Service Manual

Compact Excavator
S/N A4BP11001 & Above
S/N B4PC11001 & Above

6986785enUS (07-20) (E) Printed in U.S.A. © 2020 Bobcat Company. All rights reserved.
T2 S5-K
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807

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

CORRECT CORRECT CORRECT

P-90216 B-19964 B-19959

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

B-19965 B-19960 B-19966

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

WRONG WRONG WRONG

B-19962 B-19958 B-19798

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

1-1 E08 Service Manual

1-2 E08 Service Manual
CONTENTS

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

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

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

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

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

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

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

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

1-3 E08 Service Manual

1-4 E08 Service Manual
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

1-5 E08 Service Manual

1-6 E08 Service Manual
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 fold-down 9. Check for correct function of
TOPS is in good condition indicator lamps.
and is not modified.

2. Check that fold-down TOPS 10. Check all machine fluid

mounting hardware is levels.
tightened and is Bobcat
approved.

3. The seat belt must be 11. Inspect for fuel, oil or

correctly installed, functional hydraulic fluid leaks.
and in good condition.

4. Machine signs (decals) must 12. Lubricate the excavator.

be legible and in the correct
location.

5. Travel levers, control levers 13. Check the condition of the

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

6. Check for correct function of 14. Inspect the air cleaner for
the work lights. damage or leaks. Check the
condition of the element.

7. Attachment locking pins must 15. Check the electrical charging

function correctly and be in system.
good condition.

8. Safety treads must be in good 16. Check tracks for wear and
condition. tension. Use only approved
tracks.

FW EXC UC-0119 SM

1-7 E08 Service Manual

17. Inspect for loose or broken 20. Check the control console
parts or connections. interlocks for correct function.

18. Check for any field 21. Check function or condition of

modification not completed. all equipped options and
accessories (examples:
boom light, motion alarm,
etc.).
19. Operate the machine and 22. Recommend to the owner
check all functions. that all necessary corrections
be made before the machine
is returned to service.

FW EXC UC-0119

1-8 E08 Service Manual

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

IMPORTANT • The AEM Safety Manual delivered with the machine

gives general safety information.

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

• The Compact Excavator Operator Training Course is

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

• The Bobcat compact excavator Safety Video is

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

The signal word WARNING on the machine and in the

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

SI EXC-1016 SM

1-9 E08 Service Manual

SAFETY INSTRUCTIONS (CONT’D)

The dealer and owner / operator review the

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

Cutting or drilling concrete containing sand or rock

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

Call Before You Dig

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

SI EXC1016 SM

1-10 E08 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
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 E08 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

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 E08 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.
Earlier 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 R0089

The engine serial number is located as a plate (Item 1)

1 on the top of the engine [Figure 3].

Figure 4

R0088

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

located on the frame of the machine in the location
shown.

Figure 2
1

Module 2 - Production
Sequence (Series)
R0090
Module 1 - Model / Engine
Combination P-90175
It also appears engraved on the side of the engine (Item
1) [Figure 4].
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 E08 Service Manual

DELIVERY REPORT

Figure 5

B-16315

The delivery report [Figure 5] contains a list of items that

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

The delivery report must be reviewed and signed by the

owner or operator and the dealer.

1-14 E08 Service Manual

EXCAVATOR IDENTIFICATION

15
14 21

13
2
3 1 16
4
22
12 17

6
5
7 19

20
10 23
8 18
11 R1064
9 R1065A

ITEM DESCRIPTION ITEM DESCRIPTION

1 Operator’s Handbook 15 Tip-Over Protective Structure (TOPS)
2 Boom Cylinder 16 Operation & Maintenance Manual
3 Arm Cylinder 17 Tailgate
4 Auxiliary Quick Couplers 18 Tracks
5 Boom 19 Tie-Downs
6 Arm 20 Tie-Downs / Lift Point (Both Sides)
7 Bucket Cylinder 21 Lift Point
8 Bucket Link / Attachment Coupler (If Equipped) 22 Right Side Cover
9 Bucket [A] 23 Track Frames
10 Blade Cylinder
11 Blade
12 Upperstructure
13 Control Levers (Joysticks)
14 Operator’s Seat with Seat Belt

[A] BUCKET - Several different buckets and other attachments are available for the Bobcat excavator.

1-15 E08 Service Manual

1-16 E08 Service Manual
SAFETY & MAINTENANCE

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

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

UPPERSTRUCTURE SLEW LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

TRANSPORTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-2

FOLD-DOWN TOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

TOPS Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Lowering The Fold-Down TOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Raising The Foldable Canopy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-2

TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Opening And Closing The Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

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

Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Contents Of The Inspection Checkbook (Logbook) . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-3

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

Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing The Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

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

Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Removing And Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Removing Water From The Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Replacing The Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3

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

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

10-01 E08 Service Manual

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Checking And Adding Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Replacing The Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Replacing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Diagnostic Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-3

LUBRICATION OF THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

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

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

Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Draining The Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

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

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

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

Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

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

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

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

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

EXCAVATOR STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Return to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1

STOPPING AND LEAVING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

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

MOTION ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-2

10-02 E08 Service Manual

LIFTING AND BLOCKING THE EXCAVATOR Figure 10-10-3

Procedure

Always park the machine on a level surface.

Figure 10-10-1

S8758 S8759

The machine must be blocked up as shown in [Figure

10-10-3].

Stop the engine.

WARNING
S8452

Put jackstands under the blade and rear corners of

Raise one side of the machine (approximately 100 mm [4 the undercarriage before working under the machine.
in]) using the boom and arm as shown in [Figure 10-10- Failure to block up the machine may allow it to move
1]. or fall and result in injury or death.
W-2218-1195
Figure 10-10-2

WARNING
1 AVOID INJURY
Keep fingers and hands out of pinch points when
1 checking the track tension.
S8756 S8757 W-2142-0903

Raise the blade fully and install wooden blocks (Item 1)

[Figure 10-10-2] or jackstands under the blade and the
track frame. Lower the machine until all machine weight
is on the wooden blocks or jackstands.

Rotate the upperstructure 180 degrees and repeat

procedure for other side.

10-10-1 E08 Service Manual

10-10-2 E08 Service Manual
UPPERSTRUCTURE SLEW LOCK

Operation

Figure 10-20-1

1
R0112

Move the lever (Item 1) [Figure 10-20-1] to the right and

down to engage the Upperstructure Slew Lock. Fit the
lever properly to fully engage the Slew Lock. When the
Slew Lock is engaged (locked), the upperstructure of the
excavator is locked to the track frame and will not rotate.

NOTE: The upperstructure must be in the straight

forward or straight backward position for the
upperstructure to lock.

Move the slew lock pin (Item 1) [Figure 10-20-1] up and

to the left to disengage the upperstructure from the track
frame. Fit the lever properly to fully disengage the Slew
Lock.

WARNING
AVOID INJURY
The upperstructure slew lock lever must be engaged
when transporting the machine.
W-2197-0904

10-20-1 E08 Service Manual

10-20-2 E08 Service Manual
LIFTING THE EXCAVATOR

Procedure

Fully extend the cylinders of the bucket and arm. Fully

retract the boom cylinder.

Raise the blade all the way.

Turn the upperstructure so that the boom is at the

opposite end as the blade.

Put all the controls in NEUTRAL and engage the

upperstructure slew lock. (See UPPERSTRUCTURE
SLEW LOCK on Page 10-20-1.)

WARNING
AVOID INJURY OR DEATH
• Use a lifting fixture with sufficient capacity for
the weight of the excavator plus any added
attachments.
• Maintain center of gravity and balance when
lifting.
• Do not swing boom or upperstructure. Engage
the upperstructure slew lock.
• Never lift with operator on machine.
W-2202-0607

Figure 10-30-1
1

R0041 R0040

Fasten the chains to the ends of the blade (Item 1)

[Figure 10-30-1] and up to a lifting fixture above the
canopy.

Fasten a chain in the hook of the boom (Item 2) [Figure

10-30-1].

10-30-1 E08 Service Manual

10-30-2 E08 Service Manual
TRANSPORTING THE EXCAVATOR Figure 10-40-1

Loading And Unloading

When transporting the machine, observe the rules, motor

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

When transporting the machine, observe the rules, motor

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

Align the ramps with the center of the transport vehicle.

Secure the ramps to the truck (or trailer) bed and be sure
ramp angle does not exceed 15 degrees.
R0038A
Use metal loading ramps with a slip resistant surface.

Use ramps that are the correct length and width, and can Move the machine forward onto the transport vehicle
support the weight of the machine. [Figure 10-40-1].

The rear of the trailer must be blocked to be supported Do not change direction of the machine while it is on the
when loading or unloading to prevent the front of the ramps.
transport from raising.
Lower the boom, arm, bucket and blade to the transport
Determine the direction of the track movement before vehicle.
moving the machine (blade forward). Engage the swing
lock. (See UPPERSTRUCTURE SLEW LOCK on Page Stop the engine and remove the key.
10-20-1.)
Put blocks under the front and rear of the tracks shoes.

10-40-1 E08 Service Manual

TRANSPORTING THE EXCAVATOR (CONT’D) Use chain binders to tighten the chains and then safely
tie the chain binder levers to prevent loosening.
Fastening
Figure 10-40-5
Figure 10-40-2

1 1

S3828
R0048

Figure 10-40-3 When on the transport vehicle, loop the chains through
the holes in the mounting frame.

Loop the chain (Item 1) [Figure 10-40-5] around the

bucket link.

WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
R0047
break and cause personal injury.
W-2058-0807
Figure 10-40-4

R0039

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

[Figure 10-40-2], to both sides of the tracks (Item 2)
[Figure 10-40-3] and to the tie-down loop at the rear of
the track frame (Item 1) [Figure 10-40-4].

10-40-2 E08 Service Manual

FOLD-DOWN TOPS Lowering The Fold-Down TOPS

TOPS Position Lowering the foldable canopy allows to reduce the

machine height in order to pass through small doors.
Figure 10-50-1
Figure 10-50-2

1
2

2 2 3

S8487
R0084

The excavator has an operator canopy (TOPS) (Tip-Over

Protective Structure) (Item 1) (meets ISO 12117) as Remove the clip (Item 1), the washer (Item 2) and spindle
standard equipment [Figure 10-50-1]. (Item 3) [Figure 10-50-2] on both sides of the canopy
(Item 2) [Figure 10-50-1].
The canopy provides operator protection if the excavator
tips over. The seat belt must be worn for TOPS Figure 10-50-3
protection.

3
2

R0014

Keep the clip (Item 1) and the washer (Item 2) within the
spindle (Item 3) [Figure 10-50-3].

10-50-1 E08 Service Manual

FOLD-DOWN TOPS (CONT’D) Raising The Foldable Canopy

Lowering The Fold-Down TOPS (Cont’d) To raise the foldable canopy, follow the same procedure
in reverse.
Figure 10-50-4

R0104

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

10-50-2 E08 Service Manual

TAILGATE Figure 10-60-2

Opening And Closing The Tailgate

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

Figure 10-60-1
R0042

Pull the tailgate (Item 1) till blocking the wedge (Item 2)

[Figure 10-60-2].

To close the tailgate, carefully pull the wedge, handling

the tailgate, and then close it until the latch is closed
again.
1
NOTE: The tailgate can be locked using the start key.

R0010

Release the latch (Item 1) [Figure 10-60-1] and pull the

tailgate open.

Close the tailgate before operating the excavator.

10-60-1 E08 Service Manual

10-60-2 E08 Service Manual
SERVICE SCHEDULE
Maintenance Intervals

Maintenance work must be done at regular intervals.

Failure to do so will result in excessive wear and early
failures.

The SERVICE SCHEDULE is a guide for correct

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

See inside page of the back cover for symbols and

identification.

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 - Clean debris from oil cooler, radiator and grille. 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.
• Motion Alarm - Check for proper function (if equipped).
• TOPS - Check condition and mounting hardware.
• Indicators and Lights - Check for correct operation of all indicators and lights.
• Safety Signs and Safety Tread - Check for damaged signs (decals) and safety tread. Replace any signs and safety
treads that are damaged.
• Hydraulic Fluid - Check fluid level and add as needed.
• Track Tension - Check tension and adjust as needed.
• Pivot Points - Grease all machinery pivot points.

First 50 Hours

• Engine Oil and Filter - Replace oil and filter.

• Drive Belts (Alternator / Fan) - Check condition. Replace as needed.
Every 50 Hours

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

10-70-1 E08 Service Manual

SERVICE SCHEDULE (CONT’D)

Maintenance Intervals (Cont’d)

First 100 Hours

• Alternator and Starter - Check connections.

• Drive Motors (Final Drive) - Replace fluid.
• Hydraulic Filter - Replace the hydraulic filter.

Every 100 Hours

• Spark Arrester Muffler - Clean spark chamber.

• Drive Belts (Alternator / Fan) - Check condition. Replace as needed.

Every 250 Hours Or Every 12 Months

• Fuel Filter - Replace filter.

• Drive 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.

• Cooling System - Clean debris from radiator, hydraulic fluid cooler (if equipped).
• Hydraulic Filter and Hydraulic Reservoir Breather Cap - Replace the hydraulic filter, and the reservoir breather
cap.
• Alternator and Starter - Check connections.
• Engine Valves - Adjust the engine valve clearance.

Every 1000 Hours Or Every 12 Months

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

• Drive Motors (Final Drive) - Replace fluid.

Every 24 Months

• Coolant - Replace the coolant.

SS EXC E08-E10 S5-K 07-18

10-70-2 E08 Service Manual

SERVICE SCHEDULE (CONT’D)

Contents Of The Inspection Checkbook (Logbook)

Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat Excavator.

