensor fault
P02F1 Injector #4 fault P0547 Exhaust gas temperature sensor fault
P0562 System voltage too low
P0325 Knock sensor error P0563 System voltage too high
P0330 Knock sensor error

P0335 Crank position sensor fault P0602 Injector data fault

P0339 Crank position sensor fault P0603 ECU fault
P0340 Cam signal fault P0604 ECU fault
P0341 Cam signal fault P0605 ECU fault
P0342 Cam signal fault P0606 ECU fault
P0344 Cam signal fault

50-80-5 E85 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE CODE

P060B ECU fault P160B ECU safety monitoring fault

P160C ECU safety monitoring fault
P0611 Injector fault
P1611 ECU safety monitoring fault
P061B ECU safety monitoring fault P1612 ECU safety monitoring fault

P0628 High pressure pump fault

P0629 High pressure pump fault P1620 ECU safety monitoring fault
P1621 ECU safety monitoring fault
P1622 ECU safety monitoring fault
P062D Injector #1 and #4 fault P1623 ECU safety monitoring fault
P062E Injector #2 and #3 fault P1624 ECU safety monitoring fault
P062F ECU fault P1625 ECU safety monitoring fault
P1626 ECU safety monitoring fault
P1627 ECU safety monitoring fault

P0641 Sensor supply voltage fault

P0651 Sensor supply voltage fault
P0652 Sensor supply voltage fault P162B ECU safety monitoring fault
P0653 Sensor supply voltage fault
P1630 ECU safety monitoring fault
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P0685 ECU main relay fault P1631 ECU safety monitoring fault
P0687 ECU main relay fault P1632 ECU safety monitoring fault
P1633 ECU safety monitoring fault
P068A ECU main relay fault P1634 ECU safety monitoring fault
P1635 ECU safety monitoring fault
P1636 ECU safety monitoring fault
P0697 Sensor supply voltage fault P1637 ECU safety monitoring fault
P1638 ECU safety monitoring fault

P0C17 EGR position learning fault P1660 ECU safety monitoring fault
P0C18 EGR position learning fault P1661 ECU safety monitoring fault
P1662 ECU safety monitoring fault
P1663 ECU safety monitoring fault
P1219 ECU safety monitoring fault
P1228 ECU safety monitoring fault
P1690 ECU safety monitoring fault
P1274 Fuel pump fault P1691 ECU safety monitoring fault
P1275 Fuel pump fault P1692 ECU safety monitoring fault

P1601 ECU safety monitoring fault P16D2 ECU safety monitoring fault
P1602 ECU safety monitoring fault P16D6 ECU safety monitoring fault
P1604 ECU safety monitoring fault P16D8 ECU safety monitoring fault
P1606 ECU safety monitoring fault
P1607 ECU safety monitoring fault P1990 ECU fault

50-80-6 E85 Service Manual

DIAGNOSTIC SERVICE CODES (CONT'D)

Service Codes List (Cont’d)

CODE CODE
P3002 Exhaust temperature extremely high
P2080 Turbo temperature fault P3003 Exhaust temperature extremely high
P2081 Turbo temperature sensor fault P3004 Exhaust temperature extremely high

P2108 Intake throttle fault P3006 Particulate matter warning

P3007 Particulate matter too high
P2131 Throttle position sensor fault P3008 Particulate matter extremely high

P2143 EGR motor fault P3011 Boost pressure fault

P2144 EGR motor fault
P2145 EGR motor fault P3018 Exhaust temperature sensor fault

P2146 Injector #1 and #4 fault P3019 Pump calibration error

P2147 Injector #1 and #4 fault
P2148 Injector #1 and #4 fault P3023 Exhaust gas temperature sensor fault
P2149 Injector #2 and #3 fault
P2150 Injector #2 and #3 fault P3025 Water temperature sensor fault
P2151 Injector #2 and #3 fault

R7404 No Communication To Main Controller

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P2226 Barometric pressure fault U0075 EGR communication error
P2228 Barometric pressure fault U0076 EGR fault
P2229 Barometric pressure fault
U0077 ECU communication fault

P2264 Water in fuel sensor fault U0081 EGR communication error

P2266 Water in fuel sensor fault U0082 ECU communication fault
P2267 Water in fuel sensor fault U0083 ECU communication fault
P2269 Water in fuel detected U0084 ECU communication fault
U0085 ECU communication fault
U0086 ECU communication fault
P2413 EGR actuator fault U0087 ECU communication fault
P2414 EGR motor fault U0089 ECU communication fault

P2428 Exhaust over temperature fault

U0100 ECU communication error

P242C EGR temperature sensor fault U0140 Throttle position sensor fault
P242D EGR temperature sensor fault

P2621 Intake throttle lift sensor fault

P2622 Intake throttle lift sensor fault

P2BC4 Unknown SCR fault

50-80-7 E85 Service Manual

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50-80-8
E85 Service Manual
CONTROL PANEL SETUP Vitals

Panel Setup (Deluxe Instrument Panel)

Icon Identification Press a scroll button (Item

1) repeatedly until the
Figure 50-90-1 Vitals screen icon (Inset)
is highlighted.
1 1

Displays select system

operating levels.

You can monitor real-time displays of:


Engine Speed (RPM)
P-97990
Engine Coolant Temperature
System Voltage
ICON DESCRIPTION Hydraulic Fluid Temperature

DATE / TIME The Deluxe Instrument Panel is easy to use. Continue to

set your own preferences for operating / monitoring your
USER / USER HOURS Bobcat excavator.

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MACHINE HOURS (HOURMETER)

ACTIVE WARNINGS screen icon

VITALS screen icon

SERVICE screen icon

AUTO IDLE Status icon

ATTACHMENTS screen icon

MACHINE SETTINGS screen icon

DISPLAY screen icon

HOME icon (Return to MAIN screen)

LEFT SCROLL button


RIGHT SCROLL button

ENTER button

50-90-1 E85 Service Manual

CONTROL PANEL SETUP (CONT’D)

Panel Setup (Deluxe Instrument Panel) (Cont’d)

Date And Time Languages

Press a scroll button (Item Press a scroll button (Item

1) repeatedly until the 1) repeatedly until the
Display screen icon (Inset) Display screen icon (Inset)
is highlighted. is highlighted.

1 1 1 1

Select [1. CLOCKS]. Select [2. LANGUAGES].

Select [1. TIME].

Select the desired

language.
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Use the keypad to enter

English / Metric Display
time.

Select AM / PM / 24hr.

Press [ENTER] to Press a scroll button (Item
continue. 1) repeatedly until the
Display screen icon (Inset)
Select [2. DATE]. is highlighted.

1 1

Select [4. DISPLAY

SETTINGS].

Press [1] to cycle between

ENGLISH and METRIC.
Use the keypad to enter
date.

Press [ENTER] to
continue.

50-90-2 E85 Service Manual

CONTROL PANEL SETUP (CONT’D) Job Clock Reset

Panel Setup (Deluxe Instrument Panel) (Cont’d)

Auto Idle Time Delay

Press a scroll button (Item
1) repeatedly until the
Security screen icon
(Inset) is highlighted.
Press a scroll button (Item
1) repeatedly until the 1 1
Security screen icon
(Inset) is highlighted. Select [1. PASSWORDS /
LOCKOUTS].
1 1

Select [3. MACHINE

PERFORMANCE].

Enter owner password

and press [ENTER].

Select [1. AUTO IDLE

DELAY TIME].

Select [1. USER

SETTINGS].

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Use the keypad to enter
the desired delay time
between 4 and 250
seconds.

Press [ENTER] to save
and continue. Press left
Select user.
scroll button to exit without
saving.

Press [9] to reset job

statistics.

Press left scroll button or
[0] to exit without saving.

50-90-3 E85 Service Manual

CONTROL PANEL SETUP (CONT’D)

Panel Setup (Deluxe Instrument Panel) (Cont’d)

Alarm Clock Reset ECO MODE

Press a scroll button (Item Press a scroll button (Item

1) repeatedly until the 1) repeatedly until the
Display screen icon (Inset) Security screen icon
is highlighted. (Inset) is highlighted.

1 1 1 1

Select [3. ALARM Select [3. MACHINE

CLOCK]. PERFORMANCE].

Select [1. OFF ONCE], Select [2. ECO MODE].

Select [2. ON Daily] or
Select [3. ON WEEKLY]. 
ECO Mode will set the
maximum engine rpm to
be at 85% of the high idle
setting.
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
Select [1. OFF / ON], Example: If the machine
Select [2. TIME] or maximum engine speed is
Select [3. DAILY]. 2450 rpm, when ECO
Mode is enabled, the
maximum engine speed
will be approximately 2080
rpm.

Use key pad numbers to

set time.
Select [7. AM],
Select [8. PM] or
Select [9. 24 hr clock].


Select [ENTER] to save.
Press left scroll to back
space numbers.
Press [4] to set alarm to
sleep. (When pressed,
display will return to main
screen.)

Press [9] to shut off alarm.
Alarm will still be active for
the next day alarm setting.
(When pressed, display
will return to main screen.)

50-90-4 E85 Service Manual

CONTROL PANEL SETUP (CONT’D) Machine History - User Job Statistics

Panel Setup (Deluxe Instrument Panel) (Cont’d)

Machine History - Log In Information

Press a scroll button (Item
1) repeatedly until the
Security screen icon
(Inset) is highlighted.
Press a scroll button (Item
1) repeatedly until the 1 1
Security screen icon
(Inset) is highlighted.
MACHINE SETTINGS is
1 1 visible on screen.

Select [2. MACHINE

MACHINE SETTINGS is HISTORY].
visible on screen.

Select [2. MACHINE Select [2. USER JOB

HISTORY]. STATISTICS].

Select [1. LOG-IN

INFORMATION].

View Job Statistics (Job

Hours / Idle Time.

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Information can be viewed
View User Log hours and and reset back to zero.
last time / dated used.

Individual information can

be viewed and reset back
to zero.


Select user [KEY PAD 1 -

9] to access individual
user.

50-90-5 E85 Service Manual

CONTROL PANEL SETUP (CONT’D) Attachments

Panel Setup (Deluxe Instrument Panel) (Cont’d)

Machine History - Overall Job Statistics

Press a scroll button (Item
1) repeatedly until the
Attachment screen icon
(Inset) is highlighted.
Press a scroll button (Item
1) repeatedly until the 1 1
Security screen icon
(Inset) is highlighted.

1 1 ATTACHMENTS is visible
on screen.

MACHINE SETTINGS is Press [ENTER].

visible on screen.

Select [2. MACHINE Press [4] or [9] repeatedly

HISTORY]. until the desired
Attachment is visible in
the display screen.
Select [3. OVERALL JOB
STATISTICS].

Information about the

attachment,
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recommended auxiliary
hydraulic flow and tips
about attachment
operation will be
displayed.

50-90-6 E85 Service Manual

CONTROL PANEL SETUP (CONT’D) Password Lockout Feature

Password Setup (Keyless Start Panel) This feature allows the owner to unlock the password
feature so that a password does not need to be used
Password Description every time the engine is started.

Master Password: Turn the start switch (Item 1) [Figure 50-90-3] to the ON
position to turn on the excavators electrical system.
A permanent, randomly selected password set at the
factory that cannot be changed. This password is Enter the five digit owner password using the number
used for service by the Bobcat dealer if the owner keys (1 through 0).
password is not known or to change the owner
Figure 50-90-3
password.

Owner Password:

Allows for full use of the excavator. Must be used to

change the owner password.

Changing The Owner Password

1
Turn the start switch (Item 1) [Figure 50-90-2] to the ON
position to turn on the excavators electrical system.
3
Enter the five digit owner password using the number
2
keys (1 through 0) if locked.

Figure 50-90-2 P113012

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Press the unlock key (Item 2) [Figure 50-90-3].

The left panel display screen will show [CODE].

Enter the five digit owner password using the number

keys (1 through 0). The unlock key green light will flash,
then become solid.
1
The excavator can now be started without using a
password.
2
3 NOTE: Use the following procedure to reset the
machine lock so that the excavator requires a
password to start the engine.
P113012
Turn the start switch to the ON position to turn on the
excavators electrical system.
Press and hold the lock (Item 2) and unlock (Item 3)
[Figure 50-90-2] keys for 2 seconds.
Press the lock key (Item 3) [Figure 50-90-3].
The lock key red light will flash and the instrument panel
The lock key red light will flash and the left panel display
display screen will show [ENTER].
screen will show [CODE].
Enter a new five digit owner password using the number
Enter the five digit owner password using the number
keys (1 through 0). An asterisk will show in the left panel
keys (1 through 0). The unlock key green light will flash,
display screen for each key press. then the lock key red light will become solid.

The instrument panel display screen will show [AGAIN]. You must now enter the password every time to start the
excavator.
Enter the new five digit owner password again.

The lock key red light will become solid.

50-90-7 E85 Service Manual

CONTROL PANEL SETUP (CONT’D) Changing The Owner Password

Password Setup (Deluxe Instrument Panel)

Password Setup is available on machines with a Deluxe Press a scroll button (Item
Instrument Panel. 1) repeatedly until the
Security screen icon
Password Description (Inset) is highlighted.
1 1
All new machines with a Deluxe Instrument Panel arrive
at Bobcat dealerships with the keypad in locked mode. Select [1. PASSWORDS /
Locked mode means that a password must be used to LOCKOUTS].
start the engine.

For security purposes, your dealer may change the

password and set the keypad in the locked mode. Your
dealer will provide you with the password.
Enter owner password
Master Password:
and press [ENTER].
A permanent, randomly selected password set at the
factory that cannot be changed. This password is
used for service by the Bobcat dealer if the owner
password is not known or to change the owner
password.
Select [1. USER
Owner Password: SETTINGS].

Allows for full use of the excavator and to set up the

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Deluxe Instrument Panel. There is only one owner

password. The owner password must be used to
change the owner or user passwords. Owner should
change the password as soon as possible for security Select [1. OWNER].
of the excavator.

User Password:

Allows starting and operating the excavator; cannot

change password or any of the other setup features.

Select [2. CHANGE

PASSWORD].

Enter new owner

password and press
[ENTER].

You will be prompted to
reenter the new owner
password.

50-90-8 E85 Service Manual

CONTROL PANEL SETUP (CONT’D) Password Lockout Feature
Password Setup (Deluxe Instrument Panel) (Cont’d)
This feature allows the owner to unlock the password
Changing The User Passwords feature so that a password does not need to be used
every time the engine is started.

Press a scroll button (Item

1) repeatedly until the Press a scroll button (Item
Security screen icon 1) repeatedly until the
(Inset) is highlighted. Security screen icon
1 1 (Inset) is highlighted.
1 1
Select [1. PASSWORDS /
LOCKOUTS]. Select [1. PASSWORDS /
LOCKOUTS].

Enter owner password

and press [ENTER]. Enter owner password
and press [ENTER].

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Select [1. USER
SETTINGS].
Select [2. MACHINE
LOCK].

NOTE: The procedure above can be followed to reset

Select user. the machine lock so that the machine requires
a password to start the engine.

NOTE: When the password is in UNLOCKED, no

Select [2. CHANGE password is needed. The start switch is used
PASSWORD]. to start the machine.

Enter new user password

and press [ENTER].

50-90-9 E85 Service Manual

CONTROL PANEL SETUP (CONT’D) Setup

Maintenance Clock See your Bobcat dealer about installation of this feature.

Description Reset

The Maintenance Clock alerts the operator when the next Figure 50-90-5
service interval is due. EXAMPLE: The maintenance
clock can be set to a 500 hour interval as a reminder for 1
the next 500 hour planned maintenance.

Standard Instrument Panel

Figure 50-90-4
2
2
1

P113049

3 Press the Information button (Item 2) [Figure 50-90-5]

NA3086 until the display screen shows the maintenance clock.

Press and hold the Information button (Item 2) for 7

During machine operation, a 2 beep alarm will sound
seconds until [RESET] (Item 1) [Figure 50-90-5]
when there are less than 10 hours until the next planned
appears in the display screen.
maintenance.

The remaining hours before maintenance is required

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(Item 1) will appear in the data display for 5 seconds

while the service icon (Item 3) and the hourmeter icon
(Item 2) [Figure 50-90-4] flash.

NOTE: The display will show negative numbers after

counting down to zero.

The display will revert to the previous display and will

appear for 5 seconds every time the machine is started
until the maintenance clock is reset.

50-90-10 E85 Service Manual

CONTROL PANEL SETUP (CONT’D) Figure 50-90-7

MAINTENANCE CLOCK (Cont’d)

Deluxe Instrument Panel

Figure 50-90-6

1
P113047

The Deluxe Instrument Panel (if equipped) will display a

bar (Item 1) [Figure 50-90-7] showing the time remaining
until next service. This bar will turn red when service is
P113048
past due. NEXT MAINTENANCE DUE will change to
MAINTENANCE PAST DUE and display the number of
hours past due.
The Deluxe Instrument Panel (if equipped) will display a
message (Item 1) [Figure 50-90-6] alerting the operator Keys [4] and [9] can be used to adjust the service
to service the machine. interval when the owner is logged in [Figure 50-90-7].

This message will remain for 10 seconds and will appear To reset the service clock after servicing the machine,

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for 10 seconds every time the machine is started until the press and hold key [1] [Figure 50-90-7] (when the owner
maintenance clock is reset. is logged in) until the bar graph resets to 0.

50-90-11 E85 Service Manual

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50-90-12
E85 Service Manual
INSTRUMENT PANEL Figure 50-100-3

Removal And Installation

Figure 50-100-1
1

P112810

Pull up on the instrument panel (Item 1) [Figure 50-100-

P112808 3].

Figure 50-100-4
Pull up on the center pin (Item 1) [Figure 50-100-1].

Figure 50-100-2
1

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2

P112812

P112809 Installation: Install the tabs (Item 1) into the cover (Item
2) [Figure 50-100-4].

Remove the pin assembly (Item 1) [Figure 50-100-2].

50-100-1 E85 Service Manual

INSTRUMENT PANEL (CONT’D)

Removal And Installation (Cont’d)

Figure 50-100-5

P112811

Disconnect the wire harness from the instrument panel

[Figure 50-100-5].

Figure 50-100-6

1
1
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1 1 P112860

Remove the screws (Item 1) [Figure 50-100-6] and

remove the instrument panel.

50-100-2 E85 Service Manual

CONTROLLER (GATEWAY AND AUXILIARY) Figure 50-110-2

Description
1
The Gateway controller is the main controller. It provides
information to all other controllers.

The Gateway and Auxiliary controllers are located under

the center cover.

Gateway Controller Removal And Installation

1
Remove the center cover (See Removal And Installation
on Page 40-220-1.)

Remove the Auxiliary controller. (See Auxiliary Controller P131930

Removal And Installation on Page 50-110-2.)

Figure 50-110-1 Disconnect the wire harness (Item 1) [Figure 50-110-2].

NOTE: The wire harness connectors are keyed and

will only plug in one way.

2 Figure 50-110-3

1
1

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P131928

Remove the cable tie straps (Item 1). Reposition the wire 1
harness (Item 2) [Figure 50-110-1].
P131929

Remove the screws (Item 1) [Figure 50-110-3] and

remove the gateway controller.

Installation: Tighten the screws to 7,9 N•m (5.8 ft-lb)

torque.

50-110-1 E85 Service Manual

CONTROLLER (GATEWAY AND AUXILIARY)
(CONT’D)

Auxiliary Controller Removal And Installation

Remove the center cover (See Removal And Installation

on Page 40-220-1.)

Figure 50-110-4

P131873

Disconnect the wire harness (Item 1). Remove the

screws (Item 2) [Figure 50-110-4] and remove the
auxiliary controller from the excavator.
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Installation: Tighten the screws to 7,9 N•m (5.8 ft-lb)

torque.

NOTE: The wire harness connectors are keyed and

will only plug in one way.

50-110-2 E85 Service Manual

CONTROLLER (PIN GRABBER)

Removal And Installation

Remove the center cover. (See Removal And Installation

on Page 40-220-1.)

Figure 50-111-1

1
P131793

Disconnect the wire harness (Item 1) [Figure 50-111-1].

Figure 50-111-2

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1

P131794

Remove the bolts (Item 1) [Figure 50-111-2] and remove

the controller.

Installation: Tighten the bolts to 17 - 19 N•m (12 - 14 ft-

lb) torque.

50-111-1 E85 Service Manual

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50-111-2
E85 Service Manual
ENGINE CONTROL UNIT (ECU) Figure 50-120-1

Description

The engine ECU controls the amount, timing, mixture

and pressure of fuel that is injected. The engine ECU
operates each kind of control based on the signals from
each type of sensor.

The actuator for controlling the amount, timing and

mixture of fuel injection is the injector, while the actuator
for controlling fuel pressure is the supply pump. 1
The amount of fuel to be injected is determined using a
basic injection amount, which is calculated based on the
state of the engine and driving conditions, with P131792
corrections added for parameters such as water
temperature, fuel temperature, intake pressure, etc.
The ECU (Item 1) [Figure 50-120-1] is located under the
The ECU controls the timing for starting to energize the right side center cover.
injectors, first determining the timing for the main
injection and then the of other injections, such as pilot
injections.

By conducting a pilot injection, the initial fuel mixture is

kept to a minimum, mitigating the explosive initial
IMPORTANT
combustion and reducing NOx and noise. Avoid damage to the Engine Control Unit (ECU).
Water entering ECU atmospheric pressure sensor
The ECU calculates the set fuel injection pressure based will damage the ECU. Do not use high water pressure

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on the engine load (last injection amount and engine around the ECU when cleaning the engine
RPM) and controls the amount the supply pump supplies compartment.
and the fuel pressure inside the rail. I-2357-0512

50-120-1 E85 Service Manual

ENGINE CONTROL UNIT (ECU) (CONT’D) Figure 50-120-4

Cleaning

NOTE: The ECU connectors must to be free of all dirt

and debris before removing connectors. The
ECU is removed for photo quality.
1
Figure 50-120-2

P114460

Remove any residual dirt and debris from the connector

and slide area with a small brush (Item 1) [Figure 50-
120-4].

2 Repeat all steps until there is no visible evidence of dirt,

P114458 grit or other debris.

NOTE: Inspect the connector and repeat cleaning

Use a spray bottle (Item 1) to apply water around the process if debris remains on the connector
connectors (Item 2) [Figure 50-120-2] to remove dirt and and ECU.
debris.
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Figure 50-120-5
NOTE: Do not apply water when any connector is
removed.

Figure 50-120-3 2
3

1
1

P114461

Inspect the connector (Item 1) [Figure 50-120-5] for

2 P114459 damage and debris.

NOTE: To avoid getting debris in the terminal

Use air pressure to remove loose particles from the ECU openings, clean the connector facing the
head (Item 1) and the connectors (Item 2) [Figure 50- ground.
120-3].
Using a clean damp cloth or paper towel, not dripping
The connectors should be dry before disconnecting. wet, brush off the heavy deposits on the housing (Item 2)
but do not wipe on the terminal openings (Item 3) [Figure
50-120-5].

50-120-2 E85 Service Manual

ENGINE CONTROL UNIT (ECU) (CONT’D) Figure 50-120-7

Removal And Installation

IMPORTANT
Avoid damaging the Engine Control Unit (ECU) and
electrical connectors. Use care when removing or
installing the ECU connectors.
I-2356-0512 1

Clean the connectors before disconnecting the wire

harness. (See Cleaning on Page 50-120-2.) P131791

Figure 50-120-6
Figure 50-120-8

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1

P114356
P131792

Push the lock tab (Item 1) [Figure 50-120-6] in to release

the lock lever. Remove the four screws (Item 1) [Figure 50-120-7]
[Figure 50-120-8].

Installation: Tighten the screws to 7,9 N•m (5.8 ft-lb)

torque.

Lower the ECU to gain access to the wire harness

connectors.

50-120-3 E85 Service Manual

ENGINE CONTROL UNIT (ECU) (CONT’D)

Removal And Installation (Cont’d)

Figure 50-120-9

1
1

P131926

Lift the levers (Item 1) [Figure 50-120-9] until fully open.

NOTE: If resistance is encountered when opening the

lever, lock connector and repeat the cleaning
process.

Figure 50-120-10
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1 1

P131927

Pull the connectors (Item 1) [Figure 50-120-10] straight

out to avoid damage.

NOTE: Removing or installing the connector at an

extreme angle will result in seal “scooping”,
creating an environment for fluid ingress.
Damage to the header or connector may
result if undue force is used.

50-120-4 E85 Service Manual

KEY SWITCH

Removal And Installation

Remove the console cover. (See Console Cover

Removal And Installation on Page 40-40-1.)

Figure 50-130-1

P-93850

Disconnect the wire harness (Item 1) [Figure 50-130-1]

from the switch. Remove the switch.

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50-130-1 E85 Service Manual

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50-130-2
E85 Service Manual
WIPER MOTOR Figure 50-140-3

Removal And Installation

2
Figure 50-140-1

1
1

3
P131875

Remove the nuts (Item 1) and wiper arm (Item 2) [Figure

P131878 50-140-3].

Disconnect the washer hose (Item 3) [Figure 50-140-3].

Disconnect the wire harness (Item 1) [Figure 50-140-1].
Figure 50-140-4
Figure 50-140-2

1
1
2

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P131876
P131874

Remove the stud (Item 1) and rubber cover (Item 2)

Remove the cap (Item 1) [Figure 50-140-2]. [Figure 50-140-4].

50-140-1 E85 Service Manual

WIPER MOTOR (CONT’D) Figure 50-140-7

Removal And Installation (Cont’d)

Figure 50-140-5 1

1
1

P131880

Turn the wiper motor over and remove the screws (Item
P131877 1) and cover (Item 2) [Figure 50-140-7].

Figure 50-140-8
Remove the nut (Item 1) [Figure 50-140-5].

Figure 50-140-6

1
1
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1 2
P131881

P131879 Remove the shims (Item 1) [Figure 50-140-8].

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

2) [Figure 50-140-6].

50-140-2 E85 Service Manual

MOTION ALARM SYSTEM Figure 50-150-2

Description

This excavator may be equipped with a motion alarm 1

system. The motion alarm will sound when the operator
moves the travel control levers in either the forward or
reverse direction. Slight movement of the steering levers
in either the forward or reverse direction is required with
hydraulic components before the motion alarm will
sound.

Inspecting
P128646
Figure 50-150-1

Slightly move both travel control levers in the forward

1
direction (until the machine is slowly moving forward) and
then press the motion alarm cancel switch (Item 1)
[Figure 50-150-2]. The motion alarm will shut off. With
the machine still moving forward, move one of the levers
to the neutral position, the motion alarm must sound.

Slightly move both travel control levers in the reverse

direction (until the machine is slowly moving backward)
and then press the motion alarm cancel switch (Item 1)
[Figure 50-150-2] (the switch icon will be illuminated
when the motion alarm is deactivated). The motion alarm
P113019
will shut off. With the machine still moving backward,
move one of the levers to the neutral position, the motion

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Inspect for damaged or missing motion alarm decal (Item alarm must sound.
1) [Figure 50-150-1]. Replace if required.
Return both levers to neutral and turn excavator key to
NOTE: The excavator will need to be moved slightly OFF position. Exit the excavator.
in both the forward and reverse direction to
test the motion alarm. Keep all bystanders
away from machine during test.

WARNING
AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807

Sit in the operator’s seat and fasten the seat belt. Start
the engine.

Move the travel control levers (one lever at a time) in the

forward direction. The motion alarm must sound. Move
the travel control levers (one lever at a time) in the
reverse direction. The motion alarm must sound.

50-150-1 E85 Service Manual

MOTION ALARM SYSTEM (CONT’D) Adjusting Switch Position

Inspecting (Cont’d) Figure 50-150-4

The motion alarm is mounted to the bottom rear of the

excavator. (To the front of the engine oil pan.)

Figure 50-150-3

2
1
1

P132027

The motion alarm switch (Item 2) [Figure 50-150-4] is

P132009 located in the travel control valve located under the
floorplate. Remove the floor mat and the floorplate to
access the switch.
Inspect the motion alarm electrical connections and wire The switch (Item 2) [Figure 50-150-4] is non-adjustable.
harness (Item 1) [Figure 50-150-3], wire harness (Item It must be fully installed into the travel control valve
1) [Figure 50-150-4] and motion alarm switch (Item 2) housings and tightened. Tighten the switch to 18 - 20
[Figure 50-150-4] for tightness and damage. Repair or N•m (13 - 15 ft-lb).
replace any damaged components.
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Inspect the motion alarm system for proper function after

If the motion alarm switch requires adjustment, see the switch replacement.
following information.

WARNING
This machine is equipped with a motion alarm.
ALARM MUST SOUND!
when operating forward or backward.

Failure to maintain a clear view in the direction of

travel could result in serious injury or death.

The operator is responsible for the safe operation of

this machine.
W-2786-0309

50-150-2 E85 Service Manual

SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)

Connecting The Remote Start Tool The tools listed will be needed to do the following
procedure:
Tools that will be needed to complete the following steps
are: Order from Bobcat Parts P/N: 7217666 - Remote Start
Tool (Service Tool) Kit
MEL1563 or 7217666 - Remote Start Tool
MEL1566 - Service Tool Harness Communicator Kit Includes:
(Computer Interface) 7022042 - Remote Start Tool (Service Tool)
6689747 - Excavator Service Tool Harness
NOTE: Make all connections with the key in the OFF 6689746 - Computer Service Tool Harness
position. 6689745 - BOSS® Service Tool Harness

Figure 50-160-1 NOTE: Make all connections with the key in the OFF
position.

1 2
Figure 50-160-2

3
2

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P16119
3
1
P-76450
When the Service PC (Item 1) and the Remote Start Tool
(Item 2) [Figure 50-160-1], are connected to the
excavator, the Service PC is used to monitor, conduct When the Service PC (Item 1) and the Remote Start Tool
diagnostic and load software. (Service Tool) (Item 2) [Figure 50-160-2], are connected
to the excavator, the Service PC is used to monitor,
Connect the Service Tool Harness Communicator conduct diagnostics, and load software.
(MEL1566) (Item 3) [Figure 50-160-1] to the designated
serial port on the Service PC. Connect the Remote Start Tool (Service Tool) Computer
Service Tool Harness (Item 3) [Figure 50-160-2] to the
NOTE: The recommended serial cable length should designated serial port on the Service PC.
not exceed 4,6 m (15 ft). A serial cable longer
than 4,6 m (15 ft) will create a degraded signal NOTE: The recommended serial cable length should
causing communication errors. not exceed 4,6 m (15 ft). A serial cable longer
than 4,6 m (15 ft) will create a degraded signal
Connect the other end to the connector on the Remote causing communication errors.
Start Tool.
Connect the other end to the connector on the Remote
Connect the Remote Start Tool to the excavator. (See Start Tool (Service Tool).
Remote Start Tool - MEL1563 on Page 10-210-1.)
Connect the Remote Start Tool (Service Tool) to the
NOTE: Refer to BobcatDealerNET.com for PC excavator. (See Remote Start Tool - MEL1563 on Page
requirements and the latest Service Analyzer 10-210-1.)
software.
NOTE: Refer to BobcatDealerNET.com for PC
requirements and the latest Service Analyzer
software.

50-160-1 E85 Service Manual

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50-160-2
E85 Service Manual
SHUT-OFF SWITCH

Removal And Installation

Disconnect the negative (-) cable from the battery. (See

Removing And Installing The Battery on Page 50-20-3.)

Figure 50-170-1

2
1

P131661

Remove the nuts (Item 1) [Figure 50-170-1] and remove

the cables from the switch.

Remove the bolts (Item 2) [Figure 50-170-1] and nuts.

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Remove the switch.

50-170-1 E85 Service Manual

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50-170-2
E85 Service Manual
TRAVEL MOTOR AUTO-SHIFT

Auto-Shift Drive System (If Equipped)

When in high range, the travel motors will automatically

shift to low range when more torque is required and
return to high range when hydraulic pressure decreases.

NOTE: Always set the travel speed to low range when

loading or unloading the excavator onto a
transport vehicle.

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50-180-1 E85 Service Manual

TRAVEL MOTOR AUTO-SHIFT (CONT’D)

Troubleshooting

The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. All tests are performed with the engine running and left console lowered.

Failure Mode Symptom Causes Troubleshooting Controller

Response
No input from Travel motors will Failed switch. Inspect two-speed switch, connectors and wire No service code
two-speed not shift to high Wire harness harness. shown.
switch. range, two-speed disconnected.
icon does NOT Wire harness or
illuminate. connectors
damaged.
Short to ground.
Constant Travel motors will Failed switch. Inspect two-speed switch, connectors and wire No service code
voltage input not shift to high Short to battery. harness. shown.
from two- range, two-speed Inspect switch for short to battery.
speed switch. icon does NOT
illuminate.
Two-speed Travel motors will Failed solenoid Inspect two-speed solenoid, connectors, No service code
solenoid not shift to high valve or travel wiring, travel lever pressure switch, shown.
valve stuck in range. lever pressure connectors, wiring.
default (off) switch.
position. Wire harness Check for voltage on travel lever pressure Service code
disconnected. switch when operating one track to isolate detected for short
solenoid issue vs. travel lever pressure switch to ground only.
issue.
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Wire harness or If cause is short to ground, service code will be

connectors displayed on controller.
damaged.
Short to ground.
Two-speed Travel motors will Short to battery. If cause is short to battery, service code will be Service code
solenoid not manually shift displayed on controller. detected for short
valve stuck to low range. Failed solenoid. If no service code is displayed replace to battery only.
on. solenoid.
Travel lever Travel motors will Failed switch. If two-speed icon does illuminate when two- No service code
pressure not shift to high speed switch is depressed, inspect two-speed shown.
switch stuck range. solenoid, connectors, wiring, travel lever
open. pressure switch.
Wire harness Check for voltage on travel lever pressure
disconnected. switch when operating one track to isolate
Wire harness or solenoid issue vs. travel lever pressure switch
connectors issue.
damaged.
Short to ground.
Travel lever Travel motors will Failed switch. Test for pilot pressure when traveling in high No service code
pressure not shift to low Short to battery. range. There is no pilot pressure present when shown.
switch stuck range when travel in low range or neutral.
closed. levers are in
neutral position.

50-180-2 E85 Service Manual

TRAVEL MOTOR AUTO-SHIFT (CONT’D)

Troubleshooting (Cont’d)

Failure Mode Causes Symptom Troubleshooting Controller

Response
Load sense Failed sensor. Travel motors will Service code will be displayed. Service code
pressure Wire harness not auto-shift from detected, and
sensor not disconnected. high range to low software allows
working. Wire harness or range. travel motors to be
connectors manually upshifted
damaged. or downshifted with
Short to battery. the two-speed
Short to ground. switch.
Hydraulic oil Failed sensor. Auto shift feature Service code will be displayed. Service code
temperature Wire harness will not function detected.
sensor not disconnected. correctly.
working. Wire harness or
connectors
damaged.
Short to battery.
Short to ground.
Load sense Load sense Travel motors will Test and adjust the load sense relief valve as No service code
relief valve relief valve not auto-shift from outlined under pump testing. shown.
setting is low. setting is low. high range to low
range, because
machine reaches
load sense relief
pressure before

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reaching down shift
pressure setting.

50-180-3 E85 Service Manual

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50-180-4
E85 Service Manual
AUTO IDLE PRESSURE SENSOR

Description

The auto idle feature is controlled by the auto idle

pressure sensor located on the hydraulic control valve.
The pressure sensor reads load sense pressure. If the
load sense pressure drops below a certain pressure for
longer than 4 seconds, the engine RPM will drop down to
low idle. The engine will stay at low idle until the load
sense reaches the required pressure to increase the
engine RPM to the high speed setting.

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50-190-1 E85 Service Manual

AUTO IDLE PRESSURE SENSOR (CONT’D)

Removal And Installation

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

Page 10-60-1.)

Figure 50-190-1

P-98555

Disconnect the wire harness (Item 1) and remove the

sensor (Item 2) [Figure 50-190-1].

Installation: Tighten the sensor to 10 - 11 N•m (7.4 - 8.1

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ft-lb) torque.

50-190-2 E85 Service Manual

CONNECTED MACHINE Figure 50-200-3

Controller Removal And Installation

Remove the tool box. (See Removal And Installation on 1 2

Page 40-210-1.) 1

Turn the shut off switch to the OFF position. (See Shut-
Off Switch on Page 50-10-4.)

Figure 50-200-1

3 3 3
P131665

Mark and remove the wires (Item 1) and wire harness

(Item 2) [Figure 50-200-3].

1 Installation: Tighten the wires to 0,9 N•m (8 in-lb)

torque.

Remove the cable tie straps (Item 3) [Figure 50-200-3].

P131735
Figure 50-200-4

Disconnect the jumper harness (Item 1) [Figure 50-200-

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1].

Figure 50-200-2

1 P131667
1

Slide the mount towards the front of the excavator.

Remove the cable tie straps (Item 1) [Figure 50-200-4].
P131664
Remove the controller / bracket assembly from the
excavator.
Remove the nuts (Item 1) [Figure 50-200-2] from both
sides of the controller mount.

50-200-1 E85 Service Manual

CONNECTED MACHINE (CONT’D)

Controller Removal And Installation (Cont’d)

Figure 50-200-5

1 1

P131668

Remove the bolts and nuts (Item 1). Remove the

controller (Item 2) [Figure 50-200-5] from the bracket.
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50-200-2 E85 Service Manual

ENGINE SERVICE

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Sensor Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-12
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-14
Compression - Testing Using The Glow Plug Adapter . . . . . . . . . . . . . . . . . . . . . . 60-10-22
Compression - Testing Using The Injector Adapter . . . . . . . . . . . . . . . . . . . . . . . . 60-10-24
Injector Signal - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-26
Injector Signal - Testing (In-Line) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-28
Oil Pressure Testing (At Oil Sensor On Block) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-30
Oil Pressure Testing (At Turbocharger Oil Inlet) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-33

DIESEL OXIDATION CATALYST (DOC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

Oil Cooler / Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4

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Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-5
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-6
Testing The Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Oil Pump Relief Valve Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Oil Pump Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Oil Filter Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Oil Cooler Bypass Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-7
Oil Cooler Bypass Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-7

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Transfer Pump / High Pressure Pump Removal And Installation . . . . . . . . . . . . . . . 60-60-2
Fuel Temperature Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-5
Fuel Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-6
Fuel Recirculation Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-7
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-7
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-9

60-01 E85 Service Manual

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Glow Plugs Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-3
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-5
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-9
Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-10
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-11
Valve Step Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-12
Valve Stem Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-12
Valve Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-13
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-13
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-14
Rocker Arm Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-15
Rocker Arm Shaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-16
Push Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-16

CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Piston And Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2
Crankshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-4
Cylinder Block Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-7
Crankshaft Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-9
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-9
Engine Component Class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-10
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CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2

GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Gearcase Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Gear Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Idle Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-4
Idle Gear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-4

TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-4

FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1

Hydraulic Pump Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3

EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

60-02 E85 Service Manual

ENGINE INFORMATION

Description

Figure 60-10-1

P114390

The excavator has a Bobcat direct injected turbo charged

and intercooled diesel engine with a displacement of 2,4
L (146.5 in3). The engine is rated at an SAE J 1995 gross
49,2 kW (65.9 hp) @ 2100 rpm and has a closed
breather system [Figure 60-10-1].

The engine has 4 cylinders and the rotation is counter-

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clockwise (viewed from the flywheel side). It is equipped
with glow plugs for assisting in cold starts. Engine block
heaters are also available from Bobcat Parts.

To meet emission regulations it is equipped with an

Exhaust Gas Recirculation (EGR) system to reduce
Nitrogen Oxide (NOx).

The engine serial number is stamped on the engine and

is located near the high pressure fuel 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 in a radiator. Coolant flow is controlled by a
thermostat.

60-10-1 E85 Service Manual

ENGINE INFORMATION (CONT'D)

Specifications

Valve Springs
Free Length (Intake And Exhaust) 53,8 mm (2.12 in)
Tilt Allowable Limit (Intake And Exhaust) Below 1,8 mm (0.071 in)

Valve
Valve Clearance (Intake) 0,4 mm (0.016 in)
Valve Clearance (Exhaust) 0,45 mm (0.018 in)
Valve Stem OD (Intake) 6,97 ± 0,007 mm (0.274 ± 0.0003 in)
Valve Stem OD (Exhaust) 6,97 ± 0,007 mm (0.274 ± 0.0003 in)
Valve Face Width (Intake) 1,91 mm (0.075 in)
Valve Face Width (Exhaust) 1,89 mm (0.074 in)
Valve Face Angle 44.5° - 45°
Valve Guide Bore 7 - 7,015 mm (0.2756 - 0.2762 in)
Valve Guide Length 43,4 - 43,6 mm (1.7087 - 1.7165 in)

Valve Timing
Intake Valve (Open) 19° B.T.D.C.
(Close) 45° A.B.D.C.
Exhaust Valve (Open) 29° B.B.D.C.
(Close) 23° A.T.D.C.

Rocker Arms
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O.D. of Rocker Arm Shaft 16,0 mm (0.6299 in)

I.D. of Rocker Arm Bushings 16,05 mm (0.6319 in)

Camshaft
Journal O.D. 44,950 - 44,966 mm (1.7697 - 1.7703 in)
Bearing I.D. 45,0 - 45,025 mm (1.7717 - 1.3789 in)
Oil Clearance 0,034 - 0,075 mm (0.0013 - 0.003 in)
Camshaft End Play 0,1 - 0,2 mm (0.0039 - 0.0079 in)
Cam Lobe Height (Intake) 39,496 mm (1.555 in)
Cam Lobe Height (Exhaust) 38,555 mm (1.518in)
Side Clearance Allowable Limit 0,1 - 0,2 mm (0.0039 - 0.0080 in)

Cylinder Bore
Cylinder Bore I.D. 88,99 - 90,01 mm (3.5035 - 3.5437 in)

Piston Rings
Ring Gap (Top Ring) 0,20 - 0,30 mm (0.0080 - 0.0118 in)
Ring Gap (2nd Ring) 0,55 - 0,70 mm (0.0217 - 0.0276 in)
Ring Gap (Oil Ring) 0,20 - 0,40 mm (0.0080 - 0.0157 in)
Side Clearance of Ring Groove:
Top Ring 0,083 - 0,133 mm (0.0033 - 0.0052 in)
Second Ring 0,070 - 0,110 mm (0.0028 - 0.0043 in)
Oil Ring 0,030 - 0,070 mm (0.0118 - 0.0028 in)

Pistons
Piston Pin Bore 31,008 - 31,014 mm (1.2208- 1.2210 in)

60-10-2 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont’d)

Connecting Rod
Piston Pin O.D. 30,995 - 31,000 mm (1.2203 - 1.2205 in)
Small End Bushing I.D. 31,025 - 31,038 mm (1.2215 - 1.2220 in)
Oil Clearance Between Piston Pin And Small End Bushing 0,025 - 0,043 mm (0.0010- 0.0017 in)

Oil Pump
Oil Pressure Rated rpm 392 - 593 kPa (3,9 - 5,4 bar) (57 - 78 psi)
Idle Speed Allowable Limit 147 kPa (7,47 bar) (21 psi)

Crankshaft
Connecting Rod Large End Bore 57,0 - 57,015 mm (2.2440 - 2.2447 in)
Connecting Rod Oil Clearance (Large End Bore) 0,026 - 0,064 mm (0.0001 - 0.0025 in)
Connecting Rod End Play 0,15 - 0,30 mm (0.0059 - 0.0118 in)
Crankshaft Connecting Rod Journal 53,955 - 53,970 mm (2.1242 - 2.1248 in)
Oil Clearance Between Rod Journal and Bearing 0,029 - 0,059 mm (0.0011 - 0.0023 in)
Crankshaft End Play 0,10 - 0,31 mm (0.0039 - 0.0122 in)
I.D. of Cylinder Block Main Bearing Bore
Class A 62,000 - 62,007 mm (2.4409 - 2.4412 in)
Class B 62,007 - 62,014 mm (2.4412 - 2.4415 in)
Class C 62,014 - 62,021 mm (2.4415 - 2.4418 in)
OD of Crankshaft Main Journal
Class A 57,955 - 57,960 mm (2.2817 - 2.2819 in)

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Class B 57,960 - 57,965 mm (2.2819 - 2.2821 in)
Class C 57,965 - 57,970 mm (2.2821 - 2.2823 in)
Main Bearing Thickness
Blue 1,995 - 2,000 mm (0.0785 - 0.0787 in)
Yellow 2,000 - 2,005 mm (0.0787 - 0.0789 in)
Red 2,005 - 2,010 mm (0.0789 - 0.0791 in)

Timing Gear
Timing Gear Backlash:
Fuel Injection Pump Gear To Idle Gear 0,087 - 0,200 mm (0.0034 - 0.0080 in)
Idle Gear To Crankshaft Gear 0,087 - 0,200 mm (0.0034 - 0.0080 in)
Idle Gear To Camshaft Gear 0,087 - 0,200 mm (0.0034 - 0.0080 in)
Crankshaft Gear To Oil Pump Gear 0,060 - 0,259 mm (0.0024 - 0.0010 in)

Thermostat
Valve Opening Temperature 82°C (180°F)
Valve Fully Open 97°C (207°F)

60-10-3 E85 Service Manual

ENGINE INFORMATION (CONT'D)

Sensor Location

Figure 60-10-2

1
3

6
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P114390

1. Intake Manifold Pressure (MAP) (Boost) (Item 1)

[Figure 60-10-2]

2. Oil Pressure and Temperature (Item 2) [Figure 60-

10-2]

3. Fuel Rail Pressure (Item 3) [Figure 60-10-2]

4. Intake Manifold Temperature (Item 4) [Figure 60-10-

2]

5. Knock Sensors (2) (Item 5) [Figure 60-10-2]

6. Fuel Temperature (Item 6) [Figure 60-10-2]

7. Inlet Fuel Metering Valve (Item 7) [Figure 60-10-2]

60-10-4 E85 Service Manual

ENGINE INFORMATION (CONT'D)

Sensor Location (Cont’d)

Figure 60-10-3

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P114396

1. Coolant Temperature (Item 1) [Figure 60-10-3] Figure 60-10-4

2. CAM Position (Item 2) [Figure 60-10-3]

3. Crank Position (Item 3) [Figure 60-10-3] 6

4. Turbo Exhaust Gas Temperature (EGT) (Item 4)

[Figure 60-10-3]

5. EGR Valve Actuator (Item 5) [Figure 60-10-3]

6. Mass Air Flow and Temperature (MAF) (Item 6)

[Figure 60-10-4]

P114788

60-10-5 E85 Service Manual

ENGINE INFORMATION (CONT'D) Figure 60-10-7

Sensor Location (Cont’d)

Figure 60-10-5

1
1

P114261

Knock sensor (right side) (Item 1) [Figure 60-10-7].

P114787
Figure 60-10-8

Intake manifold pressure sensor (Item 1) [Figure 60-10-

5].

Figure 60-10-6
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1
1

P114194

Oil pressure and temperature sensor (Item 1) [Figure 60-

10-8].
P114262

Knock sensor (left side) (Item 1) [Figure 60-10-6].

60-10-6 E85 Service Manual

ENGINE INFORMATION (CONT'D) Figure 60-10-11

Sensor Location (Cont’d)

Figure 60-10-9

1
2

P114263

Fuel temperature sensor (Item 1) [Figure 60-10-11].

P114270
Inlet metering valve (Item 2) [Figure 60-10-11].

Fuel rail pressure sensor (Item 1) [Figure 60-10-9]. Figure 60-10-12

Figure 60-10-10

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1

P114379

P114260
Camshaft position sensor (Item 1) [Figure 60-10-12].

Intake manifold temperature sensor (Item 1) [Figure 60-

10-10].

60-10-7 E85 Service Manual

ENGINE INFORMATION (CONT'D) Figure 60-10-15

Sensor Location (Cont’d)

Figure 60-10-13

P114268

Turbo inlet temperature sensor (EGT) (Item 1) [Figure

P114265 60-10-15].

Figure 60-10-16
Crankshaft position sensor (Item 1) [Figure 60-10-13].

Figure 60-10-14

1 1
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P114266

P114264 EGR actuator (Item 1) [Figure 60-10-16].

Coolant temperature sensor (Item 1) [Figure 60-10-14].

60-10-8 E85 Service Manual

ENGINE INFORMATION (CONT'D) Figure 60-10-19

Sensor Location (Cont’d)

Figure 60-10-17

P114403

Atmospheric pressure sensor (Item 1) [Figure 60-10-19].

P114788

Mass air flow sensor (Item 1) [Figure 60-10-17].

Figure 60-10-18

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1

P131792

Engine control unit (ECU) (Item 1) [Figure 60-10-18].

60-10-9 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Torque Values

Thread Size
Strength Classification
(Dia. x Pitch)
8.8 10.9 12.9
M6 x 1,0 9,8 N•m 12,2 N•m 14,6 N•m
(7.2 ft-lb) (9 ft-lb) (10.8 ft-lb)
M8 x 1,25 21,7 N•m 33,4 N•m 37,3 N•m
(16 ft-lb) (22.4 ft-lb) (27.5 ft-lb)
M8 x 1,0 23,6 N•m 32,8 N•m 40,3 N•m
(17.4 ft-lb) (24.2 ft-lb) (29.7 ft-lb)
M10 x 1.5 43,1 N•m 60,7 N•m 72,5 N•m
(31.8 ft-lb) (44.8 ft-lb) (53.5 ft-lb)
M10 x 1,0 49,1 N•m 68,6 N•m 82,4 N•m
(36.2 ft-lb) (50.6 ft-lb) (60.8 ft-lb)
M12 x 1,75 73,5 N•m 103 N•m 122,6 N•m
(54.2 ft-lb) (76 ft-lb) (90.4 ft-lb)
M12 x 1,5 78,5 N•m 109,8 N•m 131,5 N•m
(57.9 ft-lb) (81 ft-lb) (97 ft-lb)
M14 x 1,5 127,4 N•m 181,7 N•m 215,6 N•m
(94 ft-lb) (134 ft-lb) (159 ft-lb)
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60-10-10 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Torque Values (Cont’d)

Thread Size Strength

Component Tightening Torque
(Diameter X Pitch) Class
54 N•m (40 ft-lb) initial torque
Main Bearing Cap Bolt M12x1.5x118 10.9 Plus 90° second torque
Plus 90° third torque
39 N•m (29 ft-lb) initial torque
Plus 90° second torque
Cylinder Head Bolt M11x1.25x130 10.9
Plus 90° third torque
Plus 90° fourth torque
19,6 N•m (14.5 ft-lb) initial torque
Connecting Rod Bolt M8x1.0x56 10.9
Plus 90° second torque
Crankshaft Pulley Bolt M14x1.5 10.9 245 - 265 N•m (181 - 195 ft-lb)
Cylinder Head Cover Bolt M6x1.0 8.8 7,4 N•m (5.4 ft-lb)
Injector Bracket Bolt M8x1.25 12.9 39 - 46 N•m (29 - 34 ft-lb)
Thermostat Bolt M8x1.25 8.8 19,6 - 23,7 N•m (14.5 - 17.5 ft-lb)
Pressure Sensor Adaptor Bolt M6x1.0 8.8 6,9 - 9,8 N•m (5.1 - 7.2 ft-lb)
Turbocharger Hollow Screw M10x1.0 17,7 - 19,6 N•m (13 - 14.5 ft-lb)
Glow Plug M8x1 8,8 - 11,8 N•m (6.5 - 8.7 ft-lb)
Glow Plug Terminal M4x0.7 2,5 - 2,9 N•m (1.8 - 2.2 ft-lb)
Turbocharger Nut M8x1.25 19,4 - 23,7 N•m (14.3 - 17.5 ft-lb)
Water Pump Nut and Bolt M8x1.25 19,4 - 23,7 N•m (14.3 - 17.5 ft-lb)

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Rocker Arm Adjust Nut M8x1.0 13,2 - 16,2 N•m (9.8 - 11.9 ft-lb)
High Pressure Pump Drive Gear Nut M14x1.5 49 - 68,6 N•m (43.4 - 50.6 ft-lb)
High Pressure Pump Nut M8x1.25 19,4 - 23,7 N•m (14.3 - 17.5 ft-lb)
Turbocharger Oil Delivery Pipe Nut Nut 17,7 - 21,6 N•m (13 - 15.9 ft-lb)
High Pressure Pipe Nut - High Pressure
Nut 27,5 - 31,4 N•m (20.3 - 23.1 ft-lb)
Pump
High Pressure Pipe Nut - Common Rail Nut 27,5 - 31,4 N•m (20.3 - 23.1 ft-lb)
High Pressure Pipe Nut - Injector Nut 27,5 - 31,4 N•m (20.3 - 23.1 ft-lb)
High Pressure Pump Fuel Hose Bracket Bolt M12x1.75 8.8 53,9 N•m (39.8 ft-lb)

60-10-11 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Troubleshooting

The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.

PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 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 warning. 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
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60-10-12 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Troubleshooting (Cont’d)

KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
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 crankcase.
6. Fuel tank empty. 33. Switch / sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking 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 flywheel alignment.
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. Faulty water pump.

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22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery

60-10-13 E85 Service Manual

ENGINE INFORMATION (CONT'D) Figure 60-10-21

Engine Removal And Installation

The following tools will be needed to do the following

procedure: 1
Figure 60-10-20

P114174

1 MEL1653-9 - Engine mounting bracket (Item 1) [Figure

60-10-21].

MEL1653-8 - Engine Lift Extension.

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P-76872

MEL1653-1 - Engine lifting bracket (Item 1) [Figure 60-

10-20].

60-10-14 E85 Service Manual

ENGINE INFORMATION (CONT’D) Remove the ECU harness (Item 2) by rotating the lock
lever (Item 3) [Figure 60-10-22] towards the rear of the
Engine Removal And Installation (Cont'd) machine.

Disconnect the negative (-) cable on the battery. (See For detailed information on ECU harness removal and
Removing And Installing The Battery on Page 50-20-3.) installation. (See Removal And Installation on Page 50-
120-3.)
Drain the hydraulic reservoir. (See Removing And
Replacing The Hydraulic Fluid on Page 10-130-3.) Disconnect the harness connector (Item 4) [Figure 60-
10-22].
Drain the radiator. (See Removing And Replacing
Coolant on Page 10-100-3.) Figure 60-10-23

Remove the DOC. (See Housing Removal And

Installation on Page 60-30-1.)

Remove the air cleaner. (See Housing Removal And

Installation on Page 60-30-1.)

Remove the tailgate. (See Removal And Installation on

Page 40-180-1.)

Remove the counterweight. (See Removal And

Installation on Page 40-80-1.)

Remove the starter. (See Removal And Installation on 1

Page 50-40-2.) P133117

Remove the alternator. (See Removal And Installation on

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Page 50-30-5.) Disconnect the three wire harness (Item 1) [Figure 60-
10-23].
Remove the hydraulic pump. (See Removal And
Installation on Page 20-50-17.) Figure 60-10-24

Remove the air conditioning compressor belt. (See Air 1

Conditioning Compressor Belt Replacement on Page 70-
20-2.)

Figure 60-10-22

P132016

4
1 Disconnect the harness (Item 1) [Figure 60-10-24] from
the filter.
1
P133116

Remove the tie straps (Item 1) [Figure 60-10-22].

60-10-15 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-27

Engine Removal And Installation (Cont'd)

Figure 60-10-25

1
2 P133374

Remove the bolt (Item 1) and ground cable (Item 2)

P133118 [Figure 60-10-27] from the excavator frame.

Figure 60-10-28
Disconnect the harness (Item 1) [Figure 60-10-25] from
the filter.

Figure 60-10-26
1

1
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P114757

Remove the cable (Item 1) [Figure 60-10-28] from the

P133373 starter.

Remove the cover (Item 1). Pull the wire harness (Item 2)
[Figure 60-10-26] into the engine compartment.

60-10-16 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-31

Engine Removal And Installation (Cont'd)

Figure 60-10-29
1

P133375

1
Remove the bolt (Item 1) [Figure 60-10-31] and nut.
P133379 Reposition the A/C compressor.

NOTE: Do not allow the compressor to be suspended

Remove the bolt (Item 1) and reposition the motion alarm by the A/C hoses.
(Item 2) [Figure 60-10-30].
Figure 60-10-32
Figure 60-10-30

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1

P133121
P114742

Disconnect both fuel lines (Item 1) [Figure 60-10-32].

Remove the bolt (Item 1) [Figure 60-10-30] and nut.

60-10-17 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-35

Engine Removal And Installation (Cont'd)

Figure 60-10-33

2 1

P133124

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

P133122 [Figure 60-10-35].

Figure 60-10-36
Loosen the clamp (Item 1) and remove the hose (Item 2)
[Figure 60-10-33].

Figure 60-10-34

1
1
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2 1
1
P114712

Remove the nuts (Item 1). Remove the pipe (Item 2)

P133381 [Figure 60-10-36] and gasket.

Remove the clamps (Item 1) and both hoses (Item 2)

[Figure 60-10-35].

60-10-18 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-39

Engine Removal And Installation (Cont'd)

1
Figure 60-10-37

2
1 P133377

Figure 60-10-40
P114713

1
Remove the hose (Item 1) [Figure 60-10-37].

Figure 60-10-38
2

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P133376

2
Position the engine bracket (Item 1) [Figure 60-10-39]
and [Figure 60-10-40] on the engine.

P114745 Bolt the bracket (Item 1) to the engine lift points (Item 2)
[Figure 60-10-39] and [Figure 60-10-40].

Loosen the clamp (Item 1) and remove the hose (Item 2) Install the lifting bracket and extension to the engine
[Figure 60-10-38]. bracket.

60-10-19 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-43

Engine Removal And Installation (Cont'd)

Figure 60-10-41

1
1

P114770

Remove the bolt and nut (Item 1) [Figure 60-10-43].

P133309

Installation: Tighten bolts 105 - 115 N•m (78 - 85 ft-lb)

torque.
Remove the bolts (Item 1) [Figure 60-10-41] and
reposition the hose guide. Figure 60-10-44

Figure 60-10-42
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P133380

P133378
Remove the bolt and nut (Item 1) [Figure 60-10-44].

Remove the bolt and nut (Item 1) [Figure 60-10-42].

60-10-20 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Engine Removal And Installation (Cont'd)

Figure 60-10-45

P114771

Raise the engine, as needed, and pull the engine out of

the excavator until the bolt (Item 1) [Figure 60-10-45] is
accessible. Remove the bolt.

Remove the engine.

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60-10-21 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-47

Compression - Testing Using The Glow Plug Adapter

The tools listed will be needed to do the following

procedure:

MEL10630 Engine Compression Kit

1
7313843 Compression Adapter

NOTE: Specifications are subject to change without

notice.

Prior to performing an engine compression test with a

gauge, it is recommended to perform a compression test
P128354
using Bobcat Engine Analyzer software to determine if a
potential compression issue exists.
Connect the compression gauge (Item 1) [Figure 60-10-
Wash the machine and then thoroughly clean the 47] to the adapter.
external portion of the fuel system components and the
surrounding area of the engine compartment with NOTE: It may be necessary to use a 45° or 90° fitting
compressed air. Perform engine service in a clean to allow better access to the test adapter
environment. when connecting the gauge quick coupler.

The engine must be at operating temperature. NOTE: Always use a fully charged battery for
performing this test.
Remove the glow plugs. (See Glow Plug Removal And
Installation on Page 60-70-2.) Monitor the engine crank speed to ensure that a
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minimum of 180 rpm is achieved or the reading will not

Figure 60-10-46 be valid.

Connect the Bobcat Engine Analyzer Diagnostic Tool and

run the Compression test in Bobcat Engine Analyzer.
This test will cause the engine to crank while the test is
running. Observe the maximum compression reading on
the compression gauge during cranking, not the test
results shown on the computer screen.

1 Repeat this procedure multiple times per cylinder until an

average reading is recorded.

P128355

Install the compression adapter (Item 1) [Figure 60-10-

46] into the cylinder head.

60-10-22 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Compression - Testing Using The Glow Plug Adapter

(Cont’d)

Use the table below to determine if the results are within

acceptable limits.

Compression Factory 2,9 - 3,5 MPa / 200 rpm

Pressure spec. (29 - 35 bar / 200 rpm) 
(420 - 508 psi / 200 rpm)
Allowable 2,5 MPa / 200 rpm
Limit (25 bar / 200 rpm)
(290 psi / 200 rpm)
Variance Factory 300 kPa (3 bar) (44 psi)
Among Spec.
Cylinders Allowable 300 kPa (3 bar) (44 psi)
Limit

If the measurement is below the allowable limit, apply a

small amount of oil to the cylinder wall through the glow
plug hole and measure the compression again.

If the compression pressure increases after applying oil,

cylinder wall and / or piston ring damage may be
possible. A bore scope may be used to look for internal
damage prior to engine disassembly.

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If the compression pressure is still less than the allowable
limit, check the top clearance, valves and cylinder head.

60-10-23 E85 Service Manual

ENGINE INFORMATION (CONT’D) NOTE: High pressure lines and return fuel lines are
single use lines. Replace with new.
Compression - Testing Using The Injector Adapter
Sealing washers must be replaced with new
NOTE: Specifications are subject to change without when installing the injectors. Save the old
notice. sealing washers to use with the compression
adapter.
Prior to performing an engine compression test with a
gauge, it is recommended to perform a compression test Figure 60-10-49
using Bobcat Engine Analyzer software to determine if a
potential compression issue exists.
1
Wash the machine and then thoroughly clean the
external portion of the fuel system components and the
surrounding area of the engine compartment with
compressed air. Perform engine service in a clean
environment.

After warming up the engine, stop the engine, wait five

minutes for fuel pressure bleed down then remove all the
injectors. (See Fuel Injector Removal And Installation on
2
Page 60-60-7.)

Figure 60-10-48 NA13030

Install the compression tester and test adapter (part

number 7299827) for diesel engines into the nozzle hole
(Item 1) [Figure 60-10-49].
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Use one of the old sealing washers to seal the adapter.

Remove the fuel line at the fuel filter outlet so no fuel is

expelled.

Plug the fuel line and cap the fuel filter outlet to help
maintain fuel system cleanliness.

P127114 NOTE: Always use a fully charged battery for

performing this test.

When removing the injectors leave the fuel lines Monitor the engine crank speed to ensure that a
connected to the fuel rail. Reroute the lines to allow any minimum of 180 rpm is achieved or reading will not be
small amount of fuel that may be present during the test valid.
to be collected [Figure 60-10-48].
Connect the Bobcat Engine Analyzer Diagnostic Tool and
Leaving the fuel lines connected to the fuel rail will also run the Compression test in Bobcat Engine Analyzer.
help prevent debris from entering the fuel rail. This test will cause the engine to crank while the test is
running. Observe the maximum compression reading on
Store each of the injectors in a new clean plastic bag. the compression gauge during cranking, not the test
results shown on the computer screen.
NOTE: Number the plastic bags to ensure that
injectors are installed in the same cylinders Repeat this procedure multiple times per cylinder until an
from which they were removed. average reading is recorded.

60-10-24 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Compression - Testing Using The Injector Adapter

(Cont’d)

Use the table below to determine if the results are within

acceptable limits.

Compression Factory 2,9 - 3,5 MPa / 200 rpm

Pressure spec. (29 - 35 bar / 200 rpm) 
(420 - 508 psi / 200 rpm)
Allowable 2,5 MPa / 200 rpm
Limit (25 bar / 200 rpm)
(290 psi / 200 rpm)
Variance Factory 300 kPa (3 bar) (44 psi)
Among Spec.
Cylinders Allowable 300 kPa (3 bar) (44 psi)
Limit

If the measurement is below the allowable limit, apply a

small amount of oil to the cylinder wall through the nozzle
hole and measure the compression again.

If the compression pressure increases after applying oil,

cylinder wall and/or piston ring damage may be possible.
A bore scope may be used to look for internal damage
prior to engine disassembly.

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If the compression pressure is still less than the allowable
limit, check the top clearance, valves and cylinder head.

60-10-25 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-51

Injector Signal - Testing

NOTE: Engine should be allowed to cool completely

1
before performing the following procedure.

The tool listed will be needed to the following procedure:

7299829 - Injector Signal Tester

MEL1563 or 7217666 - Remote Start Tool 2

WARNING
P115882

AVOID INJURY OR DEATH

Wear safety glasses to prevent eye injury when any
Remove the connector (Item 1) from the injector (Item 2)
of the following conditions exist:
[Figure 60-10-51].
• When fluids are under pressure.
• Flying debris or loose material is present.
Figure 60-10-52
• Engine is running.
• Tools are being used.
W-2019-0907

Open the tailgate. (See Opening And Closing on Page 1 2

10-50-1.)
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NOTE: Ensure the battery is fully charged before

testing.

Figure 60-10-50

P127169

Install the signal tester (Item 1) to the connector (Item 2)

[Figure 60-10-52].

1 NOTE: Injector connector must be properly oriented

with tester connector or damage will occur.

Do not pull on wires or LED holder.

P115882 Connect the Remote Start Tool. (See Remote Start Tool -
MEL1563 on Page 10-210-1.) or (See REMOTE START
TOOL (SERVICE TOOL) KIT - 7217666 on Page 10-211-
Locate the fuel injectors (Item 1) [Figure 60-10-50]. 1.)

60-10-26 E85 Service Manual

ENGINE INFORMATION (CONT’D)

Injector Signal - Testing (Cont’d)

Figure 60-10-53

P-76439

Press the RUN button (Item 1) [Figure 60-10-53] on the

Remote Start Tool.

Figure 60-10-54

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1

P127170

The signal tester light (Item 1) [Figure 60-10-54] should

flash once.

To repeat the test, press the STOP button (Item 2)

[Figure 60-10-53] and wait one minute.

If the signal tester light flashes, the electrical system is

working.

If the signal tester light is on continuously or not at all,

there is an electrical malfunction.

Repeat the above procedure for the remaining injectors.

60-10-27 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-56

Injector Signal - Testing (In-Line)

NOTE: Engine should be allowed to cool completely

1
before performing the following procedure.

The tool listed will be needed to the following procedure:

7313846 - Injector Signal Tester

2
MEL1563 or 7217666 - Remote Start Tool

WARNING P115882

AVOID INJURY OR DEATH Remove the connector (Item 1) from the injector (Item 2)
Wear safety glasses to prevent eye injury when any [Figure 60-10-56].
of the following conditions exist:
• When fluids are under pressure. Figure 60-10-57
• Flying debris or loose material is present.
• Engine is running.
2
• Tools are being used.
W-2019-0907
4

Open the tailgate. (See Opening And Closing on Page

10-50-1.)
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1
NOTE: Ensure the battery is fully charged before
3
testing.

Figure 60-10-55

P127216

Install the signal tester (Item 1) to the harness connector

(Item 2) [Figure 60-10-57].

Install the signal tester connector (Item 3) to the injector

(Item 4) [Figure 60-10-57].
1
NOTE: Injector connector must be properly oriented
with tester connector or damage will occur.

P115882 Do not pull on wires or LED holder.

Connect the Remote Start Tool. (See REMOTE START

Locate the fuel injectors (Item 1) [Figure 60-10-55]. TOOL KIT - MEL1563 on Page 10-210-1.) or (See
REMOTE START TOOL (SERVICE TOOL) KIT -
7217666 on Page 10-211-1.)

60-10-28 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-59

Injector Signal - Testing (In-Line) (Cont’d)

Figure 60-10-58
1
3

P127217

The signal tester light (Item 1) [Figure 60-10-59] should

P-76439 flash once.

Press the START button (Item 2) [Figure 60-10-58] on

Press the RUN button (Item 1) [Figure 60-10-58] on the the Remote Start Tool.
Remote Start Tool.
The signal tester light (Item 1) [Figure 60-10-59] should
flash continuously.

To repeat the test, press the STOP button (Item 3)

[Figure 60-10-58] and wait one minute.

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If the signal tester light flashes, the electrical system is
working.

If the signal tester light is on continuously or not at all,

there is an electrical malfunction.

Repeat the above procedure for the remaining injectors.

60-10-29 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-61

Oil Pressure Testing (At Oil Sensor On Block)

Prior to performing an engine oil pressure gauge test, it is

recommended to monitor oil pressure using Bobcat
Service Analyzer software to determine if a potential oil
pressure issue exists.

The tools listed will be needed to do the following

procedure:

7332314 - Turbocharger and oil sensor block adapter kit

Hydraulic hose, approximately 1,0 m (3.0 ft), purchased 1
locally. Must be rated for pressures above 689 kPa (100
psi). P133741

Pressure gauge rated for 689 kPa (100 psi).

Remove the bolts (Item 1) [Figure 60-10-61].
Open the rear door.
Figure 60-10-62
NOTE: Photos may appear different but the
procedure is the same.

Figure 60-10-60
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1 1

P133742

Remove the sensor (Item 1) [Figure 60-10-62].

P133741

Locate the oil pressure / temperature sensor (Item 1)

[Figure 60-10-60].

60-10-30 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-65

Oil Pressure Testing (At Oil Sensor On Block)

(Cont’d)

Figure 60-10-63
1
1

P133746

Install the sensor (Item 1) [Figure 60-10-65].

P133776 Figure 60-10-66

Install the 90 degree fitting (Item 1) into the adapter (Item

2) [Figure 60-10-63].

Figure 60-10-64

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1
P133747

1
Install the 50 mm long bolts (included in the kit), (Item 1)
[Figure 60-10-66] and tighten.

P133744

Install the adapter (Item 1) [Figure 60-10-64] in the

engine block.

60-10-31 E85 Service Manual

ENGINE INFORMATION (CONT’D) The following chart shows the oil pressure range at idle
and at rated RPM.
Oil Pressure Testing (At Oil Sensor On Block)
(Cont’d)
D24
Figure 60-10-67 Rated RPM 2600
Oil Pressure @ Rated RPM 350 - 450 kPa 
Oil Temperature = 100°C (212°F) (50 - 65 psi)
Idle RPM 1150
Oil Pressure @ Idle RPM 150 - 250 kPa 
Oil Temperature = 100°C (212°F) (22 - 36 psi)

P133748

Install the hose (Item 1) [Figure 60-10-67] to adapter

fitting and tighten.

Figure 60-10-68
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P133749

Install the gauge (Item 1) to the hose (Item 2) [Figure 60-

10-68].

Start the engine and allow it to reach operating

temperature. Testing with cold oil may give inaccurate
readings. Record the oil pressures at idle and at rated
engine RPM.

60-10-32 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-70

Oil Pressure Testing (At Turbocharger Oil Inlet)

Prior to performing an engine oil pressure gauge test, it is

recommended to monitor oil pressure using Bobcat
Service Analyzer software to determine if a potential oil
pressure issue exists. 1
The tools listed will be needed to do the following
procedure:

7332314 - Turbocharger and oil sensor block adapter kit

Hydraulic hose, approximately 1,0 m (3.0 ft), purchased
locally. Must be rated for pressures above 689 kPa (100
psi). P133770

Pressure gauge rated for 689 kPa (100 psi).

Install the turbocharger adapter fitting (Item 1) [Figure
NOTE: Photos may appear different but the
60-10-70] from the kit.
procedure is the same.
Figure 60-10-71
Figure 60-10-69

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1

P133771
P133769

Install the 90 degree adapter fitting (Item 1) [Figure 60-

Remove the turbocharger oil inlet line fitting (Item 1)
10-71] from the kit.
[Figure 60-10-69].

60-10-33 E85 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-74

Oil Pressure Testing (At Turbocharger Oil Inlet)

(Cont’d)

Figure 60-10-72

P133775

Start the engine and allow it to reach operating

temperature. Testing with cold oil may give inaccurate
P133772 readings. Record the oil pressures at idle and at rated
engine RPM.

Install the hose adapter fitting (Item 1) [Figure 60-10-72]. Oil pressure at the turbocharger oil inlet should be at
least 10 psi within 4 seconds of engine start. If this is not
Figure 60-10-73 achieved turbocharger damage is possible. Ensure the
correct engine oil viscosity is being used for the ambient
temperature. Oil pressure at the turbocharger oil inlet will
typically be about 5-10 psi lower than at the sensor.
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P133774

Install the hose with gauge (Item 1) [Figure 60-10-73] to

the adapter fitting.

60-10-34 E85 Service Manual

DIESEL OXIDATION CATALYST (DOC) Figure 60-20-3

Removal And Installation

Figure 60-20-1
1

1 P114696

Remove the gasket (Item 1) [Figure 60-20-3].

P128514

Remove the clamp (Item 1) [Figure 60-20-1].

Installation: Tighten the clamps to 8 N•m (6 ft-lb) torque.

Figure 60-20-2

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1

P128517

Loosen the two clamps (Item 1). Remove the DOC

assembly (Item 2) [Figure 60-20-2].

Installation: Tighten the clamps to 12 N•m (8.9 ft-lb)

torque.

60-20-1 E85 Service Manual

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60-20-2
E85 Service Manual
AIR CLEANER Figure 60-30-3

Housing Removal And Installation

Remove the center cover. (See Removal And Installation

on Page 40-220-1.)

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

Page 10-60-1.)

Figure 60-30-1

1
2 3
P131970

Rotate the housing (Item 1) [Figure 60-30-3] and remove

the housing from the excavator.

P131972

Remove the hose (Item 1) and disconnect the wire

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harness (Item 2) [Figure 60-30-1].

Loosen the hose clamp (Item 3) [Figure 60-30-1] and

remove the hose from the air cleaner housing.

Figure 60-30-2

P131971

Disconnect the wire harness (Item 1) and reposition the

harness. Remove the bolts (Item 2) [Figure 60-30-2].

60-30-1 E85 Service Manual

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60-30-2
E85 Service Manual
ENGINE COOLING SYSTEM Figure 60-40-3

Oil Cooler / Radiator Removal And Installation

1
Remove the counterweight. (See Removal And
Installation on Page 40-80-1.)

Drain the coolant. (See Removing And Replacing

Coolant on Page 10-100-3.)

Remove the fuel cooler. (See Fuel Cooler Removal And

Installation on Page 60-60-6.)

Figure 60-40-1

P114821
1

Lift up and remove the condenser from the bracket.

1 Reposition the condenser (Item 1) [Figure 60-40-3].

Figure 60-40-4

1
P133315

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Remove the bolts (Item 1) and remove the fan guard
(Item 2) [Figure 60-40-1]. 1
Figure 60-40-2

P133317

Remove the hose (Item 1) [Figure 60-40-4] from the

radiator.

P133316

Loosen the knob (Item 1) [Figure 60-40-3].

60-40-1 E85 Service Manual

ENGINE COOLING SYSTEM (CONT'D) Figure 60-40-7

Oil Cooler / Radiator Removal And Installation

(Cont'd)

Figure 60-40-5 1
1

P133335

1 Remove the two hoses (Item 1) from the bottom of the oil
cooler / radiator [Figure 60-40-7].
P133333
Figure 60-40-8

Figure 60-40-6

1
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P133334

P133340
Remove the top hose (Item 1). Reposition the hose (Item
2) [Figure 60-40-8].
Remove both hoses (Item 1) [Figure 60-40-5] and
[Figure 60-40-6] from the bottom of the oil cooler /
radiator.

60-40-2 E85 Service Manual

ENGINE COOLING SYSTEM (CONT'D) Figure 60-40-11

Oil Cooler / Radiator Removal And Installation

(Cont'd) 1

Figure 60-40-9 2 2

P133338

Support the oil cooler / radiator using a chain and hoist

(Item 1) [Figure 60-40-11].
P133336
Remove the two bolts (Item 2) [Figure 60-40-11].

Remove the two hoses (Item 1) [Figure 60-40-9] from Remove the oil cooler / radiator.
the bottom of the oil cooler / radiator.

Figure 60-40-10

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2

P133339

Remove the bolts (Item 1) and bracket (Item 2) [Figure

60-40-10].

60-40-3 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 60-40-14

Fan Removal And Installation 1

Figure 60-40-12

2
P114710

1
Remove the fan (Item 1) [Figure 60-40-14].
P133315
Figure 60-40-15

Remove the bolts (Item 1) [Figure 60-40-12] and remove

the fan guard.
1
Remove the alternator. (See Removal And Installation on
Page 50-30-5.)

Figure 60-40-13
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P114711

Remove the spacer (Item 1) [Figure 60-40-15] and

pulley.

P114709

Remove the bolts (Item 1) [Figure 60-40-13] from the

front of the fan.

Installation: Apply threadlocker (Loctite® 242) to the bolt

heads. Tighten the bolts to 22 N•m (16 ft-lb) torque.

60-40-4 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 60-40-18

Water Pump Removal And Installation

Figure 60-40-16
1
1

2
P114383
1
1
2
Remove the gasket (Item 1) [Figure 60-40-18] from the
P114381 block.

Reposition the clamps (Item 1) and remove the hoses

(Item 2) [Figure 60-40-16].

Figure 60-40-17

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1 1

2
P114382

Remove the bolts (Item 1) and nuts (Item 2) [Figure 60-

40-17]. Remove the water pump.

60-40-5 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 60-40-21

Thermostat Housing Removal And Installation

Drain the coolant. (See Removing And Replacing

Coolant on Page 10-100-3.)
1
NOTE: Some photos may appear different but the
procedure is the same.

Figure 60-40-19

P114367

1
Reposition the clamp (Item 1) [Figure 60-40-21].

Figure 60-40-22
1

2 1 2 3
P114364

Reposition the clamps (Item 1) and remove the hose

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(Item 2) [Figure 60-40-19] from the thermostat housing.

Figure 60-40-20
3 3

1 P114366

Remove the nut (Item 1). Reposition the wire harness

2
bracket and remove the stud (Item 2) [Figure 60-40-22].

Remove the bolts (Item 3) [Figure 60-40-22] and remove

the thermostat housing.

Installation: Tighten the bolts and stud to 22 N•m (16 ft-

lb) torque.
P114365

Disconnect the wire harness (Item 1). Reposition the

clamp (Item 2) [Figure 60-40-20].