The Inspection Checkbook contains the following information:

• Doosan Trading Limited Warranty Conditions

• Protection Plus Extended Warranty Conditions

• General Parts Policy

• General Information

• First Inspection

• Scheduled Services

• Authorised Identification

• Lubricants and Fluids Table

• Service Parts Charts

10-70-3 E08 Service Manual

10-70-4 E08 Service Manual
AIR CLEANER Replacing The Filters

See (See SERVICE SCHEDULE on Page 10-70-1.) for Outer Filter

the correct interval.
Pull out the locking tab (Item 2) [Figure 10-80-1].
Daily Check
Turn the dust cup (Item 3) [Figure 10-80-1] anticlockwise
Figure 10-80-1 about 1/8 turn.

1 Remove and clean the dust cup.

Figure 10-80-2

1
3

R0050

Check the condition indicator (Item 1) [Figure 10-80-1]. If

the red ring shows in the condition indicator, the filter
R0051
needs to be replaced.

Pull the outer filter (Item 1) [Figure 10-80-2] from the air
cleaner housing.

Check the housing for damage.

Clean the housing and the seal surface. DO NOT use

compressed air.

Install the dust cup (Item 3) [Figure 10-80-1] and turn it

clockwise about 1/8 turn.

Push the locking tab in (Item 2) [Figure 10-80-1].

Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.

10-80-1 E08 Service Manual

AIR CLEANER (CONT’D)

Replacing The Filters (Cont’d)

Inner Filter

Only replace the inner filter under the following

conditions:

• Replace the inner filter every third time the outer filter
is replaced.

• After the outer filter has been replaced, press the

button on the top of the condition indicator (Item 1)
[Figure 10-80-1] and start the engine. Run at full rpm,
then reduce engine speed and stop the engine. If the
red ring shows in the condition indicator, replace the
inner filter.

Figure 10-80-3

R0052

Remove the dust cap (Item 3) [Figure 10-80-1], the outer

filter (Item 1) [Figure 10-80-2] and the inner filter (Item 1)
[Figure 10-80-3].

NOTE: Make sure all sealing surfaces are free of dirt

and debris.

Install the new inner filter.

Install the outer filter and the dust cup.

Press the button on the condition indicator to reset the

condition indicator (Item 1) [Figure 10-80-1] (the red ring
will not show anymore).

10-80-2 E08 Service Manual

ENGINE COOLING SYSTEM Figure 10-90-1

Check the cooling system every day to prevent over-

heating, loss of performance or engine damage.

Cleaning The Cooling System

Open the tailgate.

Use air pressure or water pressure to clean the radiator

and oil cooler.
1
Checking The Coolant Level

R0095

WARNING The coolant level must be between the marks (Item 1)

[Figure 10-90-1] on the coolant recovery tank.
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned.
W-2070-1203
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
WARNING Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
AVOID INJURY OR DEATH
damage.
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
Too little antifreeze reduces the additives which
• When fluids are under pressure.
protect the internal engine components; reduces the
• Flying debris or loose material is present.
boiling point and freeze protection of the system.
• Engine is running.
• Tools are being used.
W-2019-0907
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
engine damage.
I-2124-0497

10-90-1 E08 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 10-90-3

Removing And Replacing The Coolant

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

correct service intervals.

WARNING 1

AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned. R0095
W-2070-1203

The coolant level must be between the marks (Item 1)

Figure 10-90-2 [Figure 10-90-3] on the coolant recovery tank.

Mix the coolant in a separate container.

NOTE: The cooling system is factory filled with

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

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

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.

Add premixed coolant; 47% water and 53% propylene

R0122
glycol to the recovery tank if the coolant level is low.

Open the drain valve (Item 1) [Figure 10-90-2] on the Use a refractometer to check the condition of propylene
engine block and drain the coolant into a container. glycol in your cooling system.

After all the coolant is removed, close the drain valve. Add premixed coolant until the level is correct.

Recycle or dispose of the used coolant in an Run the engine until it is at operating temperature. Stop
environmentally safe manner. the engine. Check the coolant level and add as needed.
Be sure the radiator cap is tight.
Mix the coolant in a separate container. (See Capacities
on Page SPEC-10-7.) Add coolant to the recovery tank as needed.

Close the tailgate.

10-90-2 E08 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.
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 machine storage; drain the fuel tank, refill with
100% petroleum diesel fuel, add fuel stabiliser, 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 three months.
marketed as B7 blended diesel fuel. B7
blended diesel fuel must meet EN590
specifications.

10-100-1 E08 Service Manual

FUEL SYSTEM (CONT’D) Removing Water From The Fuel Filter

Filling The Fuel Tank Open the tailgate.

Figure 10-100-1 Figure 10-100-2

1
2

R0050
R0053

Loosen the drain (Item 1) [Figure 10-100-2] at the

Remove the fuel fill cap (Item 1) [Figure 10-100-1] under bottom of the filter to drain water from the filter.
the left console using the key.

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

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

Install and tighten the fuel fill cap.

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

service interval when to remove water from or replace the
fuel filter.

10-100-2 E08 Service Manual

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System

Replacing The Fuel Filter After replacing the fuel filter or when the fuel tank has run
out of fuel, air must be removed from the fuel system
Remove the filter (Item 2) [Figure 10-100-2]. before starting the engine.

Clean the area around the filter housing. Put clean oil on Figure 10-100-3
the seal of the new filter. Install the fuel filter and tighten
by hand.

Remove the air from the fuel system. (See Removing Air 1
From The Fuel System on Page 10-100-3.)

Draining The Fuel Tank 3

To remove the fuel line at the engine and put the end of
the hose in a fuel can, squeeze the primer bulb (if
equipped) and drain the fuel tank that way (siphon
action).
2
(See SERVICE SCHEDULE on Page 10-70-1.) for the
correct service interval.
R0091

Open the fuel filter vent (Item 1) [Figure 10-100-3].

Operate the hand pump (priming bulb) (Item 2) [Figure

10-100-3] until the fuel flows from the vent with no air
bubbles.

Close the vent (Item 1) [Figure 10-100-3] on the fuel filter

housing.

Start the engine and let it run at low idle. It may be

necessary to open the vent at the fuel injection pump
(Item 3) [Figure 10-100-3] briefly until the engine runs
smoothly.

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

10-100-3 E08 Service Manual

10-100-4 E08 Service Manual
ENGINE LUBRICATION SYSTEM Oil Chart

Checking And Adding Engine Oil Figure 10-110-2

Check the engine oil every day before starting the engine ENGINE OIL
for the work shift. RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
Figure 10-110-1 CRANKCASE)

R0057

Open the tailgate and remove the dipstick (Item 1)

TEMPERATURE RANGE ANTICIPATED BEFORE
[Figure 10-110-1].
NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CI-4 OR BETTER)
Keep the oil level between the marks on the dipstick.
[1] Synthetic Oil - Use recommendation from Synthetic
Oil Manufacturer.

Use good quality engine oil that meets API Service

Classification of CI-4 or better [Figure 10-110-2].

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

10-110-1 E08 Service Manual

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-110-5

Removing And Replacing Oil And Filter

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

service interval for replacing the engine oil and filter.

Run the engine until it is at operating temperature. Stop

the engine.
1
Open the tailgate.

Figure 10-110-3

R0058

1
Remove the fill cap (Item 1) [Figure 10-110-5].

Put in 3,5 L (3.7 qt) of oil into the engine.

Use a good quality motor oil that meets the correct API
Service Classification [Figure 10-110-2].

Install the fill cap.

Start the engine and let it run for several minutes.

R0056

Remove the drain plug (Item 1) [Figure 10-110-3] from Stop the engine. Check for leaks at the oil filter. Check
the oil level.
the drain hose. Drain the used oil into a container and
recycle or dispose of used oil in an environmentally safe Add oil as needed if it is not at the top mark on the
manner. dipstick.

Figure 10-110-4

R0055

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

the filter housing surface.

Use a genuine Bobcat filter.

Put clean oil on the filter gasket.

Install the filter and tighten by hand.

Install the drain plug. Tighten the plug to 32,4 - 37,3 N•m
(24 - 28 ft-lb) torque.

10-110-2 E08 Service Manual

LUBRICATION OF THE EXCAVATOR Figure 10-130-3

Lubrication Locations

Lubricate the hydraulic excavator as specified in the

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

Record the operating hours each time you lubricate the

hydraulic excavator.

Always use a good quality lithium based multipurpose

3
grease when lubricating the excavator. Apply the
lubricant until extra grease shows.

Figure 10-130-1 R0080

3. Boom Swing Cylinder, Rod End, every 8 - 10 hours

(Item 3) [Figure 10-130-3].

Figure 10-130-4

R0082 5

1. Blade Cylinder-Base End, every 8 - 10 hours (Item 1)

[Figure 10-130-1].

Figure 10-130-2 R0079

4. Boom Cylinder, Rod End (Item 4) [Figure 10-130-4].

5. Boom Swing Pivot, every 8 - 10 hours (Item 5)

[Figure 10-130-4].

R0081

2. Blade Pivots, every 8 - 10 hours (Item 2) [Figure 10-

130-2].

10-130-1 E08 Service Manual

LUBRICATING THE EXCAVATOR (CONT’D) Figure 10-130-7

Lubrication Locations (Cont’d)

Figure 10-130-5

6 6

R0076

9. Arm Cylinder, Rod End, every 8 - 10 hours (Item 9)

R0078 [Figure 10-130-7].

Figure 10-130-8
6. Boom, Base Pivot, every 8 - 10 hours (Item 6) [Figure
10-130-5].

Figure 10-130-6

8 10

7
R0075

10. Arm Pivot, every 8 - 10 hours (Item 10) [Figure 10-

R0077 130-8].

7. Boom Cylinder, Base End, every 8 - 10 hours (Item 7)

[Figure 10-130-6].

8. Arm Cylinder, Base End, every 8 - 10 hours (Item 8)

[Figure 10-130-6].

10-130-2 E08 Service Manual

LUBRICATING THE EXCAVATOR (CONT’D) Figure 10-130-11

Lubrication Locations (Cont’d) 14

Figure 10-130-9

15
15
11

R0118

14. Bucket Link Pivot, every 8 - 10 hours (Item 14)

R0074 [Figure 10-130-11].

15. Bucket Pivots, every 8 - 10 hours (Item 15) [Figure

11. Bucket Cylinder, Base End, every 8 - 10 hours (Item 10-130-11].
11) [Figure 10-130-9].
Figure 10-130-12
Figure 10-130-10

16

17
13 12 13

R0083
R0073

16. Swing Circle Bearing, every 50 hours (Item 16)

12. Bucket Cylinder, Rod End, every 8 - 10 hours (Item [Figure 10-130-12].
12) [Figure 10-130-10].
17. Swing Circle Pinion, every 50 hours (Item 17) [Figure
13. Bucket Link, Bucket Cylinder Pivot, every 8 - 10 hours 10-130-12]. Pump 4 times with a grease gun. Rotate
(Item 13) [Figure 10-130-10]. the upperstructure 180° and repeat.

NOTE: Do not over-grease the swing circle; damage

to the seal could result. Pump 4 - 5 times with
a grease gun. Rotate the upperstructure 90°
and repeat three more times.

10-130-3 E08 Service Manual

LUBRICATING THE EXCAVATOR (CONT’D)

Lubrication Locations (Cont’d)

Figure 10-130-13

18 18

P59012
R0083

18. Track Expansion Tube, as required (Item 18) [Figure

10-130-13].

NOTE: Spread lubriplate gearshield extra heavy

grease evenly on wear surfaces on both sides
of excavator as required.

10-130-4 E08 Service Manual

TRAVEL MOTOR Draining The Travel Motor

Checking Oil Level (See SERVICE SCHEDULE on Page 10-70-1.) For the
correct service interval.
Figure 10-140-1
Put the machine on a level surface with the plugs
positioned as shown (Items 1 and 2) [Figure 10-140-1].

Remove the bottom plug (Item 2) and top plug (Item 1)

[Figure 10-140-1] and drain into a container. Recycle or
dispose of the used lubricant in an environmentally safe
manner.

After all the gear lube is removed, install the bottom plug
1
(Item 2) [Figure 10-140-1].

Add gear lube to the top plug hole (Item 1) [Figure 10-
140-1] until the gear lube level is at the bottom edge of
the plug hole. See Chart for capacity and type.
2
S5240
Install and tighten the top plug.

Put the machine on a level surface with the plugs Repeat the procedure for the other side.
positioned as shown (Items 1 and 2) [Figure 10-140-1].

Remove the top plug (Item 1) [Figure 10-140-1]. The oil

level should be at the bottom edge of the plug hole.

Add gear lube through the plug hole if the oil level is
below the hole. See Chart for capacity and type.

Install and tighten the top plug.

Repeat the procedure for the other side.

10-140-1 E08 Service Manual

10-140-2 E08 Service Manual
SPARK ARRESTER MUFFLER Figure 10-150-2

Cleaning Procedure

Figure 10-150-1

1
1 1
R0119

Remove the plug (Item 1) [Figure 10-150-2] from the

bottom of the muffler.
1
Start the engine and run for about 10 seconds while a
second person, wearing safety glasses, holds a piece of
S7554 wood over the outlet of the muffler (the carbon deposits
will be forced out of the muffler clean out hole).
Remove the four bolts (Item 1) [Figure 10-150-1].
Stop the engine. Install and tighten the plug.
Remove the cover.
Install the cover. Tighten the bolts. Close the tailgate.
(See SERVICE SCHEDULE on Page 10-70-1.) for the
correct service interval.

Do not operate the excavator with a defective exhaust

system.
WARNING
Stop the engine. Open the tailgate. Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
cause injury or death.
W-2068-1285
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
WARNING
W-2011-1285
When the engine is running during service, the
steering levers must be in neutral.

Failure to do so can cause injury or death.