60-40-6 E85 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Testing The Thermostat

Thermostat Housing Removal And Installation Figure 60-40-24

(Cont’d)

Figure 60-40-23

1 P114048

P112916 Place the thermostat and a thermometer in a container of

water. Gradually heat the water and inspect the operation
of the thermostat [Figure 60-40-24].
Remove the seal (Item 1) [Figure 60-40-23] from the
thermostat housing. Thermostat valve 0,3 mm (0.01 in)
Opening temperature @ 82°C (180°F)
Thermostat valve 8 mm (0.32 in)
Full Open @ 97°C (207°F)

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60-40-7 E85 Service Manual

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60-40-8
E85 Service Manual
LUBRICATION SYSTEM

Description

The oil pump delivers oil from the oil pan through the oil cooler and filter, to the main oil passage in the cylinder block.
From the cylinder block, oil is delivered to the piston cooling jets, crankshaft main bearings, connecting rod bearings,
camshaft bearings, rocker arms and turbo charger. Oil also is delivered to the idler gear located at the front of the engine.

Figure 60-50-1

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P114327

1. Oil Pump 8. Idler Gear

2. Relief Valve 9. Piston

3. Bypass Valve 10. Crankshaft Main Bearing

4. Oil Cooler 11. Connecting Rod Bearing

5. Oil Filter 12. Camshaft Bearing

6. Bypass Valve 13. Rocker Arm

7. Piston Cooling Jet 14. Turbo Charger

60-50-1 E85 Service Manual

LUBRICATION SYSTEM (CONT’D) Figure 60-50-4

Oil Pan Removal And Installation

Figure 60-50-2

1 1

P112951

Figure 60-50-5
P112949

Remove the bolts and remove the oil pan (Item 1)

[Figure 60-50-2].

Installation: Apply Loctite® 5900 to the oil pan flange.

Tighten the bolts to 22 N•m (16 ft-lb) torque.

Figure 60-50-3
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1
2 1
3
5
P112952
1

Remove the O-rings (Item 1) [Figure 60-50-4] and

[Figure 60-50-5].

1
P112950

Remove the bolts (Item 1) and the oil pick up tube (Item
2). Remove the bolts (Item 3) and (Item 4). Remove the
oil delivery pipe (Item 5) [Figure 60-50-3].

Installation: Tighten the bolts (Item 1) and (Item 3) to 22

N•m (16 ft-lb) torque. Tighten the bolts (Item 4) [Figure
60-50-3] to 9,8 N•m (7.2 ft-lb) torque.

60-50-2 E85 Service Manual

LUBRICATION SYSTEM (CONT’D)

Oil Pump Removal And Installation

Remove the timing gearcase cover. (See Gearcase

Cover Removal And Installation on Page 60-100-1.)

Figure 60-50-6

1
P112947

Remove the bolts and remove the oil pump (Item 1)

[Figure 60-50-6].

Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

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Figure 60-50-7

1
1

P112948

Remove the O-rings (Item 1) [Figure 60-50-7].

NOTE: The oil pump is not serviceable. When

installing the oil pump, inspect the pump gear
for correct backlash. (See Gear Backlash on
Page 60-100-2.)

60-50-3 E85 Service Manual

LUBRICATION SYSTEM (CONT’D) Oil Pump Relief Valve Removal And Installation

Oil Pump Relief Valve Description Figure 60-50-8

The oil pump relief valve is set to 496 kPa (4,9 bar) (72
psi).

1
P114278

Remove the plug (Item 1) [Figure 60-50-8].

Figure 60-50-9
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P114279

Remove the spring (Item 1) and poppet (Item 2) [Figure

60-50-9].

60-50-4 E85 Service Manual

LUBRICATION SYSTEM (CONT’D)

Oil Cooler Removal And Installation

Remove the starter. (See Removal And Installation on

Page 50-40-2.)

Figure 60-50-10

1 1
P112894

Remove the bolts (Item 1) [Figure 60-50-10].

Remove the cooler from the filter head.

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Figure 60-50-11

1
1

P112895

Remove the O-rings (Item 1) [Figure 60-50-11].

60-50-5 E85 Service Manual

LUBRICATION SYSTEM (CONT’D)

Oil Filter Head Removal And Installation

Remove the oil cooler. (See Oil Cooler Removal And

Installation on Page 60-50-5.)

Figure 60-50-12

1 1

P112895

Remove the bolts (Item 1) [Figure 60-50-12] and remove

the filter head.

Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

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Figure 60-50-13

P112893

Remove the O-rings (Item 1) [Figure 60-50-13].

60-50-6 E85 Service Manual

LUBRICATION SYSTEM (CONT’D) Oil Cooler Bypass Removal And Installation

Oil Cooler Bypass Description Figure 60-50-14

The oil cooler bypass is set to 145 kPa (1,4 bar) (21 psi).

P114276

Remove the plug (Item 1) [Figure 60-50-14].

Figure 60-50-15

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1

P114277

Remove the spring (Item 1) and poppet (Item 2) [Figure

60-50-15].

60-50-7 E85 Service Manual

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60-50-8
E85 Service Manual
FUEL SYSTEM

Description

Figure 60-60-1

3
6

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1 NA9400

The fuel flows from the fuel tank (Item 1) to the fuel filter (Item 2). From the filter, fuel flows to the transfer pump / high
pressure pump (Item 3). Fuel at as high of a pressure as 179264 kPa (1793 bar) (26,000 psi) is delivered from the fuel
pump to the common rail (Item 4). From the rail, fuel is delivered to the fuel injector (Item 5). Unused fuel from the injector
flows back to the pump (Item 3). Unused fuel from the pump will flow to the fuel bypass valve (Item 6). When the fuel is
colder than 49°C (120°F), the bypass valve will be open. When the bypass valve is open, fuel will flow through the bypass
valve and back to the inlet side of the fuel filter (Item 2). When the fuel is warmer than 27°C (81°F), the bypass valve will
be closed. When the valve is closed, fuel will flow to the fuel cooler (Item 7) [Figure 60-60-1] and back to the fuel tank.

60-60-1 E85 Service Manual

FUEL SYSTEM (CON’TD) Figure 60-60-4

Transfer Pump / High Pressure Pump Removal And

Installation
2
Note: Allow five minutes after the engine is shut
down for the fuel pressure to bleed down.

Remove the oil filter head. (See Oil Cooler Removal And
Installation on Page 60-50-5.)

Figure 60-60-2 1

1
P112897

Remove the bolt (Item 1) and remove the dipstick and

dipstick tube (Item 2) [Figure 60-60-4].

Figure 60-60-5

P1114161
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Disconnect the wire harness from the fuel temperature

sensor (Item 1) and inlet metering valve (Item 2) [Figure
60-60-2].

Figure 60-60-3
1

P112899

1 Remove the O-ring (Item 1) [Figure 60-60-5] from the

tube.

P1114197

Remove the fuel hose (Item 1) [Figure 60-60-3] from the

fuel supply and return fittings.

60-60-2 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-8

Transfer Pump / High Pressure Pump Removal And

Installation (Cont’d)

Figure 60-60-6

P114027

3
2
Remove the nut (Item 1) [Figure 60-60-8].

P112898 Installation: Tighten the nut to 64 N•m (47 ft-lb) torque.

Figure 60-60-9
Remove the bolt (Item 1) and clamp. Remove the high
pressure fuel line (Item 2) and return fuel line (Item 3)
[Figure 60-60-6].

Installation: Tighten the high pressure fuel line to 29,4

N•m (21.7 ft-lb) torque.

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Figure 60-60-7

1
P114028

1 Remove the gear (Item 1) [Figure 60-60-9].

P112903

Remove the three nuts (Item 1) [Figure 60-60-7] and

remove the fuel pump.

Installation: Tighten the nuts to 22 N•m (16 ft-lb) torque.

60-60-3 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-12

Transfer Pump / High Pressure Pump Removal And

Installation (Cont’d)
1
Figure 60-60-10

P114030

Remove the O-ring (Item 1) [Figure 60-60-12] from the

pump.
P114029
When replacing the high pressure pump, the pump timing
needs to be as close as possible. If the gearcase cover is
Remove the collar (Item 1) [Figure 60-60-10]. removed (See Gear Timing on Page 60-100-3.) for the
correct procedure. If installing the high pressure pump
Figure 60-60-11 without removing the gearcase cover, follow [Figure 60-
60-13] through [Figure 60-60-15] for the correct
procedure
1
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Figure 60-60-13

P114031

Remove the O-ring (Item 1) [Figure 60-60-11] from the 1

outside diameter of the collar.
P126421

Rotate the crankshaft until cylinders 1 and 4 are at top

dead center. The mark (Item 1) on the gearcase cover
will be aligned with the mark (Item 2) [Figure 60-60-13]
on the crankshaft pulley.

60-60-4 E85 Service Manual

FUEL SYSTEM (CONT’D) Fuel Temperature Sensor Removal And Installation

Transfer Pump / High Pressure Pump Removal And Figure 60-60-16

Installation (Cont’d)

Figure 60-60-14
1
2 2

1
P114161

P126420 Remove the electrical connector (Item 1) and the fuel

temperature sensor (Item 2) [Figure 60-60-16].

Rotate the gear until the notch (Item 1) on the gear pump Installation: Tighten the fuel temperature sensor to 8,8 -
housing is centered between the dots (Item 2) [Figure 11,8 N•m (78 - 104 in-lb) torque.
60-60-14] on the gear.

Figure 60-60-15

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1

3 2

P114014

Install the high pressure pump in the gearcase. The gear

(Item 1) will turn slightly as it engages the idler gear. The
timing mark (Item 2) on the idler gear will be aligned with
the timing marks (Item 3) [Figure 60-60-15] on the pump
gear.

NOTE: The gearcase cover is removed for photo

clarity.

60-60-5 E85 Service Manual

FUEL SYSTEM (CONT’D)

Fuel Cooler Removal And Installation

Figure 60-60-17

1 1

P131653

Remove the fuel lines (Item 1) [Figure 60-60-17].

Installation: Install the tab (Item 2) [Figure 60-60-19] in

the mount.

Figure 60-60-18
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P131654

Loosen the knob (Item 1) [Figure 60-60-18].

Lift up on and remove the cooler.

60-60-6 E85 Service Manual

FUEL SYSTEM (CONT’D) Fuel Injector Removal And Installation

Fuel Recirculation Valve Removal And Installation Figure 60-60-20

Figure 60-60-19 1
3 3

1
1

2 2 2
1
P112900

P131660
Remove the fuel return line (Item 1). Remove the high
pressure fuel lines (Item 2) [Figure 60-60-20].
Remove the hoses (Item 1) from the valve (Item 2)
[Figure 60-60-19]. Installation: Tighten the high pressure fuel lines to 29,4
N•m (21.7 ft-lb) torque.
Remove the valve (Item 2) [Figure 60-60-19].
NOTE: Both the high pressure fuel lines and return
fuel line are a one time use line. Replace the
fuel lines with new fuel lines after removal.

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Disconnect the wire harness (Item 3) [Figure 60-60-20]
from the fuel injectors.

Figure 60-60-21

1 1 1

1 1
1

P112927

Remove the bolts (Item 1) [Figure 60-60-21] and remove

the cylinder head cover.

Installation: Tighten the bolts to 7,8 N•m (5.8 ft-lb)

torque.

60-60-7 E85 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-24

Fuel Injector Removal And Installation (Cont’d)

Figure 60-60-22

1
P112930

Remove the injector (Item 1) [Figure 60-60-24].

P112928
Figure 60-60-25

Remove the seal (Item 1) [Figure 60-60-22] from the

cover.

Figure 60-60-23
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P112931
1
2
Remove the sealing washer from the bottom of the
injector bore (Item 1) [Figure 60-60-25].
P112929
NOTE: The sealing washers must be replaced with
new sealing washers when installing the
Remove the bolt (Item 1) and remove the injector retainer injectors.
(Item 2) [Figure 60-60-23].

Installation: Tighten the bolt to 39,2 - 46,1 N•m (29 - 40

ft-lb) torque.

60-60-8 E85 Service Manual

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System

Fuel Injector Removal And Installation (Cont’d) After removing or replacing fuel system components
(high pressure pump, fuel rail, injectors or fuel cooler) the
Figure 60-60-26 following procedure must be used to remove air from the
fuel system if equipped with a fuel recirculation valve.

NOTE: The same procedure can be used for either

the early or later fuel recirculation valve.

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.
P112932
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
Remove the O-ring (Item 1) [Figure 60-60-26] from the from a physician familiar with this injury.
injector. W-2072-0807

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

Open the right side cover. (See RIGHT SIDE COVER on

Page 10-60-1.)

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Figure 60-60-27

P132022

Open the air vent plug (Item 1) [Figure 60-60-27] on the

fuel filter assembly three full turns.

Squeeze the hand pump (primping bulb) (Item 2) [Figure

60-60-27] until the fuel flows from the air vent plug with
no air bubbles.

Close the air vent plug (Item 1) [Figure 60-60-27].

60-60-9 E85 Service Manual

FUEL SYSTEM (CONT’D)

Removing Air From The Fuel System (Cont’d)

Figure 60-60-28

1
NA13054

Pinch off the fuel hose (Item 1) [Figure 60-60-28] using a

locking hose pinching plier.

Squeeze the hand pump (primer bulb) (Item 2) [Figure

60-60-28] twenty times or until the primer bulb is difficult
to squeeze.
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Start the machine and let machine idle two minutes.

Shut the machine off and remove the pinching plier from
the fuel hose (Item 1) [Figure 60-60-28].

60-60-10 E85 Service Manual

CYLINDER HEAD Figure 60-70-2

Glow Plugs Testing

Stop the engine and open the rear door.

Figure 60-70-1

1 1
P114806
2

Figure 60-70-3

P114804

Remove the glow plug nuts (Item 1). Remove glow plug
connecting strap (Item 2) [Figure 60-70-1].

Installation: Tighten the glow plug nuts to 2,5 - 3,0 N•m

(21 - 26 ft-lb) torque.

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P114440

Touch one probe to the end of the glow plug and the
other probe to the body of the glow plug [Figure 60-70-2]
and [Figure 60-70-3].

Use an ohmmeter to check the glow plugs.The resistance

should be 1.4 ohms.

Repeat the procedure for each glow plug.

60-70-1 E85 Service Manual

CYLINDER HEAD (CONT'D) Figure 60-70-6

Glow Plug Removal And Installation

Stop the engine and open the rear door.

Figure 60-70-4

1 1
P114442
2

Inspect the glow plugs and replace as necessary [Figure

60-70-6].

P114804

Remove the glow plug nuts (Item 1) and remove the glow
plug connecting strap (Item 2) [Figure 60-70-4].

Installation: Tighten the glow plug to 2,5 - 3,0 N•m (1.8 -

2.2 ft-lb) torque.
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Figure 60-70-5

P114807

Remove the glow plug (Item 1) [Figure 60-70-5] from the

cylinder head.

Installation: Tighten the glow plug to 9,0 - 11,8 N•m (6.6

- 8.7 ft-lb) torque.

60-70-2 E85 Service Manual

CYLINDER HEAD (CONT'D) Figure 60-70-9

Valve Clearance Adjustment

Remove the air cleaner. (See Housing Removal And

Installation on Page 60-30-1.)
1
NOTE: Adjust the valve clearance on a cold engine.

Figure 60-70-7

1 1
1

P114692

Remove the bolts (Item 1) [Figure 60-70-9] and remove

2 the heat shield brackets.

Figure 60-70-10

P114689
1 1

Push the lock tabs (Item 1) in to release the hose (Item 2)

[Figure 60-70-7] from the valve cover fitting and remove

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the hose.

Figure 60-70-8

2
1
P114691

Remove the wire harness holders (Item 1) [Figure 60-

70-10].

Remove the valve covers (Item 2) [Figure 60-70-10] from

the engine.

P114690

Remove the valve cover (Item 1) [Figure 60-70-8].

60-70-3 E85 Service Manual

CYLINDER HEAD (CONT'D) Figure 60-70-13

Valve Clearance Adjustment (Cont’d) 2

Figure 60-70-11

1 1

2
P114410

Loosen the nut (Item 1) and adjust the screw (Item

P114409 2) [Figure 60-70-13] to obtain the correct clearance.

Installation: Tighten the nut to 15 N•m (11 ft-lb) torque.

Measure the valve clearance between the rocker arm
(Item 1) and the valve bridge head (Item 2) [Figure 60-
70-11].

The intake valve clearance is 0,4 mm and the exhaust

valve clearance is 0,45 mm.
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Figure 60-70-12

Cylinder
#1 #2 #3 #4
Number
Exhaust

Exhaust

Exhaust

Exhaust
Intake

Intake

Intake

Intake

Rotation
Angle

TDC (#1
Cylinder) • • • •
360°
Rotation • • • •

To adjust the valve clearance reference the chart [Figure

60-70-12].

With the #1 cylinder set at compression top dead center

set the valves on #1 cylinder intake and exhaust. #2
cylinder intake valve and #3 cylinder exhaust valve.

Rotate engine 360° to make #4 cylinder at top dead

center. Adjust the #2 cylinder exhaust valve, #3 cylinder
intake valve and #4 cylinder intake and exhaust valve.

60-70-4 E85 Service Manual

CYLINDER HEAD (CONT'D) Figure 60-70-15

Cylinder Head Removal And Installation

Remove the glow plugs. (See Glow Plug Removal And

Installation on Page 60-70-2.)
1
Remove the fuel injectors. (See Fuel Injector Removal
And Installation on Page 60-60-7.)

Remove the turbo charger. (See Removal And

Installation on Page 60-110-1.)

Remove the diesel oxidation catalyst (DOC). (See

Removal And Installation on Page 60-20-1.)
P114446
Remove the air cleaner. (See Housing Removal And
Installation on Page 60-30-1.)
Remove the bolts (Item 1) [Figure 60-70-15] and
Remove the alternator. (See Removal And Installation on gaskets.
Page 50-30-5.)
Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.
Figure 60-70-14
Figure 60-70-16

2
1 1 1 1

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1

1 1 1 1 1
P114444
P114445

Remove the bolts (Item 1), EGR cooler tube (Item 2)

[Figure 60-70-14] and gaskets. Remove the bolts (Item 1), exhaust manifold (Item 2)
[Figure 60-70-16] and gaskets.
Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.
Installation: Tighten the bolts to 30 N•m (22 ft-lb) torque.

60-70-5 E85 Service Manual

CYLINDER HEAD (CONT'D) Figure 60-70-19

Cylinder Head Removal And Installation (Cont'd)

Figure 60-70-17

P114457

Disconnect and reposition the wire harness (Item 1)

P114452 [Figure 60-70-18].

Figure 60-70-20
Remove the bolts (Item 1) [Figure 60-70-16] and gasket.

Installation: Tighten the bolts to 30 N•m (22 ft-lb) torque.

Figure 60-70-18

1
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P114454

1
Remove the high pressure fuel supply line (Item 1)
[Figure 60-70-20].
P114449

Remove the bolts (Item 1) [Figure 60-70-18] and DOC

mount.

60-70-6 E85 Service Manual

CYLINDER HEAD (CONT'D) Figure 60-70-23

Cylinder Head Removal And Installation (Cont'd)

1
Figure 60-70-21

1 1 1

P114447
1 1
1
Remove the seal (Item 1) [Figure 60-70-23] from the
P114466 cover.

Figure 60-70-24
Remove the bolts, intake manifold (Item 1) [Figure 60-
70-21] and gaskets.
1
Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

Figure 60-70-22

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1

P112935

Remove the bolts (Item 1) [Figure 60-70-24] and remove

the rocker arm assembly.

P112933 Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

Loosen the bolts and remove the cylinder head cover

(Item 1) [Figure 60-70-22].

Installation: Tighten the bolts to 7,8 N•m (5.8 ft-lb)

torque.

60-70-7 E85 Service Manual

CYLINDER HEAD (CONT'D) Figure 60-70-27

Cylinder Head Removal And Installation (Cont'd)

Figure 60-70-25

4
12 5 13
16 8 1
1 9 17

15 7 2 10 18
11 3 6 14

2 P114455

Installation: Tighten the head bolts in the sequence

P112936 shown [Figure 60-70-27].

Initial torque 40 N•m (30 ft-lb).

Remove the push rods (Item 1) and valve spring bridges
(Item 2) [Figure 60-70-25]. 2nd torque 90°.

Figure 60-70-26 3rd torque 90°.

4th torque 90°.

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1 2 NOTE: Before installing the cylinder head, piston

step height must be measured to determine
the correct head gasket thickness required.

Figure 60-70-28

P112937

Remove the head bolts (Item 1), cylinder head (Item 2)

[Figure 60-70-26] and gasket.

1
P114045

Rotate the crankshaft until the piston is at top dead

center. Measure the piston step height in the areas
shown (Item 1) [Figure 60-70-28].

Repeat the procedure for all four pistons

0,11 - 0,39 mm
Piston step height
(0.0043 - 0.0154 in)

60-70-8 E85 Service Manual

CYLINDER HEAD (CONT'D) Cylinder Head Disassembly And Assembly

Cylinder Head Removal And Installation (Cont'd) Figure 60-70-30

Figure 60-70-29

4
3
2
1

P114035

P114448
Compress the valve spring and remove the retainers
(Item 1). Release the valve spring compression tool.
Select the correct class head gasket. The class of gasket Remove the spring seat (Item 2), spring (Item 3) and
is stamped in the gasket where shown (Item 1) [Figure valve stem seals (Item 4) [Figure 60-70-30].
60-70-29].
Figure 60-70-31
Gasket Class and Average Piston Step
Thickness Height
Class A 0,77 mm 0,11 - 0,20 mm

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(0.0303 in) (0.0043 - 0.0079 in)
Class B 0,87 mm 0,20 - 0,30 mm
(0.0343 in) (0.0079 - 0.0118 in)
Class C 0,97 mm 0,30 - 0,39 mm
(0.0382 in) (0.0118 - 0.0154 in)

P114036

Remove the valves (Item 1) [Figure 60-70-31] from the

block.

60-70-9 E85 Service Manual

CYLINDER HEAD (CONT'D) Figure 60-70-33

Cylinder Head Inspection

Remove the valve and spring from the cylinder head.

(See Cylinder Head Disassembly And Assembly on Page
A
60-70-9.)
E F
Remove the carbon from the valve guide.
C D
Figure 60-70-32

1 B

PI-9988

Put the straight edge on the cylinder head’s four sides

and two diagonal as shown in figure [Figure 60-70-33].

2 The maximum distortion of the head surface is ± 0,05

mm in 100 mm (± 0.002 inches in 4.0 inches), If the
measurement exceeds the specification, replace the
cylinder head.
P-51629
Repeat the procedure on the intake and exhaust surface
of the head.
Put a straight edge (Item 1) [Figure 60-70-32] on the
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cylinder head.

NOTE: Do not put the straight edge across

combustion chambers.

Put a feeler gauge (Item 2) [Figure 60-70-32] between

the straight edge and the surface of the cylinder head.

60-70-10 E85 Service Manual

CYLINDER HEAD (CONT'D) Figure 60-70-35

Cylinder Head Top Clearance

Put the piston being checked at T.D.C.

Figure 60-70-34

1
1

P-85173

1
Remove the solder and measure it [Figure 60-70-35].
1
Top Clearance
P114045 1,12 - 2,29 mm
Intake Valve
(0.0441 - 0.0902 in)
1,44 - 2,58 mm
Place four pieces of 3 mm (0.118 in) solder on the piston Exhaust Valve
(0.0567 - 0.1016 in)
where shown (Item 1) [Figure 60-70-34].

Turn the piston to B.D.C.

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Install the cylinder head and bolts. Torque the bolts in the
correct sequence.

Rotate the crankshaft.

60-70-11 E85 Service Manual

CYLINDER HEAD (CONT'D) Valve Stem Height

Valve Step Height Figure 60-70-37

Figure 60-70-36

P114043

P114044
Measure the valve stem height from the valve to the
cylinder head as shown [Figure 60-70-37].
Measure the valve at four points as shown [Figure 60-
70-36]. Valve Stem Height
17,0 - 17,5 mm
Valve Step Height Intake Valve
(0.6692 - 0.6890 in)
0,6 - 1,8 mm 17,1 - 17,6 mm
Intake Valve Exhaust Valve
(0.0236 - 0.0709 in) (0.6732 - 0.6929 in)
0,9 - 1,5 mm
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Exhaust Valve
(0.0354 - 0.0591 in)

60-70-12 E85 Service Manual

CYLINDER HEAD (CONT'D) Valve

Valve Guide Figure 60-70-39

Figure 60-70-38

P114056

P114042
Measure the overall length of the valve [Figure 60-70-
39].
Measure the valve guide (Item 1) [Figure 60-70-38]
inside diameter at three different depths. Valve Length
Intake Valve 104,53 mm (4.1153 in)
7,0 - 7,015 mm
Valve Guide ID Exhaust Valve 106,33 mm (4.1862 in)
(0.2756 - 0.2762 in)
Measure the outside diameter of the valve stem [Figure
Measure the valve guide length.
60-70-39].

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43,4 - 43,6 mm
Valve Guide Length 6,97 ± 0,007 mm
(1,7087 - 1,7165 in) Valve Stem O.D.
(0.2744 ± 0.0003 in)

60-70-13 E85 Service Manual

CYLINDER HEAD (CONT'D)

Valve Spring

Figure 60-70-40

B-3680

Measure the length of the valve spring. If the

measurement is less than the allowable limit, replace the
spring [Figure 60-70-40].

Free Length 35,4 - 35,9 mm (1.40 - 1.41 in)

Put the spring on a flat surface, place a square on the

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side of the spring [Figure 60-70-40].

Rotate the spring and measure the maximum tilt. If the

measurement exceeds the allowable limit, replace the
spring.

Tilt Allowable Limit 1,8 mm (0.0708 in)

60-70-14 E85 Service Manual

CYLINDER HEAD (CONT'D) Figure 60-70-43

Rocker Arm Shaft Disassembly And Assembly

Figure 60-70-41

1 1

P114011

2
Remove the mount (Item 1) [Figure 60-70-43]. Continue
P114009 to remove the rocker arms, springs and mounts.

Figure 60-70-44
Remove the bolt (Item 1) and mount (Item 2) [Figure 60-
70-41].

Figure 60-70-42

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2

P114012
1

Remove the bolt (Item 1) [Figure 60-70-44] and the

P114010 mount from the shaft.