W-2203-0595

10-150-1 E08 Service Manual

10-150-2 E08 Service Manual
ALTERNATOR BELT Figure 10-160-3

Adjusting The Alternator Belt

Replace the belt if it has stretched or there are cracks in

the belt. Replace the pulley if the belt makes contact with
the bottom of the groove in the pulley. 1

The tools listed will be needed to do the following

procedure:

P/N 7001906 - Bowed Key Wrench 11x13

Figure 10-160-1

3 S8279

Loosen the upper alternator bolt using a bowed key

2 wrench [Figure 10-160-3].

Figure 10-160-4

S6774

Remove the two bolts (Item 1) and remove the fan apron
(Item 2) [Figure 10-160-1].
1
Remove the fill cap (Item 3) [Figure 10-160-1] from the
hydraulic reservoir.
S8243
Figure 10-160-2

Loosen the lower alternator mounting and adjustment

1 bolt (Item 1) [Figure 10-160-4].
1

S7554

Remove the four bolts (Item 1) [Figure 10-160-2].

Remove the cover.

10-160-1 E08 Service Manual

ALTERNATOR BELT (CONT’D)

Adjusting The Alternator Belt (Cont’d)

Figure 10-160-5

S8247

If a belt tension tool is available, move the alternator

toward the front of the machine (Item 2) [Figure 10-160-
4] until the belt (Item 1) [Figure 10-160-5] has (New belt
= 56 - 60 lbf or Used belt = 48 - 52 lbf) tension.

If a belt tension tool is not available, move the alternator

toward the front of the machine (Item 2) [Figure 10-160-
4] until the belt (Item 1) [Figure 10-160-5] has 13 mm
(0.50 in) movement at the middle of the belt span with 58
N (13 lbf) of force.

Tighten the mounting and adjustment bolts.

Install the cover, fill cap and fan apron.

10-160-2 E08 Service Manual

SEAT BELT Figure 10-170-1

Inspection And Maintenance

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

Check the seat belt daily for correct function.

Inspect the seat belt system thoroughly yearly or more

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

The seat belt system should be repaired or replaced if it

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

The items below are referenced in [Figure 10-170-1]. B-22283

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

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

2. Check the buckle and latch for correct operation.

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

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

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

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

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

10-170-1 E08 Service Manual

10-170-2 E08 Service Manual
CONTROL CONSOLE LOCKOUTS

Inspection And Maintenance

When the control lockout levers are raised, the hydraulic

control levers must not function.

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

Figure 10-180-1

1
1

R0101

Raise the control lockout levers (Item 1) [Figure 10-180-

1]. The levers must be firmly locked in neutral position
and there should not be any hydraulic function for the
boom, arm, bucket and swing.

Service the system if these controls do not deactivate

when the control lockout is raised.

10-180-1 E08 Service Manual

10-180-2 E08 Service Manual
EXCAVATOR STORAGE AND RETURN TO SERVICE Return to Service

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

necessary to follow a list of items to return the excavator
Sometimes it may be necessary to store your Bobcat to service.
excavator for an extend period of time. Below is a list of
items to perform before storage. • Check the engine and hydraulic oil levels; check
coolant level.
• Thoroughly clean the excavator including the engine
• Install a fully charged battery.
compartment.
• Remove grease from exposed cylinder rods.
• Lubricate the excavator.
• Check all belt tensions.
• Replace worn or damaged parts.
• Be sure all shields and guards are in place.
• Drive the excavator onto planks in a dry protected
shelter. • Lubricate the excavator.
• Lower the boom fully with the bucket flat on the • Remove cover from exhaust pipe opening.
ground. • Start the engine and let run for a few minutes while
observing the instrument panels and systems for
• Put grease on any exposed cylinder rods. correct operation.
• Put fuel stabilizer in the fuel tank and run the engine • Drive the excavator off of the planks.
a few minutes to circulate the stabilizer to the pump
• Operate machine, check for correct function.
and fuel injectors.
• Drain and flush the cooling system. Refill with • Stop the engine and check for leaks. Repair as
premixed coolant. needed.
• Replace all fluids and filters (engine, hydraulic).
• Replace all filters (i.e.: air cleaner, heater, etc.).
• Put all controls in neutral position.
• Remove the battery. Be sure the electrolyte level is
correct then charge the battery. Store it in a cool dry
place above freezing temperatures and charge it
periodically during storage.
• Cover the exhaust pipe opening.
• Tag the machine to indicate that it is in storage
condition.

10-190-1 E08 Service Manual

10-190-2 E08 Service Manual
STOPPING AND LEAVING THE EXCAVATOR

Procedure

Figure 10-200-1

R0111

Stop the machine on level ground. Lower the work

equipment and the blade to the ground [Figure 10-200-
1].

Figure 10-200-2

R0102

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

200-2] fully down and run the engine at idle speed for
about 5 minutes to allow it to cool.

Stop the engine.

Raise the control lockout levers.

Disconnect the seat belt. Remove the key from the switch
to prevent operation of machine by unauthorized
personnel. Exit machine.

10-200-1 E08 Service Manual

10-200-2 E08 Service Manual
MOTION ALARM Figure 10-210-2

Description

This excavator may be equipped with a motion alarm 2

system. The motion alarm will sound when the operator
moves the travel control levers in either the forward or
reverse directions.

Inspecting

Figure 10-210-1 1

R0131

Figure 10-210-3

S9704

Inspect for damaged or missing motion alarm decal (Item

1) [Figure 10-210-1]. Replace if damaged.

Sit in the operator’s seat. Turn excavator key to ON R0133

position but DO NOT start the engine.

Move the travel control levers in the forward direction. Inspect the motion alarm connections (Item 1), wire
The motion alarm must sound. Move the travel control harness (Item 2) [Figure 10-210-2] and motion alarm
levers in the reverse direction. The motion alarm must switch (Item 1) [Figure 10-210-3] for tightness and
sound. damage. Repair or replace any damaged components.

Turn the excavator key to the OFF position. If the motion alarm switch requires adjustment, see
information below.
The motion alarm is located on the lower part of the
frame, on top of the swing cylinder.

10-210-1 E08 Service Manual

MOTION ALARM (CONT’D) Figure 10-210-6

Adjusting Switch Position

Remove the instrument panel.

Figure 10-210-4
2

R0133

Place the travel control levers in the neutral position.

1
Loosen the screws (Item 1) [Figure 10-210-6] securing
S8477 the motion alarm switch.

Position the motion alarm switch roller (Item 2) so that it

Remove the four bolts (Item 1) [Figure 10-210-4] from makes contact with bearing (Item 3) until it opens the
the cover. switch circuit. (Listen for the click of the switch.) Torque
the screws (Item 1) [Figure 10-210-6] securing the
Figure 10-210-5 switch to the bracket to 1,6 - 2,1 N•m (14 - 19 in-lb).

Inspect the motion alarm system for correct operation

after adjustment.

S8478

Remove the bolts (Item 1) [Figure 10-210-5] and remove

the cover.

10-210-2 E08 Service Manual

HYDRAULIC SYSTEM

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

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting The Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting The Cylinder Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting The Swing (Upperstructure Slew) Circuit . . . . . . . . . . . . . . . . . . . . 20-10-7
Troubleshooting The Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-8

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

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

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-7

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2
Parts Identification (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Disassembly (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
Assembly (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-7
Parts Identification (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-10
Disassembly (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-11
Assembly (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-13

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-7

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

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-2
Parts Identification (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-3
Disassembly (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-4
Assembly (Earlier Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-6
Parts Identification (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-9
Disassembly (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-10
Assembly (Later Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-12

20-01 E08 Service Manual

CYLINDER (TRACK FRAME EXPANSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-9

VALVE (MAIN RELIEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Testing And Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

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

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

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9
Left Travel Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Slew Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Arm Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-18
Boom Swing Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-40-22
Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Blade Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32
Bucket Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-36
Boom Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-40
Right Travel Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 20-40-44
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-48

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

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing The Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-8

TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-11

SWIVEL JOINT (S/N A4BP11673 & ABOVE AND S/N B4PC11001 & ABOVE) . . . . . . 20-70-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-7

20-02 E08 Service Manual

SWIVEL JOINT (S/N A4BP11468 - A4BP11672) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-7

SWIVEL JOINT (S/N A4BP11117 - A4BP11467) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-72-7

SWIVEL JOINT (S/N A4BP11001 - A4BP11117) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-73-7

SLEW MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-11

HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

BLADE / TRACK EXPAND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Control Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-3

ELECTRIC BLADE / TRACK EXPAND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-2
Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-3

20-03 E08 Service Manual

20-04 E08 Service Manual
HYDRAULIC/HYDROSTATIC SCHEMATIC
E08 (S/N A4BP11001 AND ABOVE)
(PRINTED MAY 2011)
V-1215legend

LEGEND
1 HYDRAULIC RESERVOIR 9 SLEW MOTOR - CROSS PORT RELIEF
(PRESSURIZED) with FILL STRAINER VALVE: 8,0 MPa (80 bar) (1160 psi)
Reservoir Capacity: . . . . . . . 2,6 L (2.75 qt)
System Capacity to center of site gauge: 10 ANTICAVITATION VALVE
. . . . . . . 10,1 L (10.7 qt) Boom Swing Cylinder (Rod End)
2 FILL CAP – with Breather Filter
11 ANTICAVITATION VALVE
Arm Cylinder (Rod End)
3 HYDRAULIC FILTER ELEMENT
10 Micron 12 CHECK VALVE

4 FILTER BY-PASS: 0,172 MPa (1,72 bar) (25 psi) 13 ORIFICE . . . . . . . . . . 1,2 mm (0.04 in)

14 ORIFICE . . . . . . . . . . 1,1 mm (0.04 in)

5 HYDRAULIC PUMP - 2 Section Gear Pump:
Pump Section 1
15 ORIFICE . . . . . . . . . . 1,1 mm (0.043 in)
10,0 Lpm (2.6 U.S. gpm) at High Engine Idle
Pump Section 2
10,0 Lpm (2.6 U.S. gpm) at High Engine Idle 16 TRAVEL MOTOR SPOOL

6 MAIN RELIEF VALVE (2): 18,5 MPa 17 CHECK VALVE (Later Models Only)
(185 bar) (2683 psi)
18 ORIFICE . . . . . . . . . . 1,2 mm (0.04 in)
7 PORT RELIEF / ANTICAVITATION VALVE (Later Models Only)
Boom Cylinder (Base End): 32,2 MPa
(232 bar) (3365 psi) 19 PORT RELIEF / ANTICAVITATION VALVE
Bucket Cylinder (Base End) – (Later Models Only)
8 PORT RELIEF / ANTICAVITATION VALVE 23,2 MPa (232 bar) (3365 psi)
Arm Cylinder (Base End): 22,5 MPa
(225 bar) (3262 psi)

NOTE: Unless otherwise specified

springs have NO significant
pressure value.

Printed in U.S.A. V-1215 (5-17-11)

P2

6
HYDRAULIC/HYDROSTATIC SCHEMATIC
E08 S/N A4BP11001 AND ABOVE

(PRINTED MAY 2011) RH TRAVEL

A
V-1215

12
R.H. TRAVEL MOTOR

BOOM
16 BOOM
CYLINDER
A

P1 T1 12 7
B
P2
12
13

BUCKET
5
14

A PUMP 1
BLADE 19
CYLINDER

H2
F F BUCKET
B
CYLINDER PUMP 2
A A
12
B B 15
HYDRAULIC
BLADE PUMP
TRACK
H1 H A
EXPAND
VALVE
E1
E NO AUXILIARY B
E2 MALE HYDRAULIC COUPLERS
AUXILIARY
(RETURN) (STANDARD)
HYDRAULIC A
C C COUPLERS
D D TWO WAY B
G G FLOW FEMALE
(OPTIONAL) (PRESSURE)
CENTER AUX
SWIVEL JOINT
AUXILIARY MALE T1
EXPAND HYDRAULIC (RETURN)
CYLINDER COUPLERS BOOM
SWING 12
ONE WAY CYLINDER
FLOW FEMALE A
10
(OPTIONAL) (PRESSURE)

BOOM SWING

12

11 VENTED CAP 2
16

P1 T1
8
B ARM 1
P2
RESERVOIR
ARM 3
12
CYLINDER

SLEW 9
18
MOTOR UPPERSTRUCTURE
17
TURNS CCW A
B
9

A COOLER
UPPERSTRUCTURE B (OPTIONAL WITH 4
TURNS CW BREAKER KIT)
SLEW FILTER W/ BY-PASS

12

ENCLOSURE
A
PUMP SUPPLY
WORKING CIRCUITS
B PILOT PRESSURE
LH TRAVEL SYSTEM RETURN LINES
INTERSECTION OF
HYDRAULIC LINES
INDICATED BY JUNTION DOT

P1

V-1215 (5-17-11)
HYDRAULIC/HYDROSTATIC SCHEMATIC
E08 (S/N B4PC11001 AND ABOVE)
(PRINTED MAY 2019)
V-1685legend

LEGEND
1 HYDRAULIC RESERVOIR 9 SLEW MOTOR - CROSS PORT RELIEF
(PRESSURIZED) with FILL STRAINER VALVE: 8,0 MPa (80 bar) (1160 psi)
Reservoir Capacity: . . . . . . . 2,6 L (2.75 qt)
System Capacity to center of site gauge: 10 ANTICAVITATION VALVE
. . . . . . . 10,1 L (10.7 qt) Boom Swing Cylinder (Rod End)
2 FILL CAP – with Breather Filter
11 PORT RELIEF / ANTICAVITATION VALVE
Arm Cylinder (Rod End): 23,2 MPa
(232 bar) (3365 psi)
3 HYDRAULIC FILTER ELEMENT
10 Micron 12 CHECK VALVE

4 FILTER BY-PASS: 0,172 MPa (1,72 bar) (25 psi) 13 ORIFICE . . . . . . . . . . 1,2 mm (0.04 in)

14 ORIFICE . . . . . . . . . . 1,1 mm (0.04 in)

5 HYDRAULIC PUMP - 2 Section Gear Pump:
Pump Section 1
15 ORIFICE . . . . . . . . . . 1,1 mm (0.043 in)
10,0 Lpm (2.6 U.S. gpm) at High Engine Idle
Pump Section 2
10,0 Lpm (2.6 U.S. gpm) at High Engine Idle 16 TRAVEL MOTOR SPOOL

6 MAIN RELIEF VALVE (2): 18,5 MPa 17 CHECK VALVE (Later Models Only)
(185 bar) (2683 psi)
18 ORIFICE . . . . . . . . . . 1,2 mm (0.04 in)
7 PORT RELIEF / ANTICAVITATION VALVE
Boom Cylinder (Base End): 23,2 MPa
(232 bar) (3365 psi) 19 PORT RELIEF / ANTICAVITATION VALVE
Bucket Cylinder (Base End): 23,2 MPa
8 PORT RELIEF / ANTICAVITATION VALVE 23,2 MPa (232 bar) (3365 psi)
Arm Cylinder (Base End): 22,5 MPa
(225 bar) (3262 psi)

NOTE: Unless otherwise specified

springs have NO significant
pressure value.

Printed in U.S.A. V-1685 (5-22-19)

P2

HYDRAULIC/HYDROSTATIC SCHEMATIC 6

E08 S/N B4PC11001 AND ABOVE

(PRINTED MAY 2019) RH TRAVEL

V-1685 A

12
R.H. TRAVEL MOTOR

BOOM
16 BOOM
CYLINDER
A

P1 T1 12 7
B
P2
12
13

BUCKET
5
14

A PUMP 1
BLADE 19
CYLINDER

H2
F F BUCKET
B
CYLINDER PUMP 2
A A
12
B B 15
HYDRAULIC
BLADE PUMP
TRACK
H1 H A
EXPAND
VALVE
E1
E NO AUXILIARY B
E2 MALE HYDRAULIC COUPLERS
AUXILIARY
(RETURN) (STANDARD)
HYDRAULIC A
C C COUPLERS
D D TWO WAY B
G G FLOW FEMALE
(OPTIONAL) (PRESSURE)
CENTER AUX
SWIVEL JOINT
AUXILIARY MALE T1
EXPAND HYDRAULIC (RETURN)
CYLINDER COUPLERS BOOM
SWING 12
ONE WAY CYLINDER
FLOW FEMALE A
10
(OPTIONAL) (PRESSURE)

BOOM SWING

12

11 VENTED CAP 2
16

P1 T1
8
B ARM 1
P2
RESERVOIR
ARM 3
12
CYLINDER

SLEW 9
18
MOTOR UPPERSTRUCTURE
17
TURNS CCW A
B
9

A COOLER
UPPERSTRUCTURE B (OPTIONAL WITH 4
TURNS CW BREAKER KIT)
SLEW FILTER W/ BY-PASS

12

ENCLOSURE
A
PUMP SUPPLY
WORKING CIRCUITS
B PILOT PRESSURE
LH TRAVEL SYSTEM RETURN LINES
INTERSECTION OF
HYDRAULIC LINES
INDICATED BY JUNTION DOT

P1
V-1685 (5-22-19)
HYDRAULIC SYSTEM INFORMATION

Glossary Of Hydraulic / Hydrostatic Symbols

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

FLOW LINES and CONNECTIONS BASIC and MISCELLANEOUS SYMBOLS

WORKING CIRCUITS - Continuous, RESTRICTION - Line with Fixed

Solid Line - Working (Main) Line, Restriction - Affected by Viscosity
Return Line (line conducting fluid (property of resistance to flowing
from working devices to the reservoir) fluid).
and Feed line (main line conductor).
VARIABLE ADJUSTMENT
RESTRICTION - Regulated or
Variable Restriction.
PILOT PRESSURE - Dashed Line -
Pilot Line (Line which conducts TEMPERATURE CONTROL -
control fluid). (Indication of temperature).

DRAIN CIRCUITS - Dotted Line -

TEMPERATURE INDICATOR -
Drain Line (drain or bleed line - line
(temperature measurement -
conducting fluid from a component
thermometer).
housing to the reservoir.
FILTER (strainer or screen) - For fluid
conditioning.
COMPONENTS - Long Chain Line -
Enclosure outline for several
components assembled in one unit. VENTED AND FILTERED
RESERVOIR (reservoir open to
atmosphere).
MECHANICAL CONNECTIONS -
Double Line (Shaft, Lever, Piston
Rod). PRESSURIZED, VENTED AND
FILTERED RESERVOIR (Reservoir
uses a pressured cap).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection). OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).

OIL LINES CROSSING (NOT PRESSURE SENSOR - Varies

Connected). electric signal with pressure.

DIFFERENTIAL PRESSURE
COUPLER - Quick - Acting Coupling SWITCH - Switch activates when
(uncoupled, closed by non-return pressure difference reaches specified
valve). level.

PRESSURE SWITCH - Switch

activates when pressure reaches
specified level.

MUFFLER (silencer) - Reduces

noise.

20-10-1 E08 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

linear energy and in which the fluid pressure operates
alternately in both directions (forward and backward CONTROL VALVE WITH DETENT
strokes). (Holds Valve in Position) - device for
maintaining a given position
DOUBLE ACTING HYDRAULIC (mechanical).
CYLINDER, UNEQUAL
DISPLACEMENT - With single piston CONTROL VALVE ACTIVATED BY A
rod. PULL BUTTON (manual).

DOUBLE ACTING HYDRAULIC

CYLINDER, UNEQUAL CONTROL VALVE ACTIVATED BY A
DISPLACEMENT and CUSHION ON PUSH-PULL BUTTON (manual).
ONE END - With single piston rod.

CONTROL VALVE ACTIVATED BY A

LEVER (manual).
PUMP: To convert mechanical energy into hydraulic
energy.
CONTROL VALVE ACTIVATED BY A
PEDAL (manual).
FIXED CAPACITY DISPLACEMENT
HYDRAULIC PUMP - With one
direction of flow.
CONTROL VALVE WITH SPRING
RETURN (mechanical).
VARIABLE CAPACITY
DISPLACEMENT BIDIRECTIONAL
HYDRAULIC PUMP - With two CONTROL VALVE ACTIVATED BY
directions of flow (bidirectional). AN ELECTRIC SOLENOID
(electrical).

MOTOR: To convert hydraulic energy into rotary CONTROL VALVE ACTIVATED BY A

mechanical energy. PROPORTIONAL ELECTRICAL
SOLENOID (electrical).

FIXED CAPACITY DISPLACEMENT CONTROL VALVE ACTIVATED BY

BIDIRECTIONAL HYDRAULIC DUAL ELECTRICAL SOLENOID
MOTOR - With two directions of flow (electrical).
(bidirectional.
CONTROL VALVE ACTIVATED BY
PILOT PRESSURE (indirect control,
pilot actuated by application of
pressure).

20-10-2 E08 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for the
allows free flow in one direction only. opening (fully or restricted) or the closing of one or more
flow paths (represented by several squares).

NON-RETURN VALVE (Check Valve) TWO PORTS and CLOSED FLOW

OUT IN - Used as Replenishing Valve, Lock PATHS
Check Valve or Anticavitation Valve -
Opens if the Inlet pressure is higher
than the Outlet pressure. Often SOLENOID ACTIVATED
contains internal spring which has NO DIRECTIONAL CONTROL VALVE
significant pressure value. (Two Position) - controlled by an
electric solenoid (with return spring).
SPRING LOADED VALVE (bypass
OUT IN Valve) - Opens if the Inlet pressure is PILOT ACTIVATED DIRECTIONAL
greater than the Outlet pressure plus CONTROL VALVE (Two Position) -
the spring pressure. controlled by pressure (with return
spring).
PILOT CONTROLLED NON-
RETURN VALVE- It is possible to MANUALLY ACTIVATED DIRECTION
open the valve by pilot pressure. CONTROL VALVE (Variable Position)
OUT IN T Joystick Controlled, variable pressure
P
to shift the pilot activated directional
control valve spool.
SHUTTLE VALVE - The Inlet port
IN IN
connected to the higher pressure is
OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST

O
IS
D

FRONT

BACK
control switching joystick functions for
STD / ISO Control (excavators Only).

STEERING CONTROL VALVE

(Variable Position) - Used for
controlling the hydraulic flow for the
steering cylinders in relationship to
the amount the steering wheel is
rotated.

20-10-3 E08 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

control of pressure.
ACCUMULATOR - Supplies
RELIEF VALVE - When the Inlet temporary reserve pressure to the
pressure overcomes the opposing hydraulic system when the engine
IN OUT force of the spring, the valve opens has been stopped.
permitting flow from the Outlet port.

RELIEF / REPLENISHING VALVE or

RELIEF / ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.

DUAL PRESSURE RELIEF VALVE -

When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port. Pilot pressure provides a
second pressure value.

LOCK VALVE - hydraulic pressure is

applied to open the valve to allow the
hydraulic cylinder to move.

FLOW CONTROL VALVE: Valve controlling the flow in

one or both directions.

ONE WAY RESTRICTOR VALVE

(Non-Return Valve with Restriction) -
Unit allowing free flow in one direction
but restricted flow in the other
direction.

TOW VALVE - Normally in closed

position.

LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

20-10-4 E08 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Hydraulic Circuit

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. Check, repair or replace.
Main relief valve(s) defective. Readjust or replace.
Hydraulic power insufficient to one Main relief valve(s) pressure setting incorrect. Readjust or replace.
or more circuits.
Hydraulic speed too slow. Hydraulic oil level or viscosity incorrect. Refill or replace.
Engine rpm reduced. Readjust or replace.
Control valve linkage defective. Check, repair or replace
Hydraulic pump volume low. Check, repair or replace.
Oil temperature too high. Oil cooler (if equipped) or radiator fins plugged. Clean oil cooler (if equipped)
or radiator external surface.
Hydraulic oil level low. Refill or replace.
Non recommended hydraulic oil Replace.
Relief valve excessively activated. Use proper operating
procedures.
One or more relief valves not set correctly. Test, readjust or replace.
Extreme operating conditions. High ambient
temperature (e.g.: enclosed structure).
Alternator belt loose. Tighten alternator belt.

20-10-5 E08 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Cylinder Circuit

TROUBLESHOOTING THE CYLINDER CIRCUIT

PROBLEM CAUSE CORRECTION
Cylinder inoperable. Control console lockout engaged. Disengage control console
lockout.
Loose fittings or broken hoses. Repair or replace.
Lever linkage misadjusted. Readjust.
Cylinder internal leakage excessive. Repair or replace.
Cylinder force insufficient. Main relief valve(s) pressure too low. Readjust or replace.
Work port relief pressure too low. Readjust or replace.
Cylinder speed too slow. Lever linkage misadjusted. Readjust.
Cylinder internal leakage excessive. Repair or replace.
Control valve internal leakage excessive. Repair or replace.
Cylinder drift excessive. Cylinder internal leakage excessive. Repair or replace.
Work port relief valve seals leaking. Test, repair or replace.
Control valve internal leakage excessive. Repair or replace.

20-10-6 E08 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Swing (Upperstructure Slew) Circuit

TROUBLESHOOTING THE SWING (UPPERSTRUCTURE SLEW) CIRCUIT

PROBLEM CAUSE CORRECTION
Swing not operating. Control console lockout engaged. Disengage control console
lockout.
Swing lock pin engaged. Disengage lock pin.
Lever linkage mis-adjusted. Readjust.
Swing motor gear defective. Repair or replace.
Swing motor defective. Repair or replace.
Swing force. Main relief valve set too low. Readjust or replace.
Swing motor cross port relief valve pressure too Readjust or replace.
low.
Swing speed too slow. Pump flow low. Check, repair or replace.
Blocked or restricted line to swing motor. Replace.
Control valve internal leakage excessive. Repair or replace.
Swing motor internal leakage excessive. Repair or replace.
Swing over run excessive. Control valve spool sticking. Repair or replace.
Swing motor cross port relief valve set too low. Repair or replace.
Swing motor internal leakage excessive. Repair or replace.

20-10-7 E08 Service Manual

HYDRAULIC SYSTEM INFORMATION (CONT’D)

Troubleshooting The Travel Circuit

TROUBLESHOOTING THE TRAVEL CIRCUIT

PROBLEM CAUSE CORRECTION
Travel system inoperable. Lever linkage incorrectly adjusted. Readjust.
Track tension too tight. Readjust.
Defective pump. Check, repair or replace.
Travel motor counterbalance spool sticking. Repair or replace.
Travel motor internal leakage excessive. Repair or replace.
Travel motor defective. Repair or replace.
Travel motor gears defective. Repair or replace.
Swivel joint defective. Repair or replace.
Main relief valve pressure too low. Readjust or replace.
Travel power. Track tension too tight. Readjust.
Main relief valve pressure too low. Readjust or replace.
Travel motor counterbalance spool sticking. Repair or replace.
Speed too slow. Lever linkage incorrectly adjusted. Readjust.
Swivel joint internal leakage excessive. Repair or replace.
Control valve internal leakage excessive. Repair or replace.
Low pump pressure. Check, repair or replace.
Travel motor internal leakage excessive. Repair or replace.
Machine not running straight. Lever linkage incorrectly adjusted. Readjust.
Track tension not equal. Readjust.
Pump output not equal. Repair or replace.
Travel motor internal leakage not equal. Repair or replace.
Travel motor counterbalance spool sticking. Repair or replace.
Main relief valve pressure set too low. Repair or replace.
Swivel joint internal leakage excessive. Repair or replace.
Control valve internal leakage not equal. Repair or replace.
Machine will not hold on slope or Travel motor counterbalance valve leakage Repair or replace.
while digging. excessive.
Hose damage. Replace.
Blade drops while machine is Lever linkage misadjusted. Readjust.
moving. Cylinder internal leakage excessive. Repair or replace.
Control valve internal leakage excessive. Repair or replace.
Swivel joint internal leakage from travel motor Repair or replace.
pressure circuit into blade cylinder circuit.