Remove the rocker arm (Item 1), spring (Item 2), and
rocker arm (Item 3) [Figure 60-70-42].

60-70-15 E85 Service Manual

CYLINDER HEAD (CONT'D) Push Rod Inspection

Rocker Arm Shaft Inspection Figure 60-70-47

Figure 60-70-45

1
1 P-76926

P114054
Place the push rod on V blocks and measure the
alignment [Figure 60-70-47].
Inspect the wear points (Item 1) [Figure 60-70-45] for
wear and change. Push Rod Alignment 0,5 mm (0.0207 in)
Measure the ID of the rocker arms (Item 2) [Figure 60-
70-45].

Rocker Arm ID 15,98 mm (0.6291 in)

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Figure 60-70-46

P114055

Inspect the shaft (Item 1) [Figure 60-70-46] for wear and

damage.

Measure the OD of the shaft.

Rocker Arm Shaft OD 16 mm (0.6299 in)

60-70-16 E85 Service Manual

CRANKSHAFT AND PISTONS Figure 60-80-2

Piston And Connecting Rod Removal And

Installation

Remove the cylinder head. (See Cylinder Head Removal

And Installation on Page 60-70-5.) 1
Remove the top edge from the cylinder bore with a ridge 2
reamer.

Remove the oil pan and oil pump strainer. (See Oil Pan
Removal And Installation on Page 60-50-2.)

Figure 60-80-1
P112954

Remove the cap (Item 1) and bearing (Item 2) [Figure

60-80-2].

Figure 60-80-3
1

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P112953

Remove the connecting rod bolts (Item 1) [Figure 60-80-

1].

Installation: Tighten the bolts to an initial torque of 19,6

N•m (14.5 ft-lb). Tighten the bolts an additional 90°. P112955

NOTE: The rod bolts are a one time use bolt. Use new
bolts when installing the connecting rods. Remove the piston / connecting rod (Item 1) [Figure 60-
80-3] from the cylinder block.

NOTE: Install the piston / connecting rod assembly in

to the bore it was removed from.

Repeat the procedure to remove the remaining piston /

connecting rod assemblies.

60-80-1 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-6

Piston And Connecting Rod Inspection

Figure 60-80-4
1

2
2

P114005

1 Remove the connecting rod (Item 1) [Figure 60-80-6]

P114003 from the piston.

Installation: The mark (Item 2) on the piston and

Remove the bearings (Item 1) [Figure 60-80-4] from the connecting rod must be on the same side. When
rod and cap. installing the piston in the cylinder block, the marks (Item
2) [Figure 60-80-6] go the flywheel side of the engine.
NOTE: The yellow code 1,489 - 1,502 mm (0.0590 -
0.0591 in) bearing is the only service bearing Figure 60-80-7
available.
1
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The rod and cap are a fracture design. The cap can only
fit the rod in one direction and is not interchangeable with
other rods.

Figure 60-80-5

1 1 1
P114007

Remove the rings (Item 1) [Figure 60-80-7].

P114004

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

[Figure 60-80-5].

60-80-2 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-10

Piston And Connecting Rod Inspection (Cont’d)

Figure 60-80-8

1
P114052

Remove the carbon from the ring grooves. Measure the

P114008 clearance between the ring and groove with a feeler
gauge [Figure 60-80-10].

Installation: Install the rings with the R (Item 1) [Figure Top Ring 0,083 - 0,133 mm
60-80-8] towards the top of the piston. Install the rings (0.0033 - 0.0052 in)
with the ring gap 120° apart.
Second Ring 0,07 - 0,110 mm
(0.0028 - 0.0043 in)
Figure 60-80-9
Oil Ring 0,03 - 0,07 mm
(0.0012 - 0.0028 in)

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P114053

Install a piston ring into the lower part of the cylinder

bore. Measure the ring gap with a feeler gauge [Figure
60-80-9].

Top Ring Gap 0,2 - 0,3 mm

(0.0079 - 0.0118 in)
Second Ring End Gap 0,55 - 0,70 mm
(0.0217 - 0.0276 in)
Oil Ring End Gap 0,2 - 0,4 mm
(0.0079 - 0.0157 in)

60-80-3 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-13

Crankshaft Removal And Installation

Figure 60-80-11

1
2
1

P112957

1
Remove the crankcase (Item 1) [Figure 60-80-13].
P112956
Installation: Apply Loctite® 5900 on the sealing edge of
the crankcase.
Remove the main bearing bolts (Item 1) and crankcase
bolts (Item 2) [Figure 60-80-11]. Figure 60-80-14

Figure 60-80-12
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26 22 18 14 11 15 19 23

8 4 1 5 9

1
7 3 2 6 10

25 21 17 13 12 16 20 24
P114017

P114438
Remove the oil seal (Item 1) [Figure 60-80-14] from the
rear of the crankshaft.
Installation: Tighten the main bearing bolts (Item 1 - 10)
[Figure 60-80-12] to an initial torque of 54 N•m (40 ft-lb)
torque in the order shown. After the initial torque, tighten
the main bearing bolts an additional 90°. Tighten the
main bearing bolts a second time by an additional 90°.

Installation: Tighten the crankcase bolts (Item 11 - 26)

[Figure 60-80-12] 22 N•m (16 ft-lb) torque in the order
shown.

60-80-4 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-17

Crankshaft Removal And Installation (Cont’d)

Figure 60-80-15
1

1
B114019

Remove the thrust bearings (Item 1) [Figure 60-80-17].

B112958
Figure 60-80-18

Remove the crankshaft (Item 1) [Figure 60-80-15].

Figure 60-80-16

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1

1 1

P114024

Remove the bolts / check valves (Item 1) [Figure 60-80-

P114018 18] and remove the oilers.

Installation: Tighten the bolts to 20 N•m (14 ft-lb) torque.

Remove the crankshaft bearings (Item 1) [Figure 60-80-
16].

Installation: Install the bearing with the grove in the

cylinder block. The non-grooved bearing is installed in the
crankcase.

60-80-5 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D)

Crankshaft Removal And Installation (Cont’d)

Figure 60-80-19

2
1

P114026

Remove the bolt / check valve assembly (Item 1) from the

oiler (Item 2) [Figure 60-80-19].

Figure 60-80-20
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P114022

Remove the cam bearings (Item 1) [Figure 60-80-20].

Installation: Install the cam bearings with the holes in

the bearing lined up with the oil passage in the cylinder
block.

60-80-6 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-23

Cylinder Block Inspection

Figure 60-80-21

P114050

Measure the cylinder block bore [Figure 60-80-23].

P114038
Figure 60-80-24

With the bearings and crankcase installed, measure the

main journal bearings [Figure 60-80-21].

Figure 60-80-22

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P-37163

Measure the bore at three different depths and at two

points 90° apart [Figure 60-80-24].
P114039
Cylinder Block Bore 89,990 - 90,010 mm
(3.5429 - 3.5437 in)
Measure each bearing at three different points [Figure
60-80-22]. For detailed cylinder block dimensions: (See Engine
Component Class on Page 60-80-10.)
Main Journal Bearing I.D. 62 - 62,021 mm
(2.4409 - 2.4418 in)

For detailed cylinder block dimensions: (See Engine

Component Class on Page 60-80-10.)

60-80-7 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D)

Cylinder Block Inspection (Cont’d)

Figure 60-80-25

P114040

Measure the three camshaft bushings [Figure 60-80-25].

Figure 60-80-26
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P114041

Measure the bearings in three different locations [Figure

60-80-26].

60-80-8 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Connecting Rod Inspection

Crankshaft Inspection Figure 60-80-29

Figure 60-80-27

P114436

P114435
Measure the I.D. of the connecting rod small end bore.
Measure the O.D. of the piston pin and the I.D. of the
Place the crankshaft on a set of V blocks. Set a dial
piston pin bore [Figure 60-80-29].
indicator on a main bearing journal. Spin the crankshaft
to determine the crankshaft warpage [Figure 60-80-27].
Connecting Rod Small 31,025 - 31,038 mm
End Bore (1.2215 - 1.2220 in)
Crankshaft Warpage
Piston Pin O.D. 30,995- 31,000 mm
Number 3 Main Journal 0,03 mm (0.0012 in)
(1.2203 - 1.2205 in)
Number 2 & 4 Main Journal 0,02 mm (0.0008 in)
Piston Pin Bore 31,008 - 31,014 mm

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(1.2218 - 1.2210 in)
Figure 60-80-28
Figure 60-80-30

P114433

P114437
Measure the crankshaft main journals and rod journals
[Figure 60-80-28].
Measure the I.D. of the connecting rod large end bore
Main Journal Diameter 57,955 - 57,970 mm [Figure 60-80-30]. Measure the bore in three different
(2.2817 - 2.2823 in) locations

Rod Journal Diameter 53,955 - 53,970 mm Connecting Rod Large 57,000 - 57,015 mm
(2.1242 - 2.1248 in) End Bore (2.2440 - 2.2447 in)

For detailed crankshaft dimensions: (See Engine For detailed connecting rod dimensions: (See Engine
Component Class on Page 60-80-10.) Component Class on Page 60-80-10.)

60-80-9 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) The connecting rod bearings are available as a service
part in one class and are coded with yellow markings.
Engine Component Class
Connecting Rod Bearing 1,498 - 1,502 mm
The pistons, connecting rods, connecting rod bearings, (0.0590 - 0.0591 in)
crankshaft, crankshaft bearings and cylinder block are
available in different classes. The class is determined by Figure 60-80-33
the size of the components and is engraved or color
coded on the component.

Figure 60-80-31 1

1 2

P114051

The crankshaft serial number (Item 1) and main journal

P114059 diameter class (Item 2) [Figure 60-80-33] is engraved on
the flywheel end of the crankshaft.

The piston is engraved with “A” or “B” (Item 1) [Figure Crankshaft Main Journal Diameter
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60-80-31].
Class A 57,995 - 57,960 mm
(2.2817 - 2.2819 in)
Class A 89,920 - 89,930 mm
(3.5402 - 3.5406 in) Class B 57,960 - 57,965 mm
(2.2819 - 2.2821 in)
Class B 89,930 - 89,940 mm
(3.5406 - 3.5409 in) Class C 57,965 - 57,970 mm
(2.2821 - 2.2823 in)
Figure 60-80-32
Crankshaft Bearing Thickness / Color
Blue 1,995 - 2,000 mm
(0.0785 - 0.0787 in)
1 Yellow 2,000 - 2,005 mm
(0.0787 - 0.0789 in)
Red 2,005 - 2,010 mm
(0.0789 - 0.0791 in)

P114058

The connecting rod is engraved on the cap (Item 1)

[Figure 60-80-32]. This letter / number must be used to
order replacement rod assemblies.

60-80-10 E85 Service Manual

CRANKSHAFT AND PISTONS (CONT’D)

Engine Component Class (Cont’d)

Figure 60-80-34

P114060

The cylinder block bearing bore class (Item 1) [Figure

60-80-34] is engraved on the flange of the crankcase.

Cylinder Block Main Journal Diameter

Class A 62,000 - 62,007 mm
(2.4409 - 2.4412 in)
Class B 62,007 - 62,014 mm

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(2.4412 - 2.4415 in)
Class C 62,014 - 62,021 mm
(2.4415 - 2.4418 in)

When replacing crankshaft bearings, use the chart

below.

Cylinder Block Crankshaft Main Journal 

Main Journal Diameter
Diameter Class A Class B Class C
Class A Yellow Blue Blue
Bearing Bearing Bearing
Class B Yellow Yellow Blue
Bearing Bearing Bearing
Class C Red Red Yellow
Bearing Bearing Bearing

60-80-11 E85 Service Manual

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60-80-12
E85 Service Manual
CAMSHAFT Figure 60-90-3

Removal And Installation

Remove the gearcase cover. (See Gearcase Cover 1

Removal And Installation on Page 60-100-1.)

Remove the rocker arms and push rods. (See Rocker

Arm Shaft Disassembly And Assembly on Page 60-70-
15.)

Remove the oil pan. (See Oil Pan Removal And

Installation on Page 60-50-2.)

Figure 60-90-1
P114023

Remove the valve tappets (Item 1) [Figure 60-90-3].

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P114020

Remove the bolts (Item 1) [Figure 60-90-1].

Installation: Tighten the bolts to 22 N•m (16 ft-lb) torque.

NOTE: Before removing the camshaft, measure the

camshaft end play. (See Inspecting on Page
60-90-2.)

Figure 60-90-2

1
P114021

Remove the camshaft (Item 1) [Figure 60-90-2].

60-90-1 E85 Service Manual

CAMSHAFT (CONT’D) Figure 60-90-6

Inspecting

Figure 60-90-4

P114046

Measure the three camshaft journals. Measure each

P114049 journal in two different areas 90° apart [Figure 60-90-6].

Camshaft Journal 44,95 - 44,966 mm

Measure the gap between the thrust washer and the gear (1.7697 - 1.7703 in)
[Figure 60-90-4].
Figure 60-90-7
Thrust washer to 0,1 - 0,2 mm
gear clearance (0.0039 - 0.0079 in)

Figure 60-90-5
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3
2
1

P114047

Place the camshaft on V Blocks. Set up a dial indicator

P114476 as shown [Figure 60-90-7].

Rotate the camshaft and record the warpage of the

Remove the gear (Item 1), thrust washer (Item 2), and camshaft.
key (Item 3) [Figure 60-90-5].
Camshaft warpage 0,01 mm
Installation: Heat the camshaft gear to 170 - 190°C (338 (0.0004 in)
- 374°F) and press the gear on to the camshaft.

60-90-2 E85 Service Manual

CAMSHAFT (CONT’D)

Inspecting (Cont’d)

Figure 60-90-8

P114020

With the camshaft (Item 1) [Figure 60-90-8] installed,

use a dial indicator to measure camshaft end play.

Camshaft end play 0,1 - 0,2 mm

(0.0039 - 0.0079 in)

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60-90-3 E85 Service Manual

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60-90-4
E85 Service Manual
GEARCASE Figure 60-100-3

Gearcase Cover Removal And Installation

Figure 60-100-1

P112942
1

Remove the bolts and remove the gearcase cover (Item

P112940 1) [Figure 60-100-3].

Installation: Apply Loctite® 5900 to the sealing flange of

Remove the bolt (Item 1) [Figure 60-100-1] from the the cover. Tighten the bolts to 22 N•m (16 ft-lb) torque.
crank shaft.
Figure 60-100-4
Installation: Apply Loctite® 587 to the bolt flange.
Tighten the bolt to 255 N•m (188 ft-lb) torque.

Figure 60-100-2

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1

1
2
P112943

Remove the seal (Item 1) [Figure 60-100-4].

P112941

Remove the pulley (Item 1) and key (Item 2) [Figure 60-

100-2] from the crankshaft.

60-100-1 E85 Service Manual

GEARCASE Gear Backlash

Gearcase Cover Removal And Installation (Cont’d) Figure 60-100-6

Figure 60-100-5

1
4

1
2
3
2 P114013

P112945
Using a dial indicator, test the backlash between the fuel
injection pump gear (Item 1) to idle gear (Item 2), idle
Remove the pin (Item 1) and timing wheel (Item 2) gear to crankshaft gear (Item 3), idle gear to camshaft
[Figure 60-100-5] from the crank shaft. (Item 4) [Figure 60-100-6], and crankshaft gear to oil
pump gear.

Fuel injection pump gear 0,087 - 0,2 mm

to idle gear (0.0034 - 0.008 in)
Idle gear to crankshaft 0,087 - 0,2 mm
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gear (0.0034 - 0.008 in)

Idle gear to camshaft gear 0,0087 - 0,211 mm
(0.0034 - 0.008 in)
Crankshaft gear to oil 0,06 - 0,259 mm
pump gear (0.0024 - 0.10 in)

60-100-2 E85 Service Manual

GEARCASE (CONT’D) Figure 60-100-9

Gear Timing
2
Figure 60-100-7

4
1
P114015
1
2
3 Idle gear (Item 1) to camshaft gear (Item 2) [Figure 60-
P114013 100-9].

Figure 60-100-10
The fuel injection pump gear (Item 1), idle gear (Item 2),
crankshaft gear (Item 3), and camshaft gear (Item 4)
[Figure 60-100-7] have timing marks. Align the marks
when assembling the gears. 2

Figure 60-100-8

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2

P114016

Idle gear (Item 1) to crankshaft gear (Item 2) [Figure 60-

100-10].
1
P114014

Fuel injection pump (Item 1) to idle gear (Item 2) [Figure

60-100-8].

60-100-3 E85 Service Manual

GEARCASE (CONT’D) Idle Gear Inspection

Idle Gear Removal And Installation Figure 60-100-12

Figure 60-100-11

1 1 2
3
P114057

P112944
Measure the inside diameter of the idle gear (Item 1)
[Figure 60-100-12] at four different points, on either side
Remove the bolts (Item 1), idle gear shaft (Item 2) of the bearing lubrication channel.
[Figure 60-100-11] and the idle gear (Item 3).
Idle Gear I.D. 64 - 64,019 mm
Installation: Tighten the bolts to 43 N•m (32 ft-lb) torque. (2.5197 - 2.5204 in)

Measure the outside diameter of the idle gear shaft (Item

2) [Figure 60-100-12] at four different points on either
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side of the lubrication port.

Idle Gear Shaft O.D. 59,921 - 59,940 mm

(2.3591 - 2.3598 in)

60-100-4 E85 Service Manual

TURBOCHARGER Figure 60-110-2

Description
1
The turbocharger is placed between the exhaust and
intake manifolds. It is driven by hot exhaust gases and 2
supplies air at more than atmospheric pressure to the
intake. It is lubricated by oil from the main galley. The
location of the turbo is between the engine and the
blower housing.
1
Figure 60-110-1

P128513

1 Remove the nuts on the exhaust pipe (Item 1) and

remove the pipe (Item 2) [Figure 60-110-2].

2 Installation: Tighten the nuts (Item 1) [Figure 60-110-2]

to 22 N•m (16 ft-lb) torque.

Figure 60-110-3

1
P133337

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The oil is delivered to the turbocharger through a tubeline
(Item 1) and returns to the engine block through a drain 2
line (Item 2) [Figure 60-110-1].

The turbocharger internal components are not

serviceable.

Removal And Installation

Remove the left side panel.

P114714
Remove the air cleaner assembly. (See AIR CLEANER
on Page 60-30-1.)
Remove the turbo hose inlet (Item 1) [Figure 60-110-3]
Remove the DOC assembly. (See Removal And and plug the turbo inlet.
Installation on Page 60-20-1.)
Remove the breather hose (Item 2) [Figure 60-110-3].

60-110-1 E85 Service Manual

TURBOCHARGER (CONT’D) Figure 60-110-6

Removal And Installation (Cont’d)

Figure 60-110-4

P114716

Reposition the turbo drain tube hose clamp (Item 1)

P114713 [Figure 60-110-6] and remove the hose.

Remove the hose (Item 1) [Figure 60-110-4] and plug.

Figure 60-110-5
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P114715

Remove the turbo oil pressure line bolt (Item 1) [Figure

60-110-5] and plug ports.

NOTE: Replace the sealing copper washer on both

sides of the tubeline fitting.

Installation: Tighten the bolt to 17,6 - 19,7 N•m (13 - 15

ft-lb) torque.

60-110-2 E85 Service Manual

TURBOCHARGER (CONT’D)

Removal And Installation (Cont’d)

Figure 60-110-7

P114290

Figure 60-110-8

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1

P114291

Remove the four nuts (Item 1) [Figure 60-110-7] and

[Figure 60-110-8].

Installation: Tighten the nuts to 22 N•m (16 ft-lb) torque.

NOTE: Do not lift the turbocharger by the actuator.

The actuator may be damaged because of the
weight of the turbocharger.

Installation: Inject new oil into the oil inlet and spin
the turbine shaft to lubricate the bearings.

Remove the turbo and gasket.

60-110-3 E85 Service Manual

TURBOCHARGER (CONT’D) Figure 60-110-11

Inspection 1

Figure 60-110-9

1
P114283

Inspect the hose (Item 1) and linkage (Item 2) [Figure

P114284 60-110-11] for wear and damage.

Figure 60-110-10
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P114285

Move the compressor wheel (Item 1) [Figure 60-110-9]

and [Figure 60-110-10]. Inspect the compressor wheel
for radial and axial clearance.

If the wheel contacts the housing, replace the

turbocharger assembly with a new one.

60-110-4 E85 Service Manual

FLYWHEEL AND HOUSING Figure 60-120-2

Hydraulic Pump Coupler Removal And Installation

Open the tailgate. (See Opening And Closing on Page

10-50-1.)

Remove the counterweight. (See Removal And

Installation on Page 40-80-1.)

Drain the hydraulic reservoir. (See Removing And

Replacing The Hydraulic Fluid on Page 10-130-3.) 1

Remove the DOC. (See Removal And Installation on

Page 60-20-1.)
P133306
Remove the hydraulic pump. (See Removal And
Installation on Page 20-50-17.)
Slightly raise the flywheel end of the engine, and place a
Remove the starter. (See Removal And Installation on support (Item 1) [Figure 60-120-2] under the oil pan.
Page 50-40-2.)
Figure 60-120-3
Figure 60-120-1

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1
1

P133308
P133305

Remove the flywheel cover bolts (Item 1) [Figure 60-120-

Remove the nut (Item 1) [Figure 60-120-1] and bolt from 3].
the engine mount.

Installation: Tighten the bolt to 105 - 115 N•m (78 - 85 ft-

lb) torque.

60-120-1 E85 Service Manual

FLYWHEEL AND HOUSING (CONT’D) Figure 60-120-6

Hydraulic Pump Coupler Removal And Installation

(Cont’d)
1
Figure 60-120-4

1 P133311

Remove the flywheel housing (Item 1) [Figure 60-120-6].

P133309 Figure 60-120-7

Remove the two bolts (Item 1) and reposition the hoses /

bracket (Item 2) [Figure 60-120-4]. 1

Figure 60-120-5

1
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P128206

Remove the bolts (Item 1) [Figure 60-120-7] from the

1 hydraulic pump coupler.

P133310 Installation: Apply Loctite® 242 to the bolts. Tighten the

bolts to 35 - 39 N•m (25 - 28 ft-lb) torque.

Remove the flywheel housing bolts (Item 1) [Figure 60- Remove the hydraulic pump coupler.
120-4] from the back side of the engine.

Installation: Position the housing over the alignment

pins and tighten the bolts to 43 - 47 N•m (32 - 35 ft-lb)
torque.

60-120-2 E85 Service Manual

FLYWHEEL AND HOUSING (CONT’D) Ring Gear Removal And Installation

Flywheel Removal And Installation

Figure 60-120-8
WARNING
AVOID INJURY OR DEATH
1 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.
1 W-2019-0907

1 Figure 60-120-9

P128200

Remove the eight bolts (Item 1) [Figure 60-120-8] from

the flywheel.

Installation: Apply engine oil to the bolts and tighten to

67,8 N•m (50 ft-lb) torque plus 45° of added rotation in a
crisscross pattern.

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NOTE: Do not use an impact wrench. Serious
damage will occur. 1
P114378
Remove the flywheel.

The ring gear (Item 1) [Figure 60-120-9] on the flywheel

is an interference fit. Heat the ring gear enough to
expand the gear. Hit the ring gear evenly around the gear
to remove it from the flywheel.

Clean the outer surface of the flywheel thoroughly so the

new ring gear will fit smoothly onto the flywheel.

Clean the new ring gear and heat it to a temperature of

232 - 260°C (450 - 500°F).

Fit the ring gear over the flywheel. The gear must be
seated correctly.

60-120-3 E85 Service Manual

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60-120-4
E85 Service Manual
EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 60-130-2

Removal And Installation

WARNING
1
HOT SURFACES CAN CAUSE SERIOUS INJURY
• Do not touch.
• Allow to cool before servicing.
W-2533-1012

Drain the cooling system. (See Removing And Replacing

Coolant on Page 10-100-3.) P114716

Remove the air cleaner assembly. (See Housing

Removal And Installation on Page 60-30-1.) Remove the hose clamp (Item 1) [Figure 60-130-2] on
the turbo drain tube hose. Remove the tube and plug the
Remove the DOC assembly. (See Removal And hose.
Installation on Page 60-20-1.)
Figure 60-130-3
Figure 60-130-1

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1

P114332

P114713

Remove the bolt (Item 1) [Figure 60-130-3] and plug the

Remove the hose (Item 1) from the turbo and plug. port in the block.
Remove the bolts (Item 2) [Figure 60-130-1] from the
turbo drain tube and plug the port in the turbo. NOTE: Replace the sealing copper washer on both
sides of the tubeline fitting.

Installation: Tighten the bolt to 17,6 - 19,7 N•m (13 - 15

ft-lb) torque.

60-130-1 E85 Service Manual

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 60-130-6
(CONT'D)

Removal And Installation (Cont’d)

Figure 60-130-4 1

P114328

Remove the exhaust temperature sensor (Item 1)

[Figure 60-130-6].
P114715

Figure 60-130-7

Remove the bolt (Item 1) [Figure 60-130-4] and plug the

port in the turbo. Remove the oil feed line.

NOTE: Replace the sealing copper washer on both

sides of the tubeline fitting.
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Installation: Tighten the bolt to 17,6 - 19,7 N•m (13 - 15

ft-lb) torque.

Figure 60-130-5 2
1

P133393

1
Slide the lock tab (Item 1) down and remove the wire
harness (Item 2) [Figure 60-130-7].
1

P114328

Remove the hoses (Item 1) [Figure 60-130-5].

60-130-2 E85 Service Manual

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 60-130-10
(CONT'D)

Removal And Installation (Cont’d)

Figure 60-130-8

1
P114145

Figure 60-130-11

P133394

Figure 60-130-9

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1
1

P114330

Remove the bolts (Item 1) [Figure 60-130-10] and

[Figure 60-130-11].
P114331
Installation: Tighten the bolts to 22 N•m (16 ft-lb).

Remove the coolant tube bolts (Item 1) [Figure 60-130- Remove the EGR assembly.
8] and [Figure 60-130-9].

Installation: Tighten bolts to 22 N•m (16 ft-lb) torque.