20-10-8 E08 Service Manual

CYLINDER (BOOM) Figure 20-20-3

Testing

Lower the boom / bucket and blade to the ground.

Stop the engine. Raise the control console.

Figure 20-20-1
1

2
S7489

Remove the bolt and nut (Item 1) [Figure 20-20-3] from

the rod end pivot pin.

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

S7660 Figure 20-20-4

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

Figure 20-20-2

S7490

Lower control console and fasten the seat belt. Start the
engine and retract the boom cylinder.
S7488
With the key in the ON position and the engine stopped,
move the hydraulic controls to release the hydraulic
Support the boom cylinder [Figure 20-20-2]. pressure. Raise the control console.

Disconnect the boom cylinder base end hose (Item 1)

[Figure 20-20-4] from the boom cylinder.

20-20-1 E08 Service Manual

CYLINDER (BOOM) (CONT’D) Removal And Installation

Testing (Cont’d) Lower the boom / bucket and blade to the ground. Stop
the engine.

Figure 20-20-6
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
doctor familiar with this injury is not received
immediately.
W-2145-EN-0210

Figure 20-20-5

S7660

1
Support the boom using a chain hoist [Figure 20-20-6].

With the key in the ON position, move the hydraulic

controls to release the hydraulic pressure.

IMPORTANT
S7491
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
Install a cap (Item 1) [Figure 20-20-5] on the hose fitting parts clean. Always use caps and plugs on hoses,
and tighten. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Lower control console and fasten seat belt. Start the I-2003-0888
engine and retract the boom cylinder.

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

boom cylinder, remove the cylinder for repair or
replacement.

20-20-2 E08 Service Manual

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

Removal And Installation (Cont’d)

3 2
Figure 20-20-7
1

S7488

Disconnect and cap the two hoses (Item 1) [Figure 20-

S7488 20-9] from the boom cylinder.

Remove the bolt and nut (Item 2) [Figure 20-20-9] from

Support the boom cylinder [Figure 20-20-7]. the boom cylinder base end pin.

Figure 20-20-8 Remove the boom cylinder base end pin (Item 3) [Figure
20-20-9].

Remove the boom cylinder.

1
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
2 doctor familiar with this injury is not received
S7489
immediately.
W-2145-EN-0210

Remove the bolt and nut (Item 1) [Figure 20-20-8] from

the rod end pivot pin.

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

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

20-20-3 E08 Service Manual

CYLINDER (BOOM) (CONT’D)

Parts Identification

1. Piston Seal
2. Head
3. Wiper
4. Rod Seal
5. Cylinder Housing
6. Plug
7. Nut
8. Piston
9. Shaft
10. O-ring
11. O-ring* B-14213A B-14213B

12. Back-up Ring*

13. O-ring
* 11 and 12 are replaced
by one seal on later
models

8
7 10 1

6
5

B-13593A
11 12 4 13 2 3 S8456

20-20-4 E08 Service Manual

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

Disassembly
2 3
Clean the outside of the boom cylinder before
1
disassembly.

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

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

Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
S7678
Put the base end of the cylinder in a vise.

Figure 20-20-10 Remove the head and the rod assembly from the cylinder
[Figure 20-20-11]. Put the rod end in a vise.

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

1
2
1

N-22352A

Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-20-10] to loosen the head.

S7679

Remove the seal (Item 1) and O-ring (Item 2) from the

piston (Item 3) [Figure 20-20-12].

20-20-5 E08 Service Manual

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

Disassembly (Cont’d)

Figure 20-20-13

4
2
1
2

1
S7681

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

N-22356 15].

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

from the groove in the head (Item 3) [Figure 20-20-13].

NOTE: O-ring (Item 1) and back-up ring (Item 2)

[Figure 20-20-13] are replaced by one seal on
later models.

Remove the O-ring (Item 4) [Figure 20-20-13].

Figure 20-20-14

2
1

S7680

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

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

20-20-6 E08 Service Manual

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

Assembly

Use the following tools to assemble the cylinder:

2
MEL1396 - Universal Seal Expander 1
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins

Clean all parts in solvent and dry with compressed air. 3

Inspect all parts for wear or damage. Replace any worn

or damaged parts. S7679

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

and O-rings with clean hydraulic fluid before installation. Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-20-17].
Figure 20-20-16
Figure 20-20-18

S7682
N-22358

Install new seal on the tool and slowly stretch it until it fits
the piston [Figure 20-20-16]. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Allow the seal to stretch for 30 seconds before installing it 3 minutes [Figure 20-20-18].
on the piston.

20-20-7 E08 Service Manual

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

Assembly (Cont’d)

Figure 20-20-19

S7683

Install the wiper seal with the wiper (Item 1) [Figure 20-
P-7427 20-21] toward the outside of the head.

Figure 20-20-22
Install the rod seal on the rod seal tool [Figure 20-20-19].

NOTE: During installation the spring side of the seal 4

must be toward the inside of the cylinder.
1
Rotate the handles to collapse the rod seal [Figure 20- 3 2
20-19].

Figure 20-20-20

N-22356

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

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

the groove on the head (Item 4) [Figure 20-20-22].

NOTE: O-ring (Item 3) and back-up ring (Item 2)

P-7425 [Figure 20-20-22] are replaced by one seal on
later models. Use a ring compressor to
compress the seal to the correct size. Leave
Install the rod seal in the head [Figure 20-20-20]. the head in the compressor for about 3
minutes

20-20-8 E08 Service Manual

CYLINDER (BOOM) (CONT’D) Figure 20-20-24

Assembly (Cont’d)

Figure 20-20-23

2 1
3

2
S7681

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

S7678 20-24].

Tighten the base end fitting plug to 50 N•m (37 ft-lb)

Install the head (Item 1) and the piston (Item 2) [Figure torque.
20-20-23] on the rod as shown.
Tighten the rod end fitting plug to 20 N•m (15 ft-lb)
Grease the piston where the nut contacts the piston. Do torque.
not get grease on the threads. Put the base end of the hydraulic cylinder in a vise.

Provide an adequate support for the cylinder before Figure 20-20-25

tightening.

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

NOTE: Clean and dry the rod threads, from the kit 1
install a NEW NUT with preapplied Loctite®.

Tighten the nut to 406 N•m (300 ft-lb) torque.

N-22352A

Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-20-25] to tighten the head. Head to
be torqued until flush with end of the housing.

20-20-9 E08 Service Manual

20-20-10 E08 Service Manual
CYLINDER (ARM)

Testing
WARNING
Lower the boom / bucket and blade to the ground.
Hydraulic fluid escaping under pressure can have
Stop the engine. Raise the control console.
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
Figure 20-21-1
and possible death if proper medical treatment by a
doctor familiar with this injury is not received
immediately.
1 W-2145-EN-0210

Figure 20-21-3

S7959

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

Remove the bolt and nut (Item 1) [Figure 20-21-1] from

the rod end pivot pin. S7494

Figure 20-21-2
Lower control console and fasten the seat belt. Start the
engine and retract the arm cylinder.

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

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

Disconnect the arm cylinder base end hose (Item 1)

[Figure 20-21-3] from the arm cylinder.

S7958

Support the arm cylinder [Figure 20-21-2].

Remove the pivot pin (Item 1) [Figure 20-21-2].

20-21-1 E08 Service Manual

CYLINDER (ARM) (CONT’D)

Testing (Cont’d)

Figure 20-21-4

S7495

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

tighten.

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

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

arm cylinder, remove the cylinder for repair or
replacement.

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

the engine.

20-21-2 E08 Service Manual

CYLINDER (ARM) (CONT’D)

Removal And Installation

WARNING
Figure 20-21-5
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
2 sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

Figure 20-21-6
1 3
1

S7496

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

2
With the key in the ON position, move the hydraulic
controls to release the hydraulic pressure.

S7667

IMPORTANT Remove the bolt and nut (Item 1) [Figure 20-21-6] from
the arm cylinder rod end pin.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all Remove the cylinder rod end pin (Item 2) [Figure 20-21-
parts clean. Always use caps and plugs on hoses, 6].
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Remove the arm cylinder.
I-2003-0888

Remove and plug the two hoses (Item 1) [Figure 20-21-

5] from the arm cylinder.

Remove the bolt and nut (Item 2) [Figure 20-21-5] from

the arm cylinder base end pin.

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

21-5].

20-21-3 E08 Service Manual

CYLINDER (ARM) (CONT’D)

Parts Identification

1. Piston Seal
2. Head
3. O-ring
4. Wiper
5. Rod Seal
6. Piston
7. Plug
8. Tube Assembly
9. Nut
10. Shaft
B-14213A B-14213B
11. O-ring
12. O-ring*
13. Back-up Ring*
* 12 and 13 are 9 11 1 6
replaced by one seal
on later models

10

12 13 3 2 5 4
B-13593A
S8458

20-21-4 E08 Service Manual

CYLINDER (ARM) (CONT’D) Figure 20-21-9

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

MEL1074 - O-ring Seal Hook

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

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

Put the base end of the cylinder in a vise. S7966

Figure 20-21-7
Standard Piston: Remove the seal (Item 1) and O-ring
(Item 2) from the piston (Item 3) [Figure 20-21-9].

Figure 20-21-10
1

4
2
1
1

S7968

Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-21-7] to loosen the head.
N-22356
Figure 20-21-8

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

from the groove in the head (Item 3) [Figure 20-21-10].
3
2
NOTE: O-ring (Item 1) and back-up ring (Item 2)
1 [Figure 20-21-10] are replaced by one seal on
later models.

Remove the O-ring (Item 4) [Figure 20-21-10].

S7967

Remove the head and the rod assembly from the cylinder
[Figure 20-21-8]. Put the rod end in a vise.

Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-8].

20-21-5 E08 Service Manual

CYLINDER (ARM) (CONT’D)

Disassembly (Cont’d)

Figure 20-21-11

S7680

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

from the inside of the head (Item 3) [Figure 20-21-11].

Figure 20-21-12

1
S7681

Remove plug (Item 1) and O-ring (Item 2) [Figure 20-21-

12].

20-21-6 E08 Service Manual

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

Assembly
3
Use the following tools to assemble the cylinder:
2 1
MEL1396 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Special Offset Pins

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. S7966

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

and O-rings with clean hydraulic fluid before installation. Standard Piston: Install the O-ring (Item 1) and seal (Item
2) on the piston (Item 3) [Figure 20-21-14].
Figure 20-21-13
Figure 20-21-15

P-7424
N-22358

Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-21-13]. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Allow the seal to stretch for 30 seconds before installing it 3 minutes [Figure 20-21-15].
on the piston.

20-21-7 E08 Service Manual

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

Assembly (Cont’d)

Figure 20-21-16

S7683

Install the wiper seal with the wiper (Item 1) [Figure 20-
P-07427 21-18] toward the outside of the head.

Figure 20-21-19
Install the rod seal on the rod seal tool [Figure 20-21-16].

NOTE: During installation the spring side of the seal

4
must be toward the inside of the cylinder.
1
Rotate the handles to collapse the rod seal [Figure 20- 2
21-16]. 3

Figure 20-21-17

N-22356

Install the O-ring (Item 1) [Figure 20-21-19].

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

the groove on the head (Item 4) [Figure 20-21-19].

NOTE: O-ring (Item 3) and back-up ring (Item 2)

N-7425 [Figure 20-21-19] are replaced by one seal on
later models. Use a ring compressor to
compress the seal to the correct size. Leave
Install the rod seal in the head [Figure 20-21-17]. the head in the compressor for about 3
minutes.

20-21-8 E08 Service Manual

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

Assembly (Cont’d)

Figure 20-21-20

1
2

3
1

2
S7681

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

S7967 21-21].

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

Install the head (Item 1) and the piston (Item 2) [Figure
20-21-20] on the rod. Put the base end of the hydraulic cylinder in a vise.

Grease the piston where the nut contacts the piston. Do Figure 20-21-22
not get grease on the threads.

Provide an adequate support for the cylinder before

tightening.
1
Install the nut (Item 3) [Figure 20-21-20].

NOTE: Clean and dry the rod threads, from the kit
install a NEW NUT with preapplied Loctite®.

Reclean thread area for Loctite® residue.

1
Tighten the nut to 410 N•m (300 ft-lb) torque.

S7968

Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-21-22] to tighten the head. Head to
be torqued until flush with end of the housing.

20-21-9 E08 Service Manual

20-21-10 E08 Service Manual
CYLINDER (BOOM SWING) Remove the lower right hand side cover

Testing Figure 20-22-3

Lower the boom / bucket and blade to the ground.

Stop the engine. Raise the control console.

Figure 20-22-1

S6784
1

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

from the boom swing cylinder.

S8320 Figure 20-22-4

Remove the bolt and nut (Item 1) [Figure 20-22-1] from

the rod end pivot pin. 2

Remove the pivot pin from the rod end of the cylinder.

Figure 20-22-2

S6785

Install a cap (Item 1) [Figure 20-22-4] on the base end

1 hose and tighten.

Lower control console and fasten the seat belt. Start the
engine and retract the cylinder.
S8321
If there is any leakage from the base end fitting (Item 2)
[Figure 20-22-4] on the cylinder, remove the boom swing
Lower the control console and fasten the seat belt. Start cylinder for repair or replacement.
the engine and retract the boom swing cylinder (Item 1)
[Figure 20-22-2].