60-130-3 E85 Service Manual

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60-130-4
E85 Service Manual
HEATING, VENTILATION AND AIR CONDITIONING

AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6

REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Cab Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1
Air Conditioning Compressor Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2
Air Conditioning Compressor Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-3
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-3
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-3
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-5

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 70-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 70-30-1
The Compressor Operates Improperly Or Not At All . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-2
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-3
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-4

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HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-4
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-5
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-7

SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Refrigerant Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 70-40-3

COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-2
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3

CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2

EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

70-01 E85 Service Manual

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-2

EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1

HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1

HVAC DUCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-1
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70-02 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW

Description

In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.

The compressor (Item 1) Page 70-10-3 takes in heated, low pressure refrigerant gas through the suction valve (low
pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge valve
(high pressure side) on the condenser (Item 2) Page 70-10-3.

Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.

The liquid refrigerant moves on to the receiver / drier (Item 3) Page 70-10-3 where impurities such as moisture and dirt
are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid refrigerant (still
under high pressure) flows to the expansion valve (Item 4) Page Page 70-10-3.

The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) Page 70-10-3. As the refrigerant
passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-pressure liquid
and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the evaporator. The hot
humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan (Item 6) Page 70-10-
3. Since the refrigerant is colder than the air, it absorbs the heat from the air and produces cooled air, which is pushed into
the cab by the fan. The moisture in the air condenses on the evaporator coil and drips into the drain pan, which directs the
water out of the cab.

The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

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70-10-1 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D)

Chart

Thermostat
Cold Air
Evaporator

5
Evaporator
4 Expansion Valve

Blower 6
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1 Compressor

2 Condenser
Pressure
Switch
Sight
Glass

Fan
Desiccant

3 Receiver Drier

High Pressure Gas Low Pressure Liquid

High Pressure Liquid
Low Pressure Gas

70-10-2 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 70-10-3

Components

Figure 70-10-1

1 1

P131790

Receiver / Drier: The receiver / drier (Item 1) [Figure 70-

P131870 10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 70-10-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the
system. It raises the pressure of the refrigerant for heat Figure 70-10-4
transfer through the condenser and evaporator.

NOTE: The A/C system (Compressor) is 1

recommended to be turned on for at least 5

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minutes weekly throughout the year to
lubricate the internal components.

Figure 70-10-2

P113084
1

Evaporator / Heater Unit: The evaporator / heater unit

(Item 1) [Figure 70-10-4] is located in the excavator cab.
The unit delivers cold air for the A/C and warm air for heat
into the cab. The unit contains the blower, heater coil,
evaporator coil, and thermostat.
P131869

Condenser: The condenser (Item 1) [Figure 70-10-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

70-10-3 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 70-10-7

Components (Cont’d)
4
Figure 70-10-5 1

3
1

P112874

Control Panel: The panel (Item 1) [Figure 70-10-7] has

P111416
three separate components.

Fan Switch: This is a four position rotary switch (Item 2)

Expansion Valve: The expansion valve (Item 1) [Figure [Figure 70-10-7]. When the fan switch is in the off
70-10-5] controls the amount of refrigerant entering the position the A/C will not engage, but the heat valve will
evaporator coil. The expansion valve is located inside the operate, as it is controlled by the ignition power.
HVAC box.
A/C Switch: The rocker switch (Item 3) [Figure 70-10-7]
Figure 70-10-6 will be illuminated when the A/C is engaged.
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Potentiometer: The potentiometer (Item 4) [Figure 70-

2
10-7] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.

3
1

P112875

Thermostat: The thermostat (Item 1) [Figure 70-10-6]

controls the temperature of the evaporator coil.

Heater Coil: The heater coil (Item 2) [Figure 70-10-6]

supplies the warm air into the cab by passing air through
the coil.

Evaporator Coil: The evaporator coil (Item 3) [Figure 70-

10-6] cools and dehumidifies the air before it enters the
cab.

Heater / Evaporator Blower: The blower (Item 4) [Figure

70-10-6] is used to push air through the heater and
evaporator coils and into the cab.

70-10-4 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D)

Components (Cont’d)

Figure 70-10-8

P131789

Heater Valve: The heater valve (Item 1) [Figure 70-10-8]

is used to control the amount of engine coolant that flows
to the heater coil.

The heater valve is located above of the battery.

Figure 70-10-9

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1

P131790

Low Pressure / High Pressure Switch: The pressure

switch (Item 1) [Figure 70-10-9] will disengage the
compressor clutch at high pressure readings over 2500 -
2900 kPa (25 - 29 bar) (362.6 - 420.6 psi) on the high
side. The clutch will engage when the pressure is at 1900
- 2300 kPa (19 - 23 bar) (275.6 - 333.6 psi).

The pressure switch (Item 1) [Figure 70-10-9] will

disengage the compressor clutch at low pressure
readings below 180 - 220 kPa (1,8 - 2,2 bar) (26.1 - 31.9
psi) on the low side. The clutch will engage when the
pressure is at 117 - 186 kPa (1,2 - 1,9 bar) (17 - 27 psi).

70-10-5 E85 Service Manual

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 70-10-11

Safety Equipment

In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.

Figure 70-10-10

P-16399

If it spills on your skin or in your eyes you should flood the

area with cool water and SEEK MEDICAL ATTENTION
FAST! It is a good idea to wear gloves [Figure 70-10-11]
to prevent frost bite if you should get refrigerant on your
hands.

P-16398

In addition to exercising caution in your work, DO WEAR

WARNING
SAFETY GLASSES OR A FACE SHIELD [Figure 70-
HFC R-134a refrigerant can be dangerous if not
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10-10] when you are using R-134a or a leak detector,

adjusting service valves or the manifold gage set properly handled. Liquid R-134a may cause
connectors. Safety glasses or a transparent face shield blindness if it contacts the eyes and may cause
are practical safety items and one or the other is serious frostbite if it contacts the skin.
absolutely required. • Gaseous R-134a becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
WARNING even small amounts of R-134a in the air.
Any servicing work that involves release or addition
of R-134a to the system must be done by a
In the event of a leak, wear safety goggles. Escaping competent refrigeration dealer who has the proper
refrigerant can cause severe injuries to eyes. In equipment, knowledge, and experience to service
contact with a flame, R-134a refrigerant gives a toxic refrigeration equipment.
gas. W-2373-0611
W-2371-0611

R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -5,7°C (21.6°F)
“INSTANTLY”.

70-10-6 E85 Service Manual

REGULAR MAINTENANCE Fresh Air Filter

Cab Filters Figure 70-20-3

Cleaning And Maintenance

The recirculation filter and the fresh air filter must be 1 2

cleaned regularly. (See SERVICE SCHEDULE on Page
10-70-1.)

The recirculation filter is located to the right of the

operator seat and the fresh air filter is located under the
right side cover.

Recirculation Filter

P132080
Figure 70-20-1
The fresh air filter is located under the center cover.

Remove the center cover. (See CENTER COVER on

Page 40-220-1.)

Pull out on the tab (Item 1) and remove the cover (Item 2)
[Figure 70-20-3].

1 Figure 70-20-4

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1
P128579

The recirculation filter (Item 1) [Figure 70-20-1] is

located to the right of the operator’s seat.

Figure 70-20-2

P132081
1
Pull the filter (Item 1) [Figure 70-20-4] out of the housing.
Shake the filter or use low pressure air to clean the filter.
Do not use solvents. Replace the filter when very dirty or
damaged.

Installation: Position the filter (Item 1) [Figure 70-20-2]

into the housing and slowly push the filter in fully.
P128580
Place the bottom tabs of the filter cover (Item 2) into the
Pull up on the filter (Item 1) [Figure 70-20-2] until frame and push the top in until the tab (Item 1) [Figure
removed from the housing. 70-20-3] locks to the frame.

NOTE: Do not use a brush on the filter as it can push

Shake the filter or use low pressure air to clean the filter.
debris into the filter. Gently tap the sides of
Replace the filter when very dirty or if damaged. the filter and / or use low pressure
compressed air from the back side of the filter
Installation: Position the bottom of the filter (Item 1) to remove debris. If the filter is damaged,
[Figure 70-20-2] into the housing and slowly push the replace the filter.
filter down fully.

70-20-1 E85 Service Manual

REGULAR MAINTENANCE (CONT’D) Figure 70-20-6

Air Conditioning Compressor Belt Adjustment

The belt is a special maintenance free type that is

pretensioned over the pulleys. This belt eliminates the
need for a tensioning device and does not require 1
periodic adjustment.

Air Conditioning Compressor Belt Replacement

Removal

Figure 70-20-5

P-97152

Use a pry bar (Item 1) [Figure 70-20-6] to push the belt

off of the pulley. Using a pry bar on the flywheel, rotate
1 the engine by hand to push the belt off the crankshaft
pulley. Continue to rotate the flywheel until the belt is
loose. Remove the belt.

Installation

Figure 70-20-7

P133125
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The engine will need to be rotated by hand to remove the

belt. To access the flywheel, remove the plug (Item 1)
1
[Figure 70-20-5] from the flywheel housing.

P-97153

Position the belt (Item 1) [Figure 70-20-7] over the

crankshaft pulley and to the compressor pulley.

Use a pry bar (Item 2) [Figure 70-20-7] to position the

belt on the pulley while using the second pry bar at the
flywheel to rotate the engine by hand.

Continue to rotate the engine by hand until the belt is fully

on the pulleys.

Reinstall the rubber plug (Item 1) [Figure 70-20-5].

Close the tailgate.

70-20-2 E85 Service Manual

REGULAR MAINTENANCE (CONT’D) Use low pressure or low water pressure to clean the fuel
cooler (Item 1), the condenser (Item 2) (if equipped), and
Condenser the radiator / charged air / oil cooler (Item 3) [Figure 70-
20-9]. Be careful not to damage fins when cleaning.
Open the tailgate. (See Opening And Closing on Page
10-50-1.) Reposition the condenser (Item 2) (if equipped) and the
fuel cooler (Item 1) [Figure 70-20-9] to the radiator / oil
Open the right side cover. (See RIGHT SIDE COVER on cooler. Be careful not to damage fins.
Page 10-60-1.)
Install and tighten the knob (Items 1 and 2) [Figure 70-
NOTE: Allow the cooling system and engine to cool 20-9].
before servicing or cleaning the cooling
system. Air Conditioning Lubrication

Figure 70-20-8 Run the air conditioning for about five minutes every
week to lubricate the internal components.

2 Evaporator / Heater Coil

Remove the floor mat. (See Removal And Installation on

Page 40-100-1.)
1
Figure 70-20-10

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P132028

Remove the knob (Item 1) from the fuel cooler and from
the air condition condenser (Item 2) [Figure 70-20-8] (if
equipped).

Figure 70-20-9
P128638

3
Pull back on the two latches (Item 1) [Figure 70-20-10]
and remove the HVAC side cover.

To allow water to drain from the HVAC housing during the

cleaning process, it is recommended to rotate the
upperstructure 90° to the right. Then using the blade,
raise the front of the excavator to allow water to run out of
1 the housing. Use jackstands to support the front of the
upperstructure.
2

P132029

Tilt the fuel cooler (Item 1) and / or the condenser (Item

2) (if equipped) from the radiator / charged air / oil cooler
(Item 3) [Figure 70-20-9]. Be careful not to damage fins.

70-20-3 E85 Service Manual

REGULAR MAINTENANCE (CONT’D) Figure 70-20-12

Evaporator / Heater Coil (Cont’d)

1
Figure 70-20-11 1 1

1
1

P113083A

NOTE: The floor mat needs to be removed to allow

P113083 easier access for installing the HVAC side
cover.

Use a lower pressure air or a low pressure water stream Three tabs (Item 1) are on the bottom of the HVAC
to remove debris and to clean the coils (Item 1) [Figure housing that the side cover retainers (Item 2) [Figure 70-
70-20-11]. 20-12] fit into.

After the housing has been cleaned and flushed, remove Position the side cover on the tabs and starting with the
the jackstands and raise the blade so the front of the front edge of the side cover, position it into the front of the
excavator is flat on the ground. Stop the engine. HVAC housing. Press on the front of the cover to secure
the front latch (Item 1) [Figure 70-20-10]. Then press in
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There are three rubber drain valves that allow on the top edge of the side cover and work back to the
condensation to drain from the housing during normal air rear of the cover and secure the rear latch.
conditioning usage. These drain valve can get clogged
with dirt and should be cleaned at the same time the Reinstall the floor mat.
housing is cleaned.

Two of the drain valve can be accessed from the right

side cover (the drain valves are located below the HVAC
housing on the right side) and one of the valves is located
below the left rear corner of the HVAC housing and will
be accessed by removing the center floorplate.

Pinch the three rubber drain valves on the flat sides to

open the valves and allow dirt and moisture to exit from
the end of the valves.

Reinstall the center floorplate and close the right side

cover.

70-20-4 E85 Service Manual

REGULAR MAINTENANCE (CONT’D)

Air Conditioning Service Chart

Service Company Name / Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:

Pre Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure:
Low Side Pressure:
Ambient Humidity:
Observations:

Explain services required:

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Post Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure:
Low Side Pressure:
Ambient Humidity:
Observations:

70-20-5 E85 Service Manual

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70-20-6
E85 Service Manual
TROUBLESHOOTING

Blower Motor Does Not Operate

POSSIBLE CAUSE INSPECTION SOLUTION

1. Blown Fuse Inspect the fuse / wiring Replace fuse / repair wiring
2. Broken wiring or bad Check the fan motor ground and connectors Repair the wiring or connector
connection
3. Fan Motor Malfunction Check the lead wires from the motor with a circuit Replace motor
tester
4. Resistor Malfunction Check resistor using a circuit tester Replace resistor
5. Fan motor switch Check power into and out of the fan switch Replace fan switch
malfunction

Blower Motor Operates Normally, But Air Flow Is Insufficient

POSSIBLE CAUSE INSPECTION SOLUTION

1. Evaporator inlet Check evaporator for plugging Remove the obstruction and clean
obstruction evaporator fins with air or water
2. Air leak Check to make sure air hoses are properly hooked Repair or adjust
to Louvers and air ducts
3. Defective thermo switch Check thermostat using a circuit tester Replace thermostat
(frozen evaporator)
4. Plugged cab filters Check cab recirculation and fresh air filters Clean or replace filters

Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

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POSSIBLE CAUSE INSPECTION SOLUTION
1. System low on refrigerant The high side pressure will be low and bubbles Repair any leaks and recharge the
may be present in sight glass on receiver / drier refrigerant to the correct level
2. Excessive Refrigerant The high pressure side will be high Use refrigerant recovery equipment
to capture excess refrigerant.
Charge to the correct refrigerant
level

The Compressor Operates Improperly Or Not At All

POSSIBLE CAUSE INSPECTION SOLUTION

1. Loose drive belt The belt is vibrating or oscillating Replace Belt
2. Internal compressor The compressor is locked up and the belt slips Replace compressor
malfunction
Magnetic Clutch Related
3. Low battery voltage Clutch slips Recharge the battery
4. Faulty coil Clutch slips Replace the magnetic clutch
5. Oil on the clutch surface Clutch slips Replace or clean the clutch surface
6. Open coil Clutch does not engage and there is not reading Replace clutch
when a circuit tester is connected between the coil
and terminals
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair
ground connections.
8. Wiring harness Test the conductance of the pressure switch, Check operation
components thermostat, relay, etc.

70-30-1 E85 Service Manual

TROUBLESHOOTING (CONT'D)

Gauge Pressure Related Troubleshooting

Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96°F)
and compressor speed of approximately 2000 rpm are:

High pressure side pressure: 1448 - 1827 kPa (14 - 18 bar) (210 - 265 psi)

Low pressure side pressure: 103 - 228 kPa (1 - 2 bar) (15 - 33 psi)

As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

POSSIBLE CAUSE INSPECTION SOLUTION

Low Pressure Side Too High The Low pressure side pressure normally becomes
too high when the high pressure side pressure is too
high. As this is explained below, the following
inspection is only used when the low pressure side is
too high.
1. Expansion valve opens too far Frost is present on the suction hose Replace the expansion valve
2. Defective compressor The high and low pressure side gauge pressures Replace compressor
equalize when the magnetic clutch is disengaged
Low Pressure Side Too Low
1. Low refrigerant charge The high side pressure will be low and bubbles may Repair any leaks and recharge
be present in sight glass on receiver / drier the refrigerant to the correct
level
2. Clogged or closed expansion The expansion valve’s inlet side is frosted. Moisture or Clean or replace the expansion
valve other contaminants can be the cause. valve
3. Restriction between drier and Frost on the line between drier and expansion valve. Flush system or replace hose
expansion valve A negative low pressure reading may be shown.
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4. Thermostat malfunction the evaporator is frozen Adjust thermostat’s temperature

setting or probe placement or
replace thermostat
5. Restriction in receiver dryer Excessive frost on receiver dryer Replace receiver dryer
High Pressure Side Too High
1. Poor condenser performance Dirty or clogged condenser fins. Condenser fans not Clean fins and / or repair the fan
operating.
2. Excessive refrigerant The high pressure side pressure will be high Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
3. Excessive oil charge The high pressure side will be high Evacuate system. Remove oil
from condenser and
compressor. Measure oil from
compressor and add correct oil
charge back into compressor.
Flush system with nitrogen.
Replace drier.
4. Air in system Pressure is high on both high and low sides Evacuate and recharge with
refrigerant
5. Restriction in drier, condenser, or High pressure side will be high and low pressure side Evacuate and flush system
high pressure line will be low replacing defective parts
High Pressure Side Too Low
1. Low refrigerant charge The high side pressure will be low and bubbles may Repair any leaks and recharge
be present in sight glass on receiver / drier the refrigerant to the correct
level.
System Pressure Equals
1. Clutch not operating See magnetic clutch related topics above
2. Compressor not pumping Equal high and low pressures Replace compressor

70-30-2 E85 Service Manual

TROUBLESHOOTING (CONT'D)

Temperature / Pressure Chart

Normal Evaporator Range Normal Condenser Range

TEMP F PSIG TEMP F PSIG
16 15.69 93 110.20
18 17.04 94 112.10
20 18.43 95 114.10
22 19.87 100 124.30
24 21.35 102 128.50
26 22.88 104 132.90
28 24.47 106 137.30
30 26.10 108 141.9
32 27.79 110 146.50
34 29.52 112 151.30
36 31.32 114 156.10
38 33.17 116 161.10
40 35.07 118 166.10
42 37.03 120 171.30
44 39.05 122 176.60
45 40.09 124 182.00
50 45.48 126 187.50
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00

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85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 165 320.10
92 108.20 170 340.80

Evaporator

Pressures represent gas temperatures inside the coil, not the coil surface. For an estimate of the temperature of the air
coming off the coil add -13 - -12°C (8 - 10°F) to the temperature on the chart.

Condenser

Temperatures are not ambient temperatures but condensing temperatures. Add 4°C (40°F) to the ambient temperature to
get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature.

Example: Ambient Temperature = 90°F

90°F
+ 40°F
130°F condenser temperature = 200 psig

Conditions and pressures will vary from system to system.

70-30-3 E85 Service Manual

TROUBLESHOOTING (CONT'D) Check the air conditioning compressor belt for wear or
damage. (See Air Conditioning Compressor Belt
Poor A/C Performance Replacement on Page 70-20-2.)

Start the excavator. Engage the A/C system with the Check the A/C evaporator coil for dirt or mud, and clean if
blower fan on high. Run the excavator at full RPM for necessary. (See Evaporator / Heater Coil on Page 70-20-
approximately 15 minutes, with the cab door closed. 3.)

Figure 70-30-1 Inspect the sight glass located on the receiver / drier for
air bubbles. (See Gauge Pressure Related
Troubleshooting on Page 70-30-2.)
1
Check the engine coolant to see if it is bypassing the
1 heater valve.

HVAC Repair And Leaks

Figure 70-30-3

1
P-97985

1
Figure 70-30-2
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P131790

Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver /
drier (Item 1) [Figure 70-30-3] must be changed.

Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.
N-22411

Check the temperature at the louvers (Item 1) [Figure

70-30-1] with a thermometer [Figure 70-30-2].

The louver temperature should be between 2,2 - 11,6°C

(36 - 53°F) depending on the amount of humidity in the
air.

If louver temperature is too high see the System

Troubleshooting Chart. (See Gauge Pressure Related
Troubleshooting on Page 70-30-2.)

Check the blower fan for proper operation, and replace if

necessary. (See Removal And Installation on Page 70-
130-1.)

70-30-4 E85 Service Manual

TROUBLESHOOTING (CONT'D) Figure 70-30-6

Electrical System

2 1
If the excavator A/C system shows no blower motor
function, no A/C switch light and no A/C compressor
function, do the following check:

Figure 70-30-4 3
4

P133023

Voltage at pin 30 (Item 1) [Figure 70-30-6] is 12 volts at

all times.

Voltage at pin 86 (Item 2) [Figure 70-30-6] is 12 volts

when the start key is in the on position.
P132034
Pin 85 (Item 3) [Figure 70-30-6] is ground. Check for
continuity to the ground.
Remove the two bolts and fuse / relay cover (Item 1)
[Figure 70-30-4]. With the key in the ON position, A/C switch ON, turn the
fan switch ON pin 87 (Item 4) [Figure 70-30-6] is ground.

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Figure 70-30-5 Turn the fan switch OFF, and there is no continuity.

Figure 70-30-7
3
1

1
P133022

P-93415
Check the HVAC fuse (Item 1) and controller fuse (Item
2) [Figure 70-30-5].
If the voltages and continuity checks are OK but the
Replace the fuse if burned out. If the fuses are good, problem still persists, replace the A/C relay (Item 1)
remove the relay (Item 3) [Figure 70-30-5]. [Figure 70-30-7].

Using a multimeter, check the voltage at the following Check to see if the compressor clutch is engaging.
relay terminals:
With a person in the operator seat and the cab door
open, turn the key switch to RUN (Standard panel) OR
press the RUN / ENTER Button (Deluxe Panel), without
starting the excavator.

70-30-5 E85 Service Manual

TROUBLESHOOTING (CONT'D) Figure 70-30-9

Electrical System (Cont’d)

Figure 70-30-8

P133126
2
1
Disconnect the wire harness (Item 1) [Figure 70-30-9].
P112874
NOTE: The counterweight is removed for photo
clarity.
Push the A/C switch (Item 1) to the ON position. Turn the
blower fan switch (Item 2) [Figure 70-30-8] to the first ON With a multimeter, check the resistance to the
position. compressor clutch.

The compressor clutch should make a click sound, which If there is no resistance value, replace the compressor.
indicates the clutch is engaging. (See Removal And Installation on page 70-140- 1.)
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NOTE: There is a time delay of 5 - 10 seconds until the With a multimeter, check the voltage to the compressor
clutch will engage. clutch at the wire harness.

If the voltage reading is approximately 12 volts, the

system is operating correctly.

If there is no power at the clutch, reconnect the wiring

harness to the compressor clutch.

70-30-6 E85 Service Manual

TROUBLESHOOTING (CONT'D)

Engine Coolant Bypassing The Heater Valve

Figure 70-30-10

P112874

Push the A/C switch (Item 1) to the OFF position. Turn

the fan switch (Item 2) to the High Speed position. Turn
the temperature control (Item 3) [Figure 70-30-10] to the
High A/C position, with the key switch OFF.

Start the excavator and run at high idle, for ten minutes.

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Figure 70-30-11

P112876

Check the temperature of the heater coil tubelines (Item

1) [Figure 70-30-11].

If the hoses are hot, the heater valve is leaking internally

and needs to be replaced.

70-30-7 E85 Service Manual

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70-30-8
E85 Service Manual
SYSTEM CHARGING AND RECLAMATION Figure 70-40-2

Refrigerant Identification
1
Figure 70-40-1

N-23024
2

NOTE: Before reclaiming a refrigeration system, it is

P131871 recommended to identify the type of
refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Locate the low pressure port (Item 1) and high pressure Refrigerant Identifier (Item 1) [Figure 70-40-2]
port (Item 2) [Figure 70-40-1]. will determine the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
preventing mixing of dangerous material with
WARNING your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems

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that are reclaimed and charged from your
In the event of a leak, wear safety goggles. Escaping
MEL1581 Recovery / Recycling / Recharging
refrigerant can cause severe injuries to eyes. In
Machine.
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611

NOTE: This procedure is run with the excavator

engine OFF, and the A/C switch in the OFF
position.

70-40-1 E85 Service Manual

SYSTEM CHARGING AND RECLAMATION (CONT'D)

Refrigerant Identification (Cont’d)

Figure 70-40-3

P-24657

Remove the protective cap and connect the Refrigerant

Identifier to the low pressure hose (Item 1) [Figure 70-
40-3].

Connect the refrigerant identifier to a power source.

Follow the steps displayed on the refrigerant identifier

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screen.

Allow two minutes for the refrigerant identifier to display

the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.

Disconnect the refrigerant identifier from the excavator A/

C.

If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safely disposed of.

If R-134a is found, evacuate the system.

70-40-2 E85 Service Manual

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 70-40-5

Reclamation And Charging With Recovery / Charging

Unit 2

WARNING
HFC R-134a refrigerant can be dangerous if not
properly handled. Liquid R-134a may cause
blindness if it contacts the eyes and may cause
serious frostbite if it contacts the skin.
• Gaseous R-134a becomes lethal (phosgene) gas 1
when it contacts open flame or very hot
P131872
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of R-134a in the air. Connect the Red hose (Item 1) [Figure 70-40-5] to the
Any servicing work that involves release or addition high pressure port and open the valve.
of R-134a to the system must be done by a
competent refrigeration dealer who has the proper Connect the Blue hose (Item 2) [Figure 70-40-5] to the
equipment, knowledge, and experience to service low pressure port and open the valve.
refrigeration equipment.
W-2373-0611
Figure 70-40-6

Figure 70-40-4

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N-22292

N-22291
Turn the reclaimer unit to the ON position and follow the
on screen instructions [Figure 70-40-6].
Use an approved recover / charging unit [Figure 70-40-4]
to evacuate the system. NOTE: For correct quantity of refrigerant (See
Capacities on Page SPEC-10-6.).
Connect the reclaimer to the excavator A/C charge ports.

IMPORTANT: Only A/C trained technicians should

perform the reclaiming and recharging
procedure.