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

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

20-22-1 E08 Service Manual

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

Removal And Installation

IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
S8320

Remove the bolt and nut (Item 1) [Figure 20-22-5] from

WARNING the rod end pivot pin.

Remove the pivot pin from the rod end of the cylinder.
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by Figure 20-22-6
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
doctor familiar with this injury is not received
immediately.
W-2145-EN-0210

WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
S8321
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508 Lower the control console and fasten the seat belt.

Swing the upperstructure so the pin in the base end of Start the excavator and fully retract the boom swing
the cylinder is located between the tracks. cylinder [Figure 20-22-6].

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

20-22-2 E08 Service Manual

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

Removal And Installation (Cont’d)

Remove the lower right hand side cover. (See Lower

Right Side Cover Removal And Installation on Page 40-
210-3.) 1
Figure 20-22-7

S6787

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

1 22-9].

Figure 20-22-10

S6784

Remove the base end hose (Item 1) [Figure 20-22-7] 3 2

from the boom swing cylinder.

Figure 20-22-8

S6788

1 Remove the bolt (Item 1) and the retaining plate (Item 2)

[Figure 20-22-10].

Remove the pivot pin (Item 3) [Figure 20-22-10] from the

base end of the boom swing cylinder.
S8322
Remove the boom swing cylinder from the excavator.

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

the boom swing cylinder.

20-22-3 E08 Service Manual

CYLINDER (BOOM SWING) (CONT’D)

Parts Identification (Earlier Models)

1. Piston Seal * 11 and 12 are

2. Wiper replaced by one seal
3. Rod Seal on later models
4. Piston
5. Plug
6. Cylinder Housing
7. Head
8. Nut
9. Shaft
10. O-ring
B-14213A B-14213B
11. O-ring*
12. Back-up Ring*
13. O-ring

6 8 10 1 4

11 12 13 7 3 2 B-13593A
S8455

20-22-4 E08 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-12

Disassembly (Earlier Models)

2 3
Clean the outside of the boom swing cylinder before 1
disassembly.

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

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

Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
S7964
Put the base end of the cylinder in a vise.

Figure 20-22-11 Remove the head and the rod assembly from the cylinder
[Figure 20-22-12]. Put the rod end in a vise.

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

1 Figure 20-22-13

1 2

S7965

Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-22-11] to loosen the head.

S7963

Standard piston: Remove the seal (Item 1) and O-ring

(Item 2) from the piston (Item 3) [Figure 20-22-13].

20-22-5 E08 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-16

Disassembly (Earlier Models) (Cont’d)

Figure 20-22-14

2 3
1

1
S7681

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

S7962 16].

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

[Figure 20-22-14].

NOTE: O-ring (Item 1) and back-up ring (Item 2)

[Figure 20-22-14] are replaced by one seal on
later models.

Remove the O-ring (Item 3) [Figure 20-22-14].

Figure 20-22-15

2
1

S7680

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

from the inside of the head (Item 3) [Figure 20-22-15].

20-22-6 E08 Service Manual

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

Assembly (Earlier Models)

3
Use the following tools to assemble the cylinder:
2 1
MEL1396 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. S7963

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

and O-rings with clean hydraulic fluid before installation. Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-22-18].
Figure 20-22-17
Figure 20-22-19

S7960
P-22358

Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-22-17]. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Allow the seal to stretch for 30 seconds before installing it 3 minutes [Figure 20-22-19].
on the piston.

20-22-7 E08 Service Manual

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

Assembly (Earlier Models) (Cont’d)

Figure 20-22-20

S7961

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.
2 1
3
Rotate the handles to collapse the rod seal [Figure 20-
22-20].

Figure 20-22-21

S7962

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].

NOTE: O-ring (Item 3) and back-up ring (Item 2)

P-7425 [Figure 20-22-23] are replaced by one seal on
later models. Use a ring compressor to
compress the seal to the correct size. Leave
Install the rod seal in the head [Figure 20-22-21]. the head in the compressor for about 3
minutes.

20-22-8 E08 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-25

Assembly (Earlier Models) (Cont’d)

Figure 20-22-24

2 1
3

2
S7681

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

S7964 25].

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

Install the head (Item 1) and the piston (Item 2) [Figure
20-22-24] on the rod. Put the base end of the hydraulic cylinder in a vise.

Grease the piston where the nut contacts the piston. Do Figure 20-22-26
not get grease on the threads.

Provide an adequate support for the cylinder before

tightening.

Install the nut (Item 3) [Figure 20-22-24]. 1

NOTE: Clean and dry the rod threads, from the kit
install a NEW NUT with preapplied Loctite®.

Reclean thread area for Loctite® residue.

Tighten the nut to 407 N•m (300 ft-lb) torque. 1

S7965

Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-22-26] to tighten the head. Head to
be torqued until flush with end of the housing.

20-22-9 E08 Service Manual

CYLINDER (BOOM SWING) (CONT’D)

Parts Identification (Later Models)

1. Rod
2. Grease Fitting
3. Wiper
4. Rod Seal
5. Step Seal
6. Head
7. Seal
8. Dual Seal
9. Guide Ring
10. Piston
12
11. Bolt
12. Case

4 3
5
6
7

8
11 9 2
10

NA19232S

20-22-10 E08 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-28

Disassembly (Later Models)

Clean the outside of the cylinder before disassembly.

Use the following tools to disassemble the cylinder: 1

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.

Put the cylinder in a vise.

Figure 20-22-27 C204296

Use an open end wrench to loosen the head (Item 1)

[Figure 20-22-28].
1
Figure 20-22-29

3
2
1

C205651

Avoid deformation of cylinder tube. Prevent tube rotation

by inserting a bar (Item 1) [Figure 20-22-27] into the
base side pin bore.

C204297

Remove the head and the rod assembly (Item 1) [Figure

20-22-29] from the cylinder.

Put the rod end in a vise.

20-22-11 E08 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-32

Disassembly (Later Models) (Cont’d)

Figure 20-22-30

1 2

1 C204300

Remove the seal (Item 1) [Figure 20-22-32].

C204299
Remove the guide ring (Item 3) [Figure 20-22-32].

Remove the bolt (Item 1) [Figure 20-22-30]. Figure 20-22-33

Figure 20-22-31

1
1
2
C204302

C204298
Remove the O-ring (Item 1) [Figure 20-22-33].

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

20-22-31].

20-22-12 E08 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Assembly (Later Models)

Disassembly (Later Models) (Cont’d) Use the following tools to assemble the cylinder:

Figure 20-22-34 MEL1396 - Universal Seal Expander

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor

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.

1 Figure 20-22-36

C204295

Remove the seal (Item 1) [Figure 20-22-34].

Figure 20-22-35

P-7424
1
2
Install the seal on the tool and slowly stretch it until it fits
3 the piston [Figure 20-22-36].

Allow the seal to stretch for 30 seconds before installing it

on the piston.
C204301

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

step seal (Item 3) from the inside of the head (Item 4)
[Figure 20-22-35].

Remove the grease fitting from the rod end.

20-22-13 E08 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-39

Assembly (Later Models) (Cont’d)

Figure 20-22-37

N-22358

Use a ring compressor to compress the seal to the

1 correct size. Leave the piston in the compressor for about
C204302
three minutes [Figure 20-22-39].

Install the O-ring (Item 1) on the piston (Item 2) [Figure Figure 20-22-40
20-22-37].

Figure 20-22-38

2
P-7427

1
C204300 Install the rod seal on the rod seal tool [Figure 20-22-40].

NOTE: Install the spring side of the seal toward the

Install the seal (Item 1) on the piston (Item 2) [Figure 20- inside of the cylinder.
22-38].
Rotate the handles to collapse the rod seal [Figure 20-
Install the guide ring (Item 3) [Figure 20-22-38] 22-40].

20-22-14 E08 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-43

Assembly (Later Models) (Cont’d)

2 1
Figure 20-22-41

3
2
3
1 C204298

Install the head (Item 1) and piston (Item 2) on the

C204301 cylinder rod (Item 3) [Figure 20-22-43].

Put the rod end in a vice.

Install the step seal (Item 1) in the head (Item 4) [Figure
20-22-41]. Figure 20-22-44

Install the rod seal (Item 2) in the head (Item 4) [Figure

20-22-41].

Install the wiper seal with the wiper (Item 3) [Figure 20- 1
22-41] toward the outside of the head.

Figure 20-22-42

C204299

Install a new bolt (Item 1) [Figure 20-22-44] on the rod.

1 Tighten the bolt to 380 ± 10 N•m (280 ± 7.3 ft-lb) torque.

C204295

Install the seal (Item 1) [Figure 20-22-42] on the head.

20-22-15 E08 Service Manual

CYLINDER (BOOM SWING) (CONT’D) Figure 20-22-47

Assembly (Later Models) (Cont’d)

Figure 20-22-45

C204296
1
2

Apply Loctite® 222 or equivalent to the head threads

C204297 (Item 1) [Figure 20-22-47].

Use an open end wrench to tighten the head (Item 1)

Install the rod assembly (Item 1) into the cylinder (Item 2) [Figure 20-22-47].
[Figure 20-22-45].
Tighten the head to 550 ± 20 N•m (405 ± 15- ft-lb) torque.
Put the base end of the hydraulic cylinder in a vise.
Install the grease fitting on the rod end and torque to 11 -
Figure 20-22-46 15 N•m (11 - 15 ft-lb) torque

C205651

Avoid deformation of cylinder tube. Prevent tube rotation

by inserting a bar (Item 1) [Figure 20-22-46] into the
base side pin bore.

20-22-16 E08 Service Manual

CYLINDER (BUCKET) Figure 20-23-3

Testing

Lower the boom / bucket and blade to the ground.

Stop the engine. Raise the control console.

Figure 20-23-1

S7670

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

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

the hydraulic controls to release the hydraulic pressure.
S7660 Raise the control console.

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

Figure 20-23-2 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
doctor familiar with this injury is not received
1
immediately.
W-2145-EN-0210
3

S7699

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

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

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

20-23-1 E08 Service Manual

CYLINDER (BUCKET) (CONT’D) Removal And Installation

Testing (Cont’d) Lower the boom / bucket and blade to the ground. Stop
the engine.
Figure 20-23-4
Support the boom using a chain hoist.

With the key in the ON position, move the hydraulic

controls to release the hydraulic pressure.
1
Figure 20-23-5

S7668

2
Remove the bucket cylinder base end hose (Item 1)
[Figure 20-23-4] and install a plug on the hose fitting and
tighten.
S7669
Lower control console and fasten the seat belt. Start the
engine and retract the bucket cylinder.
Remove the hose clamp (Item 1) [Figure 20-23-5] from
If there is any leakage from the base end fitting on the the bucket cylinder.
bucket cylinder, remove the cylinder for repair or
replacement. Remove and plug the bucket cylinder rod end hose (Item
2) [Figure 20-23-5].

Figure 20-23-6

S7668

Remove and plug the bucket cylinder base end hose

(Item 1) [Figure 20-23-6].

20-23-2 E08 Service Manual

CYLINDER (BUCKET) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-23-7
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

1 WARNING
Hydraulic fluid escaping under pressure can have
S7667 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
Remove the bolt and nut (Item 1) [Figure 20-23-7] from doctor familiar with this injury is not received
the base end pivot pin. immediately.
W-2145-EN-0210
Remove the base end pivot pin (Item 2) [Figure 20-23-7]
and lower the base end of the cylinder to the floor.

Figure 20-23-8
WARNING
1 1
AVOID INJURY OR DEATH
2 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
3 explosion or fire.
W-2103-0508

S7901

Remove the two snap rings and washers (Item 1) [Figure

20-23-8].

Remove the bucket link (Item 2) [Figure 20-23-8].

Remove the bucket link pins (Item 3) [Figure 20-23-8].

Remove the bucket cylinder.

20-23-3 E08 Service Manual

CYLINDER (BUCKET) (CONT’D)

Parts Identification

1. Piston Seal
2. Head
3. Piston
4. Cylinder Housing
5. Rod Wiper
6. Rod Seal
7. Plug
8. Shaft
9. O-ring
10. Nut
B-14213A B-14213B
11. O-ring
12. O-ring*
13. Back-up Ring*
* 12 and 13 are
replaced by one seal
on later models

4 10 11 1 3

12 13 9 2 6 5 8
B-13593A
S8461

20-23-4 E08 Service Manual

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

Disassembly
2 3
Clean the outside of the bucket cylinder before
1
disassembly.

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

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

Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
N-22436
Put the base end of the cylinder in a vise.

Figure 20-23-9 Remove the head and the rod assembly from the cylinder
[Figure 20-23-10]. Put the rod end in a vise.

Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-23-10].

1 Figure 20-23-11

2
1 1

N-22434

Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-23-9] to loosen the head.

N-22414

Standard Piston: Remove the seal (Item 1) and O-ring

(Item 2) from the piston (Item 3) [Figure 20-23-11].

20-23-5 E08 Service Manual

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

Disassembly (Cont’d)

Figure 20-23-12

4
1 2
2

N-22364

Remove plug (Item 1) and O-ring (Item 2) [Figure 20-23-

N-22356 14].

Figure 20-23-15
Remove the O-ring (Item 1) and the back-up ring (Item 2)
from the groove in the head (Item 3) [Figure 20-23-12].

NOTE: O-ring (Item 1) and back-up ring (Item 2) 1

[Figure 20-23-12] are replaced by one seal on
later models.

Remove the O-ring (Item 4) [Figure 20-23-12].

Figure 20-23-13

1
2
3
N-22433

2
1 Remove the seals (Item 1) and bushing (Item 2) [Figure
20-23-15].

N-22357

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

from the inside of the head (Item 3) [Figure 20-23-13].