70-40-3 E85 Service Manual

SYSTEM CHARGING AND RECLAMATION (CONT'D)

Reclamation And Charging With Recovery / Charging

Unit (Cont’d)

Figure 70-40-7

N-22381

NOTE: The reclaimer unit has a complete step by

step set of instructions [Figure 70-40-7] to
follow for reclamation and recharging of the
A/C system. A trained technician should
follow these instructions as they may vary
slightly depending on the model and brand of
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reclaimer used.

70-40-4 E85 Service Manual

COMPRESSOR Figure 70-50-2

Removal And Installation

Remove the counterweight. (See Removal And

Installation on Page 40-80-1.)

Remove the compressor belt. (See Air Conditioning

Compressor Belt Replacement on Page 70-20-2.)
1
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 70-40-
3.)

Figure 70-50-1
P114742

Remove the bolt (Item 1) [Figure 70-50-2].

1
Figure 70-50-3
4

2
1

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P114741

Remove the hose (Item 1) and (Item 2) [Figure 70-50-1].

NOTE: Always replace O-rings and lube with

compressor oil. Care must be taken not to P133318
damage O-rings when installing the hose
fittings.
Remove the bolt (Item 1) [Figure 70-50-3].
Installation: Tighten the hose (Item 1) to 28 - 37 N•m (21
- 27 ft-lb) torque. Tighten the hose (Item 2) [Figure 70- Remove the compressor.
50-1] to 20 - 27 N•m (15 - 20 ft-lb) torque.
The compressor is not serviceable and must be replaced
as an assembly.

WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611

Disconnect the wire harness (Item 3) [Figure 70-50-1].

Remove the bolts (Item 4) [Figure 70-50-1].

70-50-1 E85 Service Manual

COMPRESSOR (CONT’D)

Oil

Figure 70-50-4

P114862

The compressor (Item 1) [Figure 70-50-4] is factory filled

with 150 - 170 cc's of PAG 100 refrigerant oil
(Polyalkelene Glycol).

It is not necessary to frequently check or change the

compressor oil.
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It is necessary to check, replenish or replace the

compressor oil in the following cases:

1. When the evaporator, condenser or receiver / drier is

replaced.

2. When refrigerant has leaked from the system.

3. When refrigerant is suddenly released from the

cooling cycle.

4. When any oil related problems occur in the cooling

cycle.

When one of the components (the evaporator, condenser

or receiver / drier) is replaced, 30 cc of PAG oil should be
added for each component replaced.

If the A/C compressor is changed, no oil should be added

to the system, the compressor comes factory filled with
oil.

NOTE: Only PAG oil should be used. Never mix R-12

and R-134a Oils.

70-50-2 E85 Service Manual

COMPRESSOR (CONT’D) Figure 70-50-6

Oil Check

The compressor oil should be checked as follows when 2

oil is being added to an in service excavator.

There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. When checking the amount of 1
oil in the system or replacing any system component, the
compressor must be run in advance to insure return of oil
to the compressor.

If the amount of refrigerant in the system has decreased,

charge the system. (See Reclamation And Charging With P114864
Recovery / Charging Unit on Page 70-40-3.)

Open the cab door and windows. Drain the oil through the connectors (Item 1) and the oil
drain hole (Item 2) [Figure 70-50-6].
Run the blower at maximum speed.
Installation: Tighten the oil drain plug to 13 - 15 N•m (9.4
Run the compressor for at least 20 minutes at 800 - 1200 - 10.8 ft-lb) torque.
rpm.
Figure 70-50-7
Remove the compressor from the excavator. (See
Removal And Installation on Page 70-50-1.)

Figure 70-50-5

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1

P114865

NOTE: After draining the oil through the drain hole

P114863
and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 70-50-
Remove the drain plug (Item 1) [Figure 70-50-5]. 7] several times by hand.

Measure the drained oil in a measuring cylinder.

Check the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.

NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.

70-50-3 E85 Service Manual

COMPRESSOR (CONT’D)

Oil Check (Cont'd)

Figure 70-50-8

P114866

Add new compressor oil through the suction side

connector (Item 1) [Figure 70-50-8].

Installation: Add 150 - 170 cc's of PAG 100 oil.

NOTE: The suction port on the compressor is marked

with an S and is the larger port on the
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compressor.

70-50-4 E85 Service Manual

CONDENSER

Removal And Installation

WARNING
Open the tailgate. (See Opening And Closing on Page
10-50-1.) In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
Open the right side cover. (See Opening And Closing on contact with a flame, R-134a refrigerant gives a toxic
Page 10-60-1.) gas.
W-2371-0611
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 70-40- Remove the hose (Item 3) [Figure 70-60-1] from the
3.) condenser.

Figure 70-60-1 NOTE: Always replace O-rings and lube with

compressor oil. Care must be taken not to
damage O-rings when installing the hose
4 fittings.

3 Installation: Tighten the hose to 20 - 27 N•m (15 - 20 ft-

lb) torque.

Cap the hose and plug the fitting on the condenser.

Loosen the knob (Item 4) [Figure 70-60-1].

1
Remove the condenser from the excavator.

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1

P131652

Cut and remove the cable ties (Item 1) [Figure 70-60-1].

Remove hose (Item 2) [Figure 70-60-1] from the

condenser.

Installation: Tighten the hose to 15 - 18 N•m (11 - 13 ft-

lb) torque.

Cap the hose and plug the fitting on the condenser.

70-60-1 E85 Service Manual

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70-60-2
E85 Service Manual
RECEIVER / DRIER

Receiver / Drier Removal And Installation

WARNING
Evacuate the A/C system. (See Reclamation And
Charging With Recovery / Charging Unit on Page 70-40- In the event of a leak, wear safety goggles. Escaping
3.) refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
Open the right side cover. (See Opening And Closing on gas.
Page 10-60-1.) W-2371-0611

Remove the right upperstructure cover. (See Removal Remove the A/C hoses (Item 1) [Figure 70-70-1] from
And Installation on Page 40-70-1.) the receiver / drier.

Figure 70-70-1 Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.
2 1 Disconnect the wire harness (Item 2) [Figure 70-70-1].

Loosen the hose clamps (Item 3) [Figure 70-70-1] that

hold the receiver / drier to the mount.

Remove the receiver / drier from the excavator.

NOTE: When replacing a receiver / drier in an A/C

system 30 cc (1 U.S. fl oz) of PAG 100 oil must
1
be added to the system when recharging.

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P131871

Mark the hoses (Item 1) [Figure 70-70-1] for proper

installation.

NOTE: Always replace O-rings and lube with

compressor oil. Care must be taken not to
damage O-rings when installing the hose
fittings.

Installation: Tighten the hoses to 15 - 18 N•m (11 - 13 ft-

lb) torque.

Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.

Note the flow direction on the drier for proper installation.

70-70-1 E85 Service Manual

RECEIVER / DRIER (CONT’D)

Pressure Switch Removal And Installation

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

Page 10-60-1.)

Evacuate the A/C System. (See Reclamation And

Charging With Recovery / Charging Unit on Page 70-40-
3.)

Remove the right upperstructure cover. (See Removal

And Installation on Page 40-70-1.)

Figure 70-70-2

2
1
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P131790

Locate the pressure switch (Item 1) [Figure 70-70-2].

WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic
gas.
W-2371-0611

Disconnect the wire harness (Item 2) [Figure 70-70-2]

from the pressure switch wire harness.

Remove the pressure switch from the excavator.

70-70-2 E85 Service Manual

EVAPORATOR / HEATER UNIT For detailed information on ECU harness removal and
installation. (See Removal And Installation on Page 50-
Removal And Installation 120-3.)

Remove the cab. (See Removal And Installation on Page Disconnect the harness connector (Item 5) [Figure 70-
40-20-1.) 80-1].

Discharge the A/C system. (See Reclamation And Figure 70-80-2

Charging With Recovery / Charging Unit on Page 70-40-
3.) 1

Remove the engine coolant. (See Removing And

Replacing Coolant on Page 10-100-3.)

Remove the right upperstructure cover. (See Removal

And Installation on Page 40-80-1.) 1

Remove the tool box. (See Removal And Installation on

Page 40-210-1.)

WARNING P131929

In the event of a leak, wear safety goggles. Escaping Remove the screws (Item 1) [Figure 70-80-3] and
refrigerant can cause severe injuries to eyes. In remove the gateway controller.
contact with a flame, R-134a refrigerant gives a toxic
gas. Installation: Tighten the screws to 7,9 N•m (5.8 ft-lb)
W-2371-0611

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torque.

Figure 70-80-1 Figure 70-80-3

2
4
1

4
1
1
5

1
P133116 P-95971

Remove the tie straps (Item 1) [Figure 70-80-1]. Disconnect the wire harness (Item 1) [Figure 70-80-3].

Remove the ECU harness (Item 2) by rotating the lock

lever (Item 3) [Figure 70-80-1] towards the rear of the
machine.

Remove the four screws (Item 4) [Figure 70-80-1].

70-80-1 E85 Service Manual

EVAPORATOR / HEATER UNIT (CONT’D) Figure 70-80-6

Removal And Installation (Cont’d)

Figure 70-80-4

1
1

P133370

Remove the bolt (Item 1) [Figure 70-80-6].

P133367
Figure 70-80-7

Disconnect the wire harnesses (Item 1) [Figure 70-80-4].

Figure 70-80-5

1
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3 1

2
P133369

Remove the bolts (Item 1) [Figure 70-80-7].

P133368
Remove the evaporator / heater unit.

Remove the air conditioning hoses (Item 1) and (Item 2).

Remove the heater hoses (Item 3) [Figure 70-80-5].

NOTE: Always replace O-rings and lube with

compressor oil. Care must be taken not to
damage O-rings when installing the hose
fittings.

Installation: Tighten the hose (Item 1) to 28 - 37 N•m (21

- 27 ft-lb) torque. Tighten the hose (Item 2) [Figure 70-
80-5] to 20 - 27 N•m (15 - 18 ft-lb) torque.

70-80-2 E85 Service Manual

THERMOSTAT The EDT has the following protection built in:
1. Over temperature
Description
2. Over current from clutch output
The Electronic De-icing Thermostat (EDT) is a micro
controller based module that measures evaporator coil 3. Voltage (Above and below operational limits or
temperature and cycles the compressor clutch to reverse voltage)
maintain a constant evaporator pressure. Onboard circuit
protection and diagnostics are also built into the module. 4. Short circuit protection (Output shorted to ground)

NOTE: The EDT has a six second delay before 5. Temperature sensor open and short detection
startup to protect the compressor clutch.

The EDT will turn the clutch on when the evaporator coil DETECTION
MALFUNCTION STATUS LED
temperature is above 2°C (35.6°F). If the EDT does not INTERVAL
detect any malfunction, it will continue to operate and the Temperature Continuous 1x per second
status LED will be lit continuously. When the evaporator sensor
temperature is below -2°C (28.4°F), the EDT will turn off
Temperature At A/C startup 2x per second
the clutch and status LED.
sensor open and
short detection
Figure 70-90-1
Compressor Continuous 3x per second
clutch short to
battery

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P-90576

When the EDT detects an open or short from the

temperature sensor, the status LED (Item 1) [Figure 70-
90-1] will blink once per second and the output signal to
the clutch will be turned off. The status LED will flash two
times per second when EDT detects an open circuit
(current draw less than 200 mA), short circuit or over
current (current draw greater than 7A) from the clutch
output. The status LED will flash three times per second
when the compressor clutch is shorted to ground.

NOTE: The EDT will attempt to restart every 20

seconds until the fault is repaired.

70-90-1 E85 Service Manual

THERMOSTAT (CONT’D) Figure 70-90-4

Removal And Installation

NOTE: The thermostat can be changed without

evacuating the A/C system, or removing the
evaporator / heater unit from the excavator.

Remove the floor mat. (See Removal And Installation on

Page 40-100-1.)
1
Figure 70-90-2

1
1
P112877

Remove the probe (Item 1) [Figure 70-90-4] from under

the AC tape on the coil tubeline.

NOTE: Reinstall the probe in the same location.

Moving the thermostat probe location will
effect air conditioning performance.

Figure 70-90-5
P128638
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Pull back on the two latches (Item 1) [Figure 70-90-2]

and remove the HVAC side cover.
1
Figure 70-90-3

P112878

Remove the wire harness connector (Item 1) [Figure 70-

1 90-5] from the mount.

P-112876

Cut and remove the cable tie (Item 1) [Figure 70-90-3].

70-90-2 E85 Service Manual

THERMOSTAT (CONT’D)

Removal And Installation (Cont’d)

Figure 70-90-6

P112879

Disconnect the wire harness (Item 1) [Figure 70-90-6].

Remove the thermostat from the unit.

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70-90-3 E85 Service Manual

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70-90-4
E85 Service Manual
EXPANSION VALVE Figure 70-100-2

Removal And Installation

Evacuate the A/C system. (See Reclamation And

Charging With Recovery / Charging Unit on Page 70-40-
3.)

Remove the blower fan. (See Removal And Installation

1
on Page 70-100-1.)
2

WARNING
1
P111416
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R-134a refrigerant gives a toxic Remove the evaporator fittings (Item 1) [Figure 70-100-
gas. 2] from the expansion valve.
W-2371-0611

Installation: Tighten the evaporator fittings to 29,8 N•m

Figure 70-100-1 (22 ft-lb) torque.

Remove the bolts (Item 2) [Figure 70-100-2].

Remove the expansion valve from the excavator.

Cap and plug the evaporator tubelines and the expansion

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valve fittings with the proper A/C caps and plugs.

The expansion valve is not serviceable and must be

replaced as an assembly.
1
NOTE: The HVAC box is shown removed from the
excavator for photo clarity.

P133127

Remove the A/C hose (Item 1) and (Item 2) [Figure 70-

100-1] from the expansion valve.

NOTE: Always replace O-rings and lube with

compressor oil. Care must be taken not to
damage O-rings when installing the hose
fittings.

Installation: Tighten the hose (Item 1) to 15 - 18 N•m (11

- 13 ft-lb) torque. Tighten the hose (Item 2) [Figure 70-
100-1] to 28 - 37 N•m (21 - 27 ft-lb) torque.

70-100-1 E85 Service Manual

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70-100-2
E85 Service Manual
EVAPORATOR COIL Figure 70-110-3

Removal And Installation

1
Remove the blower fan. (See Removal And Installation
on Page 70-130-1.)

Remove the expansion valve. (See Removal And

Installation on Page 70-100-1.)

Remove the heater coil. (See Removal And Installation

on Page 70-120-1.)

Figure 70-110-1

P-92833

Remove the evaporator (Item 1) [Figure 70-110-3].

Inspect the evaporator coil for leaks, and replace as

needed.

Clean with low water or air pressure.

NOTE: The HVAC box is shown removed for photo

1 clarity.

P111417

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Disconnect the wire harness (Item 1) [Figure 70-110-1].

Figure 70-110-2

1
P111418

Remove the screws (Item 1) [Figure 70-110-2].

70-110-1 E85 Service Manual

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70-110-2
E85 Service Manual
HEATER COIL Figure 70-120-3

Removal And Installation

1
Remove the engine coolant. (See Removal And
Installation on Page 70-90-2.)

Remove the HVAC Duct. (See Removal And Installation

on Page 70-150-1.)

Remove the blower fan. (See Removal And Installation

on Page 70-120-1.)

Figure 70-120-1

P111421

1
Remove the coil (Item 1) [Figure 70-120-3].

1
1

P111420

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Remove the heater hoses. Remove the four screws (Item
1) [Figure 70-120-1] from the bottom of the HVAC box.

Figure 70-120-2

1
P111419

Remove the two screws (Item 1) [Figure 70-120-2].

70-120-1 E85 Service Manual

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70-120-2
E85 Service Manual
BLOWER FAN

Removal And Installation

Figure 70-130-1

P111412

Mark and remove the wire connectors from the motor

[Figure 70-130-1].

Figure 70-130-2

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1
1

1
1
P111413

Remove the two bolts (Item 1) [Figure 70-130-2].

Remove the motor.

70-130-1 E85 Service Manual

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70-130-2
E85 Service Manual
HEATER VALVE

Removal And Installation

Drain the radiator. (See Removing And Replacing

Coolant on Page 10-100-3.)

Figure 70-140-1

1
3

P131789

Disconnect the wire harness (Item 1). Remove the hoses

(Item 2) and nuts (Item 3) [Figure 70-140-1]. Remove the
valve.

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70-140-1 E85 Service Manual

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70-140-2
E85 Service Manual
HVAC DUCT

Removal And Installation

Remove the instrument panel. (See Removal And

Installation on Page 70-150-1.)

Figure 70-150-1

P112813

Remove the bolts (Item 1) [Figure 70-150-1]. Remove

the plate and duct.

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70-150-1 E85 Service Manual

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70-150-2
E85 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-10-5
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Slew System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7

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 SPECIFICATION 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-40-1
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-5
Push To Connect Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-6

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-60-2

SPEC-01 E85 Service Manual

SERVICE TOOLS REQUIRED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Remote Start Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Hydraulic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-2
Engine Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-5
Electrical Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-7
HVAC Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-7

Certain specification(s) are based on engineering calculations and are not actual measurements. Specification(s)
are provided for comparison purposes only and are subject to change without notice. Specification(s) for your
individual Bobcat equipment will vary based on normal variations in design, manufacturing, operating conditions,
and other factors.
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SPEC-02 E85 Service Manual

EXCAVATOR SPECIFICATIONS

Machine Dimensions

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

1429 mm
(56.3 in) 622 mm
(24.5 in)

2282 mm
(89.8 in)

2030 mm
(79.9 in)

250 mm 874 mm
(9.8 in) (34.4 in)

6241 mm
(245.7 in)
2188 mm
4808 mm

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(86.1 in)
(189.5 in)
1902 mm
(74.9 in)

2536 mm
(99.8 in)

710 mm
382mm TRACK
(27.9 in)
2195 mm (15.0 in) 2200 mm
(86.4 in) (86.6 in)

2863 mm BLADE
(112.7 in) 2205 mm
(86.8 in)
3342 mm
(131.6 in)

NA13735

SPEC-10-1 E85 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.

7336 mm
(210.7 in)
3993 mm
(157.2 in)
3793 mm
(149.3 in)
6905 mm
2825 mm
(271.8 in)
(111.2 in) 181°

3558 mm
5976 mm
(140.1 in)
(235.3 in)
119°
5055 mm
(199.0 in)

28.5° 1835 mm
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(72.2 in)

392 mm 3417mm
(15.4 in) (134.5 in)
2324 mm
(91.5 in)
425 mm 4510 mm
(16.7 in) (177.6 in)

4692 mm
1785 mm (184.7 in)
(70.3 in)

2853 mm
(112.3 in)
3415 mm
(134.4 in)
5230 mm
(205.9 in)
7198 mm
(283.4 in)

NA13736

SPEC-10-2 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Performance

E85
operating weight (Includes cab with
HVAC, rubber tracks, 609 mm (24 in) 8608 kg (18977 lb)
bucket and 75 kg (165 lb) operator)
If equipped with the following, add: Steel tracks, add 106 kg (234 lb);
Segmented tracks, add 164 kg (362 lb);
Additional Counterweight 407 kg (897 lb)
Travel Speed (Low / High) 2.7 km/h / 4.7 km/h (1.7 mph / 2.9 mph)
Digging Force (per ISO 6015)
With Standard Arm Arm - 36712 N (8253 lbf)
Bucket - 72368 N (16269 lbf)
Drawbar Pull 68564 N (15414 lbf)

Controls

Steering Two hand levers (with foot pedals)

Hydraulics Two hand operated levers (joysticks) control boom, bucket, arm and
upperstructure slew
Blade Hand lever
Two-Speed Switch on blade lever
Boom Offset Switch Electric switch in left joystick
Auxiliary Hydraulics Electric switch in right joystick

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Auxiliary Pressure Release Electric switch in right joystick
Engine Engine speed control dial with auto idle feature, key type start switch
Starting Aid Glow Plugs - activated by key switch
Brakes
Travel
Service & Parking Hydraulic lock in motor
Swing
Service Hydraulic lock on motor
Holding Spring applied - hydraulic release

SPEC-10-3 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)
Engine
Make / Model Bobcat Engine / D24NAP Tier 4
Fuel / Cooling Diesel / Liquid
Horsepower:
– ISO 14396 Gross 48,5 kW (65.1 hp) @ 2100 rpm
– SAE J1995 Gross 49,2 kW (65.9 hp) @ 2100 rpm
Torque:
– SAE J1995 Gross 248 N•m (208 ft-lb) @ 1600 rpm
Low Idle rpm 1195 – 1245
High Idle rpm 2075 – 2125
Number of Cylinders 4
Displacement 2392 cm3 (146.0 in3)
Bore / Stroke 90 mm / 94 mm (3.54 in / 3.70 in)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel – Compression
Air Induction Turbo-Charged and Charged Air Cooled
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Glow plugs automatically activated as needed in RUN position
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SPEC-10-4 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Hydraulic System

Pump Type Engine driven, single outlet, variable displacement,

pressure compensating, load sensing, torque limiter, piston pump
Pump Capacity 
Piston Pump 149,1 L/min (39.4 U.S. gpm)
Auxiliary Flow (Aux3) 95,0 L/min (25.1 U.S. gpm)
Auxiliary Flow - 2nd Aux
(Female coupler) 62,0 L/min (16.4 U.S. gpm)
(Male coupler) 41,0 L/min (10.8 U.S. gpm)
Hydraulic Filter Full flow replaceable, 3 micron synthetic media element
Control Valve 9 spool closed center individually compensated
Fluid Type Bobcat Fluid, Hydraulic / Hydrostatic
6903117 - (2.5 U.S. gal)
6903118 - (5 U.S. gal)
6903119 - (55 U.S. gal)
System Relief Pressure 29500 kPa (295 bar) (4279 psi)
Slew Circuit 21570 kPa (216 bar) (3129 psi)
Travel Motor 28000 kPa (280 bar) (4061 psi)
Offset Circuit 38000 kPa (380 bar) (5511 psi)
Auxiliary Relief - Main 21000 kPa (210 bar) (3045 psi)
- Second 20700 kPa (207 bar) (3002 psi)
Arm Port Relief, Base End And Rod End 34000 kPa (340 bar) (4931 psi)
Boom Port Relief, Base End And Rod End 34000 kPa (340 bar) (4931 psi)

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Bucket Port Relief Base End And Rod End 34000 kPa (340 bar) (4931 psi)
Blade Port Relief Base End 38000 kPa (380 bar) (5511 psi)
Main Hydraulic Filter Bypass 340 kPa (3,4 bar) (50 psi)
Case Drain 172 kPa (1,7 bar) (25 psi)

Hydraulic Cylinders

Cylinder Bore Rod Stroke

Boom (cushion up) 115 mm (4.52 in) 75 mm (2.95 in) 775 mm (30.51 in)
Arm 100 mm (3.93 in) 65 mm (1.75 in) 846 mm (33.30 in)
Bucket (cushion retract / 85 mm (3.35 in) 55 mm (2.17 in) 690 mm (27.17 in)
extend)
Boom Swing (cushion left / 1016 mm (4.00 in) 57,2 mm (2.25 in) 697,2 mm (27.45 in)
right)
Blade 100 mm (3.94 in) 60 mm (2.36 in) 149 mm (5.87 in)

SPEC-10-5 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Hydraulic Cycle Times

Bucket Curl 2.8 Seconds

Bucket Dump 1.8 Seconds
Arm Retract 3.0 Seconds
Arm Extend 2.9 Seconds
Boom Raise 4.7 Seconds
Boom Lower 4.6 Seconds
Boom Swing Left 5.6 Seconds
Boom Swing Right 5.3 Seconds
Blade Raise 2.2 Seconds
Blade Lower 2.2 Seconds

Drive System

Final Drive Each track is driven by hydrostatic axial piston motor

Type of Reduction 50.1:1 two stage planetary

Slew System

Slew Motor Axel piston connected to a planetary drive

Slew Circle Single row shear type ball bearing with internal gear
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Slew Speed 9.0 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 2200 mm (86.6 in)

Capacities

Fuel Tank 116,0 L (30.6 U.S. gal)

Hydraulic Reservoir Only (Center of 22,7 L (6.0 U.S. gal)
Sight Glass)
Hydraulic System (with Reservoir) 83,0 L (22.0 U.S. gal)
Cooling System 10.0 L (2.65 U.S. gal)
Engine Oil and Filter 8,6 L (9.1 qt)
Final Drive (each) 1,1 L (1.16 qt)
Air Conditioning Refrigerant (R-134a) 1,36 kg (3.0 lb)

SPEC-10-6 E85 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Electrical

Starting Aid Glow Plugs

Alternator 12 volt, 90 Amp open frame w / internal regulator
Battery 12 volt - 1000 CCA @ -18C (0F)
Starter 2.0 kW (12 volt; gear reduction 2.7 hp)
Lights 37.5 watt (2)
Instrumentation Gauges:
Engine Coolant Temperature, Fuel Level.
Warning lights:
Fuel Level, Seat Belt, Engine Coolant Temperature, Engine Malfunction,
Hydraulic System Malfunction, General Warning.
Indicators:
Two-Speed, Engine Preheat.
Data Display:
Operating Hours, Engine rpm, Maintenance Clock Countdown, Battery Voltage,
Service Codes, Engine Preheat.
Other:
Audible Alarm, Lights.
Optional Deluxe Instrumentation Panel:
*Additional displays for: Engine rpm, Coolant Temperature and Oil Pressure;
System Voltage and Hydraulic Oil Temperature.
*Additional Features Included: Keyless Start, Digital Clock, Job Clock, Password
Lockout, Multi-language Display, Help Screens, Diagnostic Capability and
Engine / Hydraulic Systems Shutdown Function.