20-23-6 E08 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-17

Assembly
3
Use the following tools to assemble the cylinder:
1
MEL1396 - Universal Seal Expander
2
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-2 - Special Offset Pins

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. N-22414

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

and O-rings with clean hydraulic fluid before installation. Standard Piston: Install the O-ring (Item 1) and seal (Item
2) on the piston (Item 3) [Figure 20-23-17].
Figure 20-23-16
Figure 20-23-18

P-7424
N-22358

Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-23-16]. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Allow the seal to stretch for 30 seconds before installing it 3 minutes [Figure 20-23-18].
on the piston.

20-23-7 E08 Service Manual

CYLINDER (BUCKET) (CONT’D) Figure 20-23-21

Assembly (Cont’d)

Figure 20-23-19

N-22359

Install the wiper seal with the wiper (Item 1) [Figure 20-
P-07427 23-21] toward the outside of the head.

Figure 20-23-22
Install the rod seal on the rod seal tool [Figure 20-23-19].

NOTE: During installation the spring side of the seal 4

must be toward the inside of the cylinder.
1
Rotate the handles to collapse the rod seal [Figure 20- 2
3
23-19].

Figure 20-23-20

N-22356

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

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

the groove on the head (Item 4) [Figure 20-23-22].

NOTE: O-ring (Item 3) and back-up ring (Item 2)

N-7425 [Figure 20-23-22] are replaced by one seal on
later models. Use a ring compressor to
compress the seal to the correct size. Leave
Install the rod seal in the head [Figure 20-23-20]. the head in the compressor for about 3
minutes.

20-23-8 E08 Service Manual

CYLINDER (BUCKET) (CONT’D) Tighten the plug to 20 N•m (15 ft-lb) torque.

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

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

Figure 20-23-25
2 1
3

1
N-22436

N-22434
Install the head (Item 1) and the piston (Item 2) [Figure
20-23-23] on the rod.
Insert the adjustable gland nut wrench into the two holes
Grease the piston where the nut contacts the piston. Do (Item 1) [Figure 20-23-25] to tighten the head. Head to
not get grease on the threads. be torqued until flush with end of cylinder housing.

Provide an adequate support for the cylinder before Figure 20-23-26

tightening.

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

2
NOTE: Clean and dry the rod threads, from the kit
install a NEW NUT with preapplied Loctite®.

Reclean thread area for Loctite® residue.

Tighten the nut to 190 N•m (140 ft-lb) torque.

Figure 20-23-24 2
1

N-22433

Install the bushing (Item 1) [Figure 20-23-26]. The

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

Install the seals (Item 2) [Figure 20-23-26] with the lips

1
facing out.
2

N-22364

Install O-ring (Item 1) and plug (Item 2) [Figure 20-23-

24].

20-23-9 E08 Service Manual

20-23-10 E08 Service Manual
CYLINDER (BLADE)

Testing

Swing the upperstructure out of the way. Lower the boom

WARNING
/ bucket to the ground. Raise the blade up until it stops.
Hydraulic fluid escaping under pressure can have
Stop the engine. sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
Figure 20-24-1 and possible death if proper medical treatment by a
doctor familiar with this injury is not received
immediately.
W-2145-EN-0210

Figure 20-24-3

S8711

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

the blade control to release the hydraulic pressure. Raise
the control console.
S7903

Figure 20-24-2 Remove the blade cylinder base end hose (Item 1)
[Figure 20-24-3].

Figure 20-24-4

S7902

Loosen the top nut (Item 1) and the bottom nut (Item 2)
S7904
[Figure 20-24-2] fastening the shield to the blade
cylinder. Install a plug (Item 1) [Figure 20-24-4] on the hose fitting
and tighten.
Remove the blade cylinder shield from the blade cylinder.
Lower control console. Start the engine and retract the
blade cylinder.
If there is any leakage from the base end fitting on the
blade cylinder, remove the cylinder for repair or
replacement.

20-24-1 E08 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-6

Removal And Installation

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

the engine. 1

With the key in the ON position, move the blade control to

release the hydraulic pressure.

Figure 20-24-5
2

S7903
2

Remove and plug the blade cylinder hoses (Item 1)

[Figure 20-24-6].

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

24-6] from the blade cylinder base end pin.

S7902 Remove the blade cylinder base end pin (Item 3) [Figure
20-24-6].
Loosen the top nut (Item 1) and the bottom nut (Item 2)
[Figure 20-24-5] fastening the shield to the blade Figure 20-24-7
cylinder.

Remove the blade cylinder shield from the blade cylinder.

1
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,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
S7905
I-2003-0888

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

24-7] from the blade cylinder rod end.

WARNING Remove the blade cylinder rod end pin (Item 2) [Figure
20-24-7].
AVOID INJURY OR DEATH
Remove the blade cylinder.
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

20-24-2 E08 Service Manual

CYLINDER (BLADE) (CONT’D)

Parts Identification (Earlier Models)

1. Piston Seal
2. Head
3. Wiper
4. Rod Seal
5. Piston
6. Plug
7. Cylinder Housing
8. Shaft
9. Nut
10. O-ring
11. O-ring B-14213D B-14213B
12. O-ring
13. Back-up Ring
* 11 and 12 are
replaced by one seal
on later models

6 9 10 1 5

6 7

12 11 3 13 2 4 B-13593A
S8451

20-24-3 E08 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-10

Disassembly (Earlier Models)

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

MEL1074 - O-ring Seal Hook

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

Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
N-22414
Put the base end of the cylinder in a vise.

Figure 20-24-8 Standard Piston: Remove the seal (Item 1) and O-ring
(Item 2) from the piston (Item 3) [Figure 20-24-10].

Figure 20-24-11

1 4
1 2

N-22442A

Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-24-8] to loosen the head.
N-22356

Figure 20-24-9
Remove the O-ring (Item 1) and the back-up ring (Item 2)
from the groove in the head (Item 3) [Figure 20-24-11].

3 NOTE: O-ring (Item 1) and back-up ring (Item 2)

2 [Figure 20-24-11] are replaced by one seal on
1 later models.

Remove the O-ring (Item 4) [Figure 20-24-11].

N-22413A

Remove the head and the rod assembly from the cylinder
[Figure 20-24-9]. Put the rod end in a vise.

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

20-24-4 E08 Service Manual

CYLINDER (BLADE) (CONT’D)

Disassembly (Earlier Models) (Cont’d)

Figure 20-24-12

2
1

N-22357

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

from the inside of the head (Item 3) [Figure 20-24-12].

Figure 20-24-13

N-22364

Remove plug (Item 1) and O-ring (Item 2) [Figure 20-24-

13].

20-24-5 E08 Service Manual

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

Assembly (Earlier Models)

3
Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander

1
MEL1033 - Rod Seal Installation Tool 2
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. N-22414

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

and O-rings with clean hydraulic fluid before installation. Standard Piston: Install the O-ring (Item 1) and seal (Item
2) on the piston (Item 3) [Figure 20-24-15].
Figure 20-24-14
Figure 20-24-16

N-07424
N-22358

Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-24-14]. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Allow the seal to stretch for 30 seconds before installing it 3 minutes [Figure 20-24-16].
on the piston.

20-24-6 E08 Service Manual

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

Assembly (Earlier Models) (Cont’d)

Figure 20-24-17

P-22359

Install the wiper seal with the wiper (Item 1) [Figure 20-
P-07427
24-19] toward the outside of the head.

Figure 20-24-20
Install the rod seal on the rod seal tool [Figure 20-24-17].

NOTE: During installation the spring side of the seal 4

must be toward the inside of the cylinder.
1
Rotate the handles to collapse the rod seal [Figure 20- 3 2
24-17].

Figure 20-24-18

N-22356

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

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

the groove on the head (Item 4) [Figure 20-24-20].

NOTE: O-ring (Item 1) and back-up ring (Item 2)

[Figure 20-24-20] are replaced by one seal on
P-07425
later models. Use a ring compressor to
compress the seal to the correct size. Leave
Install the rod seal in the head [Figure 20-24-18]. the piston in the compressor for about 3
minutes.

20-24-7 E08 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-22

Assembly (Earlier Models) (Cont’d)

Figure 20-24-21

1
2
3
1

N-22364

Install O-ring (Item 1) and plug (Item 2) [Figure 20-24-

22].
N-22413A

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

Install the head (Item 1) and piston (Item 2) [Figure 20-
24-21] on the rod. Put the base end of the hydraulic cylinder in a vise.

Grease the piston where the nut contacts the piston. Do Figure 20-24-23
not get grease on the threads.

Provide an adequate support for the cylinder before

tightening.

Install the nut (Item 3) [Figure 20-24-21].

NOTE: Clean and dry the rod threads, from the kit 1
install a NEW NUT with preapplied Loctite®.

Reclean thread area for Loctite® residue.

Tighten the nut to 339 N•m (250 ft-lb) torque.

1

N-22442A

Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-24-23] to tighten the head. Head to
be torqued until flush with end of the housing.

20-24-8 E08 Service Manual

CYLINDER (BLADE) (CONT’D)

Parts Identification (Later Models)

1. Rod
2. Wiper
3. Rod Seal
4. Head
5. O-ring
6. Piston
7. Guide Ring
8. Seal
9. Bolt
10. Case
10

3 2
4
5

7 6
7 8

NA19230S

20-24-9 E08 Service Manual

CYLINDER (BLADE) (CONT’D) Remove the head and the rod assembly from the
cylinder. Put the rod end in a vise.
Disassembly (Later Models)
Figure 20-24-26
Clean the outside of the cylinder before disassembly.

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

MEL1075-2 - Offset Pins
1
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.

Put the cylinder in a vise.

Figure 20-24-24 3
2
C205785

Remove the bolt (Item 1) [Figure 20-24-26].

1
Remove the piston (Item 2) and head (Item 3) [Figure
20-24-26] from the rod.

Figure 20-24-27

C205651

Avoid deformation of cylinder tube. Prevent tube rotation

by inserting a bar (Item 1) [Figure 20-24-24] into the
base side pin bore.
1
1
Figure 20-24-25

1 C205787

Remove the guide rings (Item 1) [Figure 20-24-27] from

the cylinder piston.

C204296

Use an open end wrench to loosen the head (Item 1)

[Figure 20-24-25].

20-24-10 E08 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-30

Disassembly (Later Models) (Cont’d)

Figure 20-24-28

C205790

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

C205788
20-24-30] from the cylinder head.

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

piston.

Figure 20-24-29

C205789

Remove the O-ring (Item 1) [Figure 20-24-29] from the

head.

20-24-11 E08 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-32

Assembly (Later Models)

Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander

2
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. 1

Always install new seals and O-rings. Lubricate all seals C205788
and O-rings with clean hydraulic fluid before installation.

Figure 20-24-31 Install the seal (Item 1) on the piston (Item 2) [Figure 20-
24-32].

Figure 20-24-33

1 1

S35773

Install the seal on the tool and slowly stretch it until it fits C205787
the piston [Figure 20-24-31].

Allow the seal to stretch for 30 seconds before installing it Install the guide rings (Item 1) on the piston (Item 2)
on the piston. [Figure 20-24-33].

20-24-12 E08 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-36

Assembly (Later Models) (Cont’d)

Figure 20-24-34

1 3

C205790

Install the rod seal (Item 1) and wiper seal (Item 2) in the
N-22358 head (Item 3) [Figure 20-24-36].

Install the wiper seal with the wiper (Item 2) [Figure 20-
Use a ring compressor to compress the seal to the
24-36] toward the outside of the head.
correct size. Leave the piston in the compressor for about
three minutes [Figure 20-24-34].
Figure 20-24-37
Figure 20-24-35

C204295

P7427

Install the O-ring (Item 1) [Figure 20-24-37] on the head.

Install the rod seal on the rod seal tool [Figure 20-24-35].

NOTE: Install the spring side of the seal toward the

inside of the cylinder.

Rotate the handles to collapse the rod seal.

20-24-13 E08 Service Manual

CYLINDER (BLADE) (CONT’D) Figure 20-24-40

Assembly (Later Models) (Cont’d) 1

Figure 20-24-38

1
2

C205784

3 Apply Loctite® 222 or equivalent to the head threads

C205785
(Item 1) [Figure 20-24-40].

Use an open end wrench (Item 1) [Figure 20-24-40] to

Install the head (Item 1), piston (Item 2) and bolt (Item 3) tighten the head.
[Figure 20-24-38] on the cylinder rod.
Tighten the head to 400 ±20 N•m (295 ± 15 ft-lb) torque.
Put the rod assembly in a vise.

Tighten the bolt (Item 3)[Figure 20-24-38] to 250 ± 10

N•m (184 ± 7 ft-lb) torque.

Figure 20-24-39

C205651

Avoid deformation of cylinder tube. Prevent tube rotation

by inserting a bar (Item 1) [Figure 20-24-39] into the
base side pin bore.

20-24-14 E08 Service Manual

CYLINDER (TRACK FRAME EXPANSION) Figure 20-25-3

Testing

Retract the track frame fully.

Figure 20-25-1

S8253

Remove the expansion cylinder base end hose (Item 1)

[Figure 20-25-3].

S8352
WARNING
Place blocks under the excavator tracks. Lower the
Hydraulic fluid escaping under pressure can have
bucket to the ground and the blade on the blocks [Figure
sufficient force to enter a person’s body by
20-25-1].
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
Stop the engine. Raise the control console.
physician familiar with this injury is not received
immediately.
Figure 20-25-2 W-2145-0290

Figure 20-25-4
1 1

2 1

S8250

Remove the two bolts (Item 1) and access plate (Item 2) S8257
[Figure 20-25-2] on the right side of the undercarriage.
Install a plug (Item 1) [Figure 20-25-4] on the hose fitting
and tighten.

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

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

expansion cylinder, remove the cylinder for repair or
replacement.

20-25-1 E08 Service Manual

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

Removal And Installation

Expand the track frame fully.

Figure 20-25-5

S8251

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

cylinder rod end.