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Tracks

Type Rubber Steel Segmented

Width 450 mm (17.7 in) 450 mm (17.7 in) 450 mm (17.7 in)
Number Of Shoes Single Assembly 39 39
Number of Track Rollers (per side) 5 5 5

Ground Pressure

Rubber Tracks 38,3 kPa (0,383 bar) (5.56 psi)

Steel Tracks 38,8 kPa (0,388 bar) (5.63 psi)
Segmented Tracks 39,1 kPa (0,391 bar) (5.67 psi)

SPEC-10-7 E85 Service Manual

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SPEC-10-8
E85 Service Manual
TECHNICAL SERVICE GUIDE SPECIFICATIONS

Engine

Engine Oil Pressure at Low Idle 147 kPa (1,47 bar) (21.3 psi)
Engine Oil Pressure at High Idle 392 - 539 kPa (3,92 - 5,39 bar) (57 - 78 psi)
Location of Number 1 Cylinder Closest to water pump
Crankshaft Rotation (Facing
Clockwise
Crankshaft Pulley)
Valve Clearance (Cold) Intake 0,4 mm (0.016 in)
Valve Clearance (Cold) Exhaust 0,45 mm (0.018 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)

Fuel Injector Retaining Bolt 39 - 46 N•m (29 - 34 ft-lb)
Glow Plugs 8,8 - 11,8 N•m (6.5 - 8.7 ft-lb)
Valve Cover Bolts 7,8 N•m (5.8 ft-lb)
Head Bolts Initial torque 39 N•m (29 ft-lb) + 90° + 90° + 90°

NOTE: For additional engine torques, (See Engine Removal And Installation on Page 60-10-14.)

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 97°C (207°F)

NOTE: For additional cooling system information, (See ENGINE COOLING SYSTEM on Page 60-40-1.)

Excavator Torques

Drive Motor To Frame Bolt 160 - 180 N•m (118 - 133 ft-lb)
Sprocket To Drive Motor 245 N•m (181 ft-lb)
Swing Bearing To Frame Bolt 345 - 385 N•m (255 - 285 ft-lb)
Swing Bearing To Upperstructure Bolt 345 - 385 N•m (255 - 285 ft-lb)
Swing Motor Drive Carrier 255 - 285 N•m (188 - 210 ft-lb)
Swing Motor Mounting Bolts 86 - 118 N•m (63 - 87 ft-lb)

SPEC-20-1 E85 Service Manual

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SPEC-20-2
E85 Service Manual
TORQUE SPECIFICATION FOR BOLTS

Torque For General SAE Bolts

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

THREAD SIZE SAE GRADE 5 SAE GRADE 8

0.250 9,0 - 10,2 12,4 - 13,6
N•m (80 - 90) (110 - 120)
(in-lb) 0.3125 20,3 - 22,6 24,2 - 27,1
(180 - 200) (215 - 240)
0.375 34 - 38 47 - 54
(25 - 28) (35 - 40)
0.4375 54 - 61 81 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 122 - 136
(65 - 70) (90 - 100)
0.5625 122 - 136 170 - 190
(90 - 100) (125 - 140)
0.625 170 - 190 240 - 260
(125 - 140) (175 - 190)
0.750 300 - 330 410 - 450
N•m (220 - 245) (300 - 330)
(ft-lb) 0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600

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(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 5830 - 6500
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

SPEC-30-1 E85 Service Manual

TORQUE SPECIFICATIONS FOR BOLTS (CONT’D)

Torque For General Metric 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 PROPERTY CLASS

NOM. DIA 8.8 10.9 12.9
- N•m ft-lb N•m ft-lb N•m ft-lb
M4 3,5 - 2,5 2.5 - 2.0 4,2 - 3,8 3.1 - 2.8 5,3 - 4,7 3.9 - 3.5
M5 6,5 - 5,5 5.0 - 4.0 8,4 - 7,6 6.2 - 5.6 9,5 - 8,5 7.0 - 6.2
M6 10,5 - 9,5 7.5 - 7.0 13,7 - 12,3 10.1 - 9.1 15,8 - 14,2 11.6 - 10.4
M7 17 - 15 12.5 - 11.0 22 - 20 16.2 - 14.7 26,3 - 23,7 19.5 - 17.5
M8 26 - 24 19 - 18 32,6 - 29,4 24.0 - 21.7 39 - 35 28.5 - 25.5
M10 47 - 43 35 - 32 63 - 57 46.5 - 42.0 79 - 71 58.5 - 52.5
M12 85 - 75 60 - 55 115 - 105 85 - 78 137 - 123 110 - 91
M14 140 - 125 100 - 90 180 - 160 133 - 118 210 - 190 155 - 140
M16 210 - 190 155 - 140 285 - 255 210 - 188 330 - 300 245 - 225
M18 290 - 260 215 - 190 385 - 345 285 - 255 460 - 420 340 - 310
M20 410 - 370 300 - 275 550 - 490 405 - 360 650 - 590 490 - 440
M22 550 - 500 400 - 370 740 - 760 545 - 560 880 - 800 650 - 590
M24 700 - 640 520 - 470 950 - 850 700 - 625 1120 - 1000 830 - 730
M27 1030 - 930 760 - 680 1370 - 1230 1000 - 900 1630 - 1470 1200 - 1100
M30 1400 - 1260 1030 - 930 1900 - 1700 1400 - 1250 2200 - 2000 1600 - 1500
M33 1900 - 1720 1400 - 1270 2500 - 2300 1850 - 1700 3100 - 2700 2300 - 2000
M36 2450 - 2200 1800 - 1620 3200 - 2900 2400 - 2200 3900 - 3500 2900 - 2600

NOTE: Use the torque value for the part having the lesser property class when a fastener and nut are used
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together but have a different property class.

SPEC-30-2 E85 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting

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

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

Figure SPEC-40-1
A-1852

Lubricate the O-ring before installing the fitting. Loosen

the nut and install the fitting. Tighten the nut until the
washer is tight against the surface [Figure SPEC-40-2].

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B-7575

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

SPEC-40-1 E85 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-3
(CONT'D)

Tubelines And Hoses

Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause 1
heat.

Replace hoses which show signs of wear, damage or

weather cracked rubber.
2
Always use two wrenches when loosening and tightening
hose or tubeline fittings.

Flare Fitting
TS-1619

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-40-3].

Use the chart below to find the correct tightness needed

(Item 2) [Figure SPEC-40-3]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
damage.

FLARE FITTING TIGHTENING TORQUE

Tubeline TORQUE NEW RE-ASSEMBLY
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Outside N•m Rotate No. Rotate No.

Wrench Size Diameter Thread Size (ft-lb) of Hex Flats of Hex Flats
5/8” 5/16” 1/2” - 20 23 (17) 2 - 1/2 1
11/16” 3/8” 9/1”6 - 18 30 (22) 2 1
7/8” 1/2” 3/4” - 16 54 (40) 2 1
1” 5/8” 7/8” - 14 81 (60) 1 - 1/2 1
1-1/4” 3/4” 1-1/16” - 12 114 (84) 1 3/4
1-3/8” 1” 1-5/16” - 12 160 (118) 3/4 3/4

SPEC-40-2 E85 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the O-ring flare
(CONT'D) fitting.

O-ring Flare Fitting Figure SPEC-40-5

Figure SPEC-40-4
O-ring Flare
Primary
Seal
1

TS-1619
Secondary
Seal P-13009
Tighten the nut until it contacts with the seat. Make a
mark across the flats of both the male and female parts
The flare is the primary seal, the O-ring is the secondary of the connection (Item 1) [Figure SPEC-40-5].
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-4]. Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC-40-5]. If the fitting leaks after
If necessary, the O-ring-flare fitting can be used without tightening, disconnect it and inspect the seat area for
an O-ring. damage.

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O-RING FLARE FITTING TIGHTENING TORQUE
* ** ***
Tubeline TORQUE NEW RE-ASSEMBLY
Outside N•m Rotate No. Rotate No.
Wrench Size Diameter Thread Size (ft-lb) of Hex Flats of Hex Flats
5/8” 5/16” 1/2” - 20 23 (17) 2 - 1/2 1
11/16” 3/8” 9/16” - 18 30 (22) 2 1
7/8” 1/2” 3/4” - 16 54 (40) 2 1
1” 5/8” 7/8” - 14 81 (60) 1 - 1/2 1
1-1/4” 3/4” 1-1/16” - 12 114 (84) 1 3/4
1-3/8” 1” 1-5/16” - 12 160 (118) 3/4 3/4

*If a torque wrench is used to tighten a new fitting to a **If using the hex flat tightening method to tighten a new
used hose / tubeline. fitting to a new hose / tubleline.

*If a torque wrench is used to tighten a used fitting to a **If using the hex flat tightening method to tighten a new
new hose / tubeline. fitting to a used hose / tubeline.

*If a torque wrench is used to tighten a new fitting to a ***If using the hex flat tightening method to tighten a used
new hose / tubeline. fitting to a new hose / tubeline.

SPEC-40-3 E85 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-7
(CONT'D)

O-ring Flare Fitting (Cont’d)

NOTE: O-ring flare fittings are not recommended in 2

all applications. Use the standard flare fittings
in these applications.

Do not use a O-ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing.

Figure SPEC-40-6 1

P-13573

Copper Bonnet Orifice

When a O-ring flare fitting is used as a straight thread
port adapter the O-ring flare face is not used to seal. The
O-ring may come off the fitting and enter the system.

Always remove the O-ring (Item 1) [Figure SPEC-40-7]

from the flare face as shown.

1 An O-ring (Item 2) [Figure SPEC-40-7] is added to the

flat boss of the fitting to seal the connection in this
application.
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P-13572

Use a standard flare fitting (Item 1) [Figure SPEC-40-6]

as shown.

SPEC-40-4 E85 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS NOTE: Port seal fittings are not recommended in all
(CONT'D) applications. Use O-ring boss fittings in these
applications.
Port Seal Fitting
Figure SPEC-40-9
Figure SPEC-40-8

Nut Seals
To Fitting P-13571

Nut Seals
To Port Do not use port seal fittings when a thread in orifice (Item
1) [Figure SPEC-40-9] is used in the port. The orifice
may interfere with the fitting and prevent it from sealing.

Use an O-ring boss fitting (Item 2) [Figure SPEC-40-9]

as shown.

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PORT SEAL AND O-RING BOSS TIGHTENING
Secondary O-ring Seal TORQUE
P-13008
Fitting TORQUE
Nut N•m
The nut is the primary seal, the O-ring is the secondary Wrench Size Thread Size (ft-lb)
seal and helps absorb vibration and pressure pulses at 11/16” 9/16” - 18 30 (22)
the connection [Figure SPEC-40-8]. 15/16” 3/4” - 16 50 (40)
1-1/8” 7/8” - 14 81 (60)
The hex portion of the nut does not contact the surface of 1-1/4” 1 - 1/16” - 12 114 (84)
the component when the nut is tight. 1-1/2” 1 - 5/16” 114 (84)

Use the following procedure to tighten the port seal

fitting:

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

fittings use the same tightening torque valve chart.

If a torque wrench cannot be used, use the following

method.

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

you can feel the resistance. Tighten the nut with a wrench
no more than one hex flat maximum.

Do not over tighten the port seal fitting.

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

hex flat tightening method as an approximate
guideline.

SPEC-40-5 E85 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-12
(CONT'D)

Push To Connect Fittings

The push to connect fittings provide a leak free seal that

also acts as a swivel fitting.

Figure SPEC-40-10

P-91854

To install the hose, install the retainer clip (Item 1)

1 [Figure SPEC-40-12] in the fitting.

Figure SPEC-40-13

P-91857
1

To disconnect the hose, pull up on the grommet (Item 1)

[Figure SPEC-40-10].

Figure SPEC-40-11 2
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P-91855

Install the hose (Item 1) in the fitting. Press down on the

1 hose until the top of the hose flare is fully seated in the
fitting and the retainer clip is over the top of the hose flare
(Item 2) [Figure SPEC-40-13].

P-91858

Use a O-ring pick to remove the retainer clip (Item 1). Pull
up on the hose (Item 2) [Figure SPEC-40-11] and
remove the hose from the fitting.

SPEC-40-6 E85 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS
(CONT'D)

Push To Connect Fittings (Cont’d)

Figure SPEC-40-14

P-91856

Push the grommet (Item 1) down and over the top of the
fitting (Item 2) [Figure SPEC-40-14].

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SPEC-40-7 E85 Service Manual

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SPEC-40-8
E85 Service Manual
HYDRAULIC FLUID SPECIFICATIONS

Specifications

Use only Bobcat hydraulic fluid.

WARNING
During cold weather (0°C [32°F] and below), do not
DO NOT use automatic transmission fluids in the
operate machine until the engine has run for at least
excavator or permanent damage to the hydraulic system
5 minutes at less than half throttle. This warm-up
will result.
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
Bobcat hydraulic fluid is available in:
period.
• 9,5 L (2.5 U.S. gal) qty 2 (P/N 6903117)
When temperatures are below -30°C (-20°F), the
hydrostatic oil must be heated or kept warm. The
• 18,9 L (5 U.S. gal) (P/N 6903118)
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
• 208 L (55 U.S. gal) (P/N 6903119)
temperature will be above -18°C (0°F) if possible.
W-2027-0311

WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
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

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from a physician familiar with this injury.
W-2072-0807

When temperatures below -18°C (0°F) are common, the

excavator must be kept in a warm building. Extra warm-
up time must be used each time the excavator is started
during cold temperature conditions. Cold fluid will not flow
easily and it makes action of the hydraulic function
slower. Loss of fluid flow to the hydraulic system
(Indicated by hydraulic temp / pressure lights on) can
cause system damage in less than 60 seconds.

SPEC-50-1 E85 Service Manual

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SPEC-50-2
E85 Service Manual
CONVERSIONS

Decimal And Millimeter Equivalent Chart

SPEC-60-1
E85 Service Manual
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CONVERSIONS (CONT’D)

U.S. To Metric Conversion Chart

SPEC-60-2
E85 Service Manual
SERVICE TOOLS REQUIRED

The following is a list of service tools required for servicing excavators.

Remote Start Tools

TOOL PART MODELS USED

DESCRIPTION COMMENT IMAGE
NUMBER ON
MEL1563 Remote Start Tool E20 - E55 This tool has been replaced by
the new remote start tool
7003031, see below. MEL1563
includes: MEL1565 and
MEL1566.
MEL1565 Service Tool Harness Used with MEL1563 to connect
remote start tool to machine

MEL1566 Service Tool Harness Used with MEL1563 to connect

Communicator remote start tool to PC

7217666 Remote Start Tool Kit E20 - E55 This tool replaced the original
 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 E85 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Hydraulic Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1744 Hydraulic Tester E08 - E85 Hydraulic tester MEL1744, MEL10003
(Flow Meter) or TWX-RFIK200-S-6 can be used for
hydraulic testing.

MEL10003 Hydraulic Tester MEL10003 and TWX-RFIK22-S-6 are

(Flow Meter) no longer available, order MEL1744.

TWX-RFIK200- Hydraulic Tester

S-6 (Flow Meter)

MEL1074 O-Ring Seal Hook

MEL1075 Adjustable Gland Nut Includes MEL1075-1 and MEL1075-2

Wrench
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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 E85 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Hydraulic Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1033 Rod Seal Installation E08 - E85
Tool

MEL1355 Hydraulic Test Kit This test kit includes various gauges,
adapters, couplers and hoses that are
used when testing hydraulic functions.
MEL1355 Includes: MEL1355-1 thru
MEL1355-12

MEL1355-2 1000 psi gauge

MEL1355-3 5000 psi gauge

MEL1355-12 Coupler

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 E85 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 E85 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 E85 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

7313843 Glow Plug 1.8L & 2.4L Used in glow plug port for testing
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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 E85 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,

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Recharging Machine

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 E85 Service Manual

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SPEC-70-8
E85 Service Manual
ALPHABETICAL INDEX

AIR CLEANER SERVICE . . . . . . . . . . . 10-80-1 DIESEL OXIDATION CATALYST (DOC)

AIR CLEANER . . . . . . . . . . . . . . . . . . . 60-30-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-1
AIR CONDITIONING SYSTEM FLOW ELECTRICAL SYSTEM INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . 50-30-1 EMERGENCY EXIT . . . . . . . . . . . . . .10-170-1
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1 ENGINE CONTROL UNIT (ECU) . . . .50-120-1
AUTO IDLE PRESSURE SENSOR ENGINE COOLING SYSTEM . . . . . .10-100-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-190-1 ENGINE COOLING SYSTEM . . . . . . .60-40-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 50-20-1 ENGINE INFORMATION . . . . . . . . . . .60-10-1
BLADE CONTROL LEVER . . . . . . . . 20-160-1 ENGINE LUBRICATION SYSTEM . . .10-120-1
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 EVAPORATOR / HEATER UNIT . . . . . .70-80-1
BLOWER FAN . . . . . . . . . . . . . . . . . . 70-130-1 EVAPORATOR COIL . . . . . . . . . . . . .70-110-1
BOOM . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1 EXCAVATOR IDENTIFICATION . . . . . . . . 1-15
BUCKET . . . . . . . . . . . . . . . . . . . . . . . 40-160-1 EXCAVATOR SPECIFICATIONS
CAB FILTERS . . . . . . . . . . . . . . . . . . . . 10-90-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 EXHAUST GAS RECIRCULATION (EGR)
SYSTEM . . . . . . . . . . . . . . . . . . . . . . .60-130-1
CAMSHAFT . . . . . . . . . . . . . . . . . . . . . 60-90-1
EXPANSION VALVE . . . . . . . . . . . . . .70-100-1
CASE DRAIN FILTER MOUNT . . . . . 20-170-1
FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-11
CENTER COVER . . . . . . . . . . . . . . . . . 10-61-1
FLOOR MAT . . . . . . . . . . . . . . . . . . . .40-100-1
CENTER COVER . . . . . . . . . . . . . . . . 40-220-1
FLYWHEEL AND HOUSING . . . . . . .60-120-1
CLAMP . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1

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FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
COMPRESSOR . . . . . . . . . . . . . . . . . . 70-50-1
FUEL LEVEL SENDER . . . . . . . . . . . .50-70-1
CONDENSER . . . . . . . . . . . . . . . . . . . 70-60-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-110-1
CONNECTED MACHINE . . . . . . . . . . 50-200-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . .60-60-1
CONTROL CONSOLE LOCKOUTS . . 10-190-1
FUEL TANK . . . . . . . . . . . . . . . . . . . .40-110-1
CONTROL PANEL SETUP . . . . . . . . . 50-90-1
GEARCASE . . . . . . . . . . . . . . . . . . . .60-100-1
CONTROL PATTERN SELECTOR VALVE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1 HEATER COIL . . . . . . . . . . . . . . . . . .70-120-1
CONTROLLER (GATEWAY AND AUXILIARY) HEATER VALVE . . . . . . . . . . . . . . . . .70-140-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1 HORN . . . . . . . . . . . . . . . . . . . . . . . . .40-120-1
CONTROLLER (PIN GRABBER) . . . . 50-111-1 HVAC DUCT . . . . . . . . . . . . . . . . . . . .70-150-1
CONVERSIONS . . . . . . . . . . . . . . . SPEC-60-1 HYDRAULIC CONNECTION
COUNTERWEIGHT . . . . . . . . . . . . . . . 40-80-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-40-1
CRANKSHAFT AND PISTONS . . . . . . 60-80-1 HYDRAULIC CONTROL VALVE . . . . . .20-40-1
CYLINDER (ARM) . . . . . . . . . . . . . . . . 20-21-1 HYDRAULIC FILTER MOUNT . . . . . .20-130-1
CYLINDER (BLADE) . . . . . . . . . . . . . . 20-24-1 HYDRAULIC FLUID SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
CYLINDER (BOOM SWING) . . . . . . . . 20-22-1
HYDRAULIC PUMP . . . . . . . . . . . . . . .20-50-1
CYLINDER (BOOM) . . . . . . . . . . . . . . . 20-20-1
HYDRAULIC RESERVOIR . . . . . . . . .20-140-1
CYLINDER (BUCKET) . . . . . . . . . . . . . 20-23-1
HYDRAULIC SYSTEM INFORMATION
CYLINDER (CLAMP) . . . . . . . . . . . . . . 20-25-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1
CYLINDER HEAD . . . . . . . . . . . . . . . . 60-70-1 HYDRAULIC SYSTEM . . . . . . . . . . . .10-130-1
DELIVERY REPORT . . . . . . . . . . . . . . . . 1-14 INSTRUMENT PANEL . . . . . . . . . . . .50-100-1
DIAGNOSTIC SERVICE CODES . . . . . 50-80-1 KEY SWITCH . . . . . . . . . . . . . . . . . . .50-130-1

INDEX-01 E85 Service Manual

LEFT CONSOLE . . . . . . . . . . . . . . . . .40-50-1 SERVICE SCHEDULE . . . . . . . . . . . . 10-70-1
LEFT CONTROL LEVER (JOYSTICK) SERVICE TOOLS REQUIRED . . . .SPEC-70-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-120-1 SHUT-OFF SWITCH . . . . . . . . . . . . . 50-170-1
LEFT UPPERSTRUCTURE COVER . .40-60-1 STARTER . . . . . . . . . . . . . . . . . . . . . . 50-40-1
LIFTING AND BLOCKING THE EXCAVATOR SWING CIRCLE GEAR . . . . . . . . . . . 30-40-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1
SWING FRAME . . . . . . . . . . . . . . . . 40-130-1
LIFTING THE EXCAVATOR . . . . . . . . .10-20-1
SWING MOTOR (DRIVE CARRIER) . 20-91-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .50-50-1
SWING MOTOR . . . . . . . . . . . . . . . . . 20-90-1
LUBRICATING THE EXCAVATOR . . .10-140-1
SWIVEL JOINT . . . . . . . . . . . . . . . . . . 20-80-1
LUBRICATION SYSTEM . . . . . . . . . . .60-50-1
SYSTEM CHARGING AND RECLAMATION
MAGNETIC LOCKOUT SENSOR . . . .50-60-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1 TAILGATE . . . . . . . . . . . . . . . . . . . . . . 10-50-1
MANIFOLD (PIN GRABBER) . . . . . . .20-200-1 TAILGATE . . . . . . . . . . . . . . . . . . . . . 40-180-1
MANIFOLD ASSEMBLY / ACCUMULATOR TECHNICAL SERVICE GUIDE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-60-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-20-1
MOTION ALARM SYSTEM . . . . . . . .50-150-1 THERMOSTAT . . . . . . . . . . . . . . . . . . 70-90-1
OIL COOLER . . . . . . . . . . . . . . . . . . .20-150-1 TOOL BOX . . . . . . . . . . . . . . . . . . . . 40-210-1
OPERATOR CAB (ROPS / TOPS / FOPS) TORQUE SPECIFICATION FOR BOLTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-31-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
OPERATOR CAB (ROPS / TOPS) . . . .10-30-1 TOWING THE EXCAVATOR . . . . . . . 10-200-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . .10-150-1 TRACK MAINTENANCE . . . . . . . . . . 30-30-1
QUICK COUPLER (PIN GRABBER)  TRACK UNDERCARRIAGE COMPONENTS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-190-1 (RUBBER TRACK) . . . . . . . . . . . . . . . 30-20-1
Page 889 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off

RECEIVER / DRIER . . . . . . . . . . . . . . .70-70-1 TRACK UNDERCARRIAGE COMPONENTS

REGULAR MAINTENANCE . . . . . . . . .70-20-1 (STEEL TRACK) . . . . . . . . . . . . . . . . . 30-21-1
REMOTE START TOOL (SERVICE TOOL) KIT TRANSPORTING THE EXCAVATOR ON A
- 7217666 . . . . . . . . . . . . . . . . . . . . . .10-211-1 TRAILER . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
REMOTE START TOOL KIT - MEL1563 TRAVEL CONTROL VALVE . . . . . . . 20-180-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-210-1 TRAVEL LEVERS AND PEDALS . . . . 40-90-1
REMOVING AIR FROM THE HYDRAULIC TRAVEL MOTOR AUTO-SHIFT . . . . 50-180-1
SYSTEM . . . . . . . . . . . . . . . . . . . . . . .20-190-1
TRAVEL MOTOR . . . . . . . . . . . . . . . 10-160-1
RIGHT CONSOLE . . . . . . . . . . . . . . . .40-40-1
TRAVEL MOTOR . . . . . . . . . . . . . . . . 20-70-1
RIGHT CONTROL LEVER (JOYSTICK)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1 TROUBLESHOOTING . . . . . . . . . . . . 70-30-1
RIGHT SIDE COVER . . . . . . . . . . . . . .10-60-1 TURBOCHARGER . . . . . . . . . . . . . . 60-110-1
RIGHT SIDE COVER . . . . . . . . . . . . .40-200-1 UPPERSTRUCTURE . . . . . . . . . . . . . 40-10-1
RIGHT UPPERSTRUCTURE COVER  VALVE (ARM LOCK) . . . . . . . . . . . . . 20-221-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-70-1 VALVE (BOOM LOCK) . . . . . . . . . . . 20-220-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . 1-9 VALVE (CROSS PORT RELIEF) . . . . 20-32-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . .10-180-1 VALVE (MAIN RELIEF) . . . . . . . . . . . . 20-30-1
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-1 VALVE (PORT RELIEF) . . . . . . . . . . . 20-31-1
SECONDARY AUXILIARY VALVE . . .20-210-1 VALVE (PRESSURE REDUCING) . . . 20-33-1
SERIAL NUMBER LOCATIONS . . . . . . . . 1-13 WIPER MOTOR . . . . . . . . . . . . . . . . 50-140-1
SERVICE PC (LAPTOP COMPUTER) 
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-160-1
SERVICE SCHEDULE SYMBOLS . . . INDEX-3

INDEX-02 E85 Service Manual

SERVICE SCHEDULE SYMBOLS

Check Engine Oil Check Gear Box and / or Travel Motor Fluid

Change Engine Oil and Filter Change Gear Box and / or Travel Motor Fluid

Check Engine Coolant Check Track Tension, Adjust As Needed

Change Engine Coolant Check Belt Tension, Adjust Or Replace As

Page 890 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - Produced by Ken Cook Co. with media1off
Needed

Check Engine Air Filter, Change As Lubricate Grease Fittings

Necessary

Drain Contaminants From Fuel Filter

Drain Contaminants From Fuel Tank

Change Fuel Filter

Check Hydraulic Fluid

Change Hydraulic Fluid and Filter(s)

Page 891 - OSS# 6300436662 - All rights reserved by Bobcat Company - 11/13/2018 - 06:30:44 - 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.