S8352

Place blocks under the excavator tracks for increased

access to the expansion cylinder [Figure 20-25-5].
IMPORTANT
Figure 20-25-6 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 1 I-2003-0888

WARNING
2 Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
S8250 and possible death if proper medical treatment by a
doctor familiar with this injury is not received
immediately.
Remove the bolts (Item 1) [Figure 20-25-6]. W-2145-EN-0210

Remove the access plate (Item 2) [Figure 20-25-6].

NOTE: Remove the access plates on both sides of

the undercarriage.

20-25-2 E08 Service Manual

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

Removal And Installation (Cont’d)

Figure 20-25-8

1
1 S8254

Plug the base end hose (Item 1) [Figure 20-25-10].

S8252
Install a hose (Item 2) [Figure 20-25-10] on the cylinder
base end. Place the other end of the hose in a drain pan.
Install a hose (Item 1) [Figure 20-25-8] on the cylinder
rod end. Place the other end of the hose in a drain pan. Figure 20-25-11

Figure 20-25-9

1 S8255

S8253
Remove the bolt (Item 1) [Figure 20-25-11].

Remove the hose (Item 1) [Figure 20-25-9] from the Remove the rod end pivot pin (Item 2) [Figure 20-25-11].
cylinder base end.
Remove the rod end of the cylinder from the
undercarriage.

20-25-3 E08 Service Manual

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

Removal And Installation (Cont’d)

Figure 20-25-12

2 S8895

1
Gently lift one side of the undercarriage until the
S8256 excavator tracks are free of the blocks [Figure 20-25-14].

Figure 20-25-15
Remove the bolt (Item 1) [Figure 20-25-12].

Remove the base end pivot pin (Item 2) [Figure 20-25-

12].

Remove the base end of the cylinder from the

undercarriage.

Figure 20-25-13

S8896
1

Place blocks under the undercarriage [Figure 20-25-15].

Gently lower the excavator onto the blocks, then remove

the jacks.

S8475

Remove the nut (Item 1) [Figure 20-25-13] from the track

frame.

Installation: Tighten the nut to 305 N•m (225 ft-lb)

torque.

20-25-4 E08 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-25-16

S8897

Move the tracks frame towards the outside of the

excavator to provide extra clearance for track frame
expansion cylinder removal.

Remove the track frame expansion cylinder from the side

by using the opening between undercarriage and track
frame.

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

20-25-5 E08 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D)

Parts Identification

1. Piston Seal
2. Head
3. Piston
4. Rod Wiper
5. Rod Seal
6. Plug
7. Cylinder Housing
8. Nut
9. Shaft
10. O-ring
11. O-ring*
12. Back-up Ring*
13. O-ring
* 11 and 12 are replaced 6 7 8 10 1 3
by one seal on later
models

12 11 13 2 5 4 S8462

20-25-6 E08 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-18

Disassembly
3
Clean the outside of the expansion cylinder before 2
disassembly. 1

Use the following tools to disassemble the cylinder:

MEL1074 - O-ring Seal Hook

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

Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
N-22416
Put the base end of the cylinder in a vise.

Figure 20-25-17 Remove the head and the rod assembly from the cylinder
[Figure 20-25-18]. Put the rod end in a vise.

Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-25-18].
1
Figure 20-25-19

2
1
1
S7968

Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-25-17] to loosen the head.

N-22418

Remove the seal (Item 1) and O-ring (Item 2) from the

piston (Item 3) [Figure 20-25-19].

20-25-7 E08 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-22

Disassembly (Cont’d)

Figure 20-25-20

4
2
1 2

N-22364

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

N-22356 22].

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

from the groove in the head (Item 3) [Figure 20-25-20].

NOTE: O-ring (Item 1) and back-up ring (Item 2)

[Figure 20-25-20] are replaced by one seal on
later models.

Remove the thin O-ring (Item 4) [Figure 20-25-20].

Figure 20-25-21

2
1

N-22357

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

from the inside of the head (Item 3) [Figure 20-25-21].

20-25-8 E08 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-24

Assembly
3
Use the following tools to assemble the cylinder:

MEL1396 - Universal Seal Expander 1

MEL1033 - Rod Seal Installation Tool 2
Piston Ring Compressor
MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts. N-22418

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

and O-rings with clean hydraulic fluid before installation. Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-25-24].
Figure 20-25-23
Figure 20-25-25

P-07424
N-22358

Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-25-23]. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Allow the seal to stretch for 30 seconds before installing it 3 minutes [Figure 20-25-25].
on the piston.

20-25-9 E08 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-28

Assembly (Cont’d)

Figure 20-25-26

N-22359

Install the wiper seal with the wiper (Item 1) [Figure 20-
P-07427 25-28] toward the outside of the head.

Figure 20-25-29
Install the rod seal on the rod seal tool [Figure 20-25-26].

NOTE: During installation the spring side of the seal 4

must be toward the inside of the cylinder.
1
Rotate the handles to collapse the rod seal [Figure 20-
25-26]. 3 2

Figure 20-25-27

N-22356

Install the O-ring (Item 1) [Figure 20-25-29].

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

into the groove on the head (Item 4) [Figure 20-25-29].

NOTE: O-ring (Item 3) and back-up ring (Item 2)

P-07425 [Figure 20-25-29] are replaced by one seal on
later models. Use a ring compressor to
compress the seal to the correct size. Leave
Install the rod seal in the head [Figure 20-25-27]. the head in the compressor for about 3
minutes.

20-25-10 E08 Service Manual

CYLINDER (TRACK FRAME EXPANSION) (CONT’D) Figure 20-25-31

Assembly (Cont’d)

Figure 20-25-30

1
2
3
1

N-22364

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

25-31].
N-22416

Tighten the plug to 11 N•m (8 ft-lb) torque.

Install the head (Item 1) and the piston (Item 2) [Figure
20-25-30] on the rod. Put the base end of the hydraulic cylinder in a vise.

Grease the piston where the nut contacts the piston. Do Figure 20-25-32
not get grease on the threads.
Provide an adequate support for the cylinder before
tightening.
1
Install the nut (Item 3) [Figure 20-25-30].

NOTE: Clean and dry the rod threads, from the kit
install a NEW NUT with preapplied Loctite®.
Tighten the nut to 190 N•m (140 ft-lb) torque.

1
S7968

Insert the adjustable gland nut wrench into the two holes
(Item 1) [Figure 20-25-32] to tighten the head. Head to
be torqued until flush with end of the housing.

20-25-11 E08 Service Manual

20-25-12 E08 Service Manual
VALVE (MAIN RELIEF) The following tools will be needed for the testing at the
diagnostic coupler:
Testing And Adjusting
MEL1355 - Test Kit includes the following:
All testing is done with the hydraulic oil at operating MEL1355-3 - 5000 psi Gauge
temperature and the engine at high speed setting of 2500 MEL1355-12 - Coupler
rpm Maximum. MEL1355-9 - Thermometer

Figure 20-30-1 System Pressures At Gauge Port Specifications

TEST CONDITIONS

1 1. Engine High Idle Speed

1 2. Warm oil over relief function to minimum 66C

(150F). Cycle all functions during warm up
procedure.
Warm oil until the pressure build-up valve stabilizes
near its target pressure.

3. Activate function until cylinder movement stops. Hold

over relief for 5-10 seconds.
Record pressure.
S8567

Remove the upper left hand side cover. (See Upper Left
Side Cover Removal And Installation on Page 40-210-1.)

There are two diagnostic couplers (Item 1) [Figure 20-

30-1] on the hydraulic pump for checking each of the
pump section pressure.

 TEST TARGET kPa

SYSTEM CHECK FUNCTION TO ENGAGE CIRCUIT PRESSURIZED PORT (bar) (psi) ACCEPTABLE RANGE kPa
(bar) (psi)

MAIN RELIEF ON MAIN VALVE BUCKET P2 V2 18500 (185) 18000 - 19000 (180-190) (2611-
(2683) 2756)
MAIN RELIEF ON MAIN VALVE AUXILIARY P1 and P2 V1 and V2 18500(185) 18000 - 19000 (180-190) (2611-
(2683) 2756)
MAIN RELIEF ON MAIN VALVE ARM P1 V1 18500 (185) 18000 - 19000 (180-190) (2611-
(2683) 2756)
SWING MOTOR - PORT RELIEF SLEW RIGHT P1 V1 8400 (84) 8000 - 8800 (80-88)
(1218) (1160-1276)
SWING MOTOR - PORT RELIEF SLEW LEFT P1 V1 8400 (84) 8000 - 8800 (80-88)
(1218) (1160-1276)

20-30-1 E08 Service Manual

VALVE (MAIN RELIEF) (CONT’D) Figure 20-30-3

Testing And Adjusting (Cont’d)

1
Figure 20-30-2

S8569

If adjustment is needed, remove the plug (Item 1) [Figure

S8568 20-30-3] from the main relief valve.

Turn the main relief valve (Item 2) [Figure 20-30-3]

Connect the test gauge coupler from the test kit to the clockwise to increase the pressure or counterclockwise
“V1” diagnostic port [Figure 20-30-2]. to decrease the pressure.

Lower the control console and fasten seat belt. Tighten the nut (Item 1) [Figure 20-30-3].

Start the engine and run at low rpm until hydraulic fluid is Retest the main relief valve after adjustment.
at operating temperatures 66°C (150°F).

With the hydraulic fluid at operating temperature, run

engine at full rpm.

Operate the following circuits over relief and record the

pressure for each circuit.

NOTE: Do not operate the blade circuit due to a

bypass orifice in spool.

The main relief valve pressure at “V1” diagnostic port

[Figure 20-30-2] should be as follows:

Arm in:
18 - 19 MPa (180 - 190 bar) (2611 - 2756 psi)

Auxiliary:
18 - 19 MPa (180 - 190 bar) (2611 - 2756 psi)

Stop the engine.

20-30-2 E08 Service Manual

VALVE (MAIN RELIEF) (CONT’D) Figure 20-30-5

Testing And Adjusting (Cont’d) 1

Figure 20-30-4 2

S8571

If adjustment is needed, remove the plug (Item 1) [Figure

S8570 20-30-5] from the main relief valve.

Turn the main relief valve (Item 2) [Figure 20-30-5]

Connect the test gauge coupler from the test kit to the clockwise to increase the pressure or counterclockwise
“V2” diagnostic port [Figure 20-30-4]. to decrease the pressure.

Lower the control console and fasten seat belt. Tighten the nut (Item 1) [Figure 20-30-5].

Start the engine and run at low rpm until hydraulic fluid is Retest the main relief valve after adjustment.
at operating temperatures 66°C (150°F).

With the hydraulic fluid at operating temperature, run

engine at full rpm.

Operate the following circuits over relief and record the

pressure for each circuit.

NOTE: Do not operate the blade circuit due to a

bypass orifice in spool.

The main relief valve pressure at “V2” diagnostic port

[Figure 20-30-4] should be as follows:

Bucket in:
18 - 19 MPa (180 - 190 bar) (2611 - 2756 psi)

Auxiliary:
18 - 19 MPa (180 - 190 bar) (2611 - 2756 psi)

Stop the engine.

20-30-3 E08 Service Manual

20-30-4 E08 Service Manual
VALVE (PORT RELIEF) Figure 20-31-2

Testing And Adjusting

Figure 20-31-1

3 2

S8557
4 1
A portable hydraulic hand pump will be used to test the
S8501 work port relief valves. The hand pump must be clean
and contain the correct Bobcat hydraulic fluid.

Install the hand pump hose and a pressure gauge

Boom Port Relief set at: (minimum of 33,5 MPa [345 bar] [5000 psi]) into the valve
section work port in which the port relief valve is located
Base End (Item 1) [Figure 20-31-1] 23,2 MPa
[Figure 20-31-2]. Slowly pressurize this section with the
(232 bar)
hand pump until the port relief valve opens and make a
(3365 psi)
note of the pressure reading.
Arm Port Relief set at:
Base End (Item 2) [Figure 20-31-1] 22,5 MPa NOTE: Pumping the hand pump too fast will alter the
(225 bar) pressure readings up to 344,7 kPa (3,4 bar)
(3263 psi) (50 psi).
Slew Port Relief set at:
If the port relief pressure setting is incorrect, replace the
CW (Item 3) [Figure 20-31-1] 8,0 MPa port relief valve.
(80 bar)
(1160 psi)
CCW (Item 4) [Figure 20-31-1] 8,0 MPa
(80 bar)
(1160 psi) WARNING
AVOID INJURY OR DEATH
Traction and Chain Drives must be adjusted so that
neutral is at the location of the Neutral Start Switch.
Trencher or Chain can move suddenly when engine
starts if neutral adjustments are not correct. Start
trencher only from operator position.
W-2109-1186

20-31-1 E08 Service Manual

20-31-2 E08 Service Manual
HYDRAULIC CONTROL VALVE Figure 20-40-1

Description

The hydraulic control valve has 18,5 MPa (185 bar) (2683
psi) main relief valves for the left hand and right hand 1
travel sections. The hydraulic control valve has two 8
MPa (80 bar) (1160 psi) work port relief valves for the
slew section.The hydraulic control valve has 22,5 MPa
(225 bar) (2163 psi) work port relief valve for the arm
section. The hydraulic control valve has 23,2 MPa (232
bar) (3365 psi) work port relief valve for the boom (base
end) section.
1
Removal And Installation
S8477
Lower the boom / bucket and blade to the ground.

With the engine off, turn the start key to the ON position Remove the four bolts (Item 1) [Figure 20-40-1] from the
and move the hydraulic control levers to relieve hydraulic cover.
pressure.
Figure 20-40-2

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, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
Remove the instrument panel.
S8478
Remove the floor panels. (See FLOOR PANELS on Page
40-120-1.)
Remove the bolts (Item 1) [Figure 20-40-2] and remove
the cover.

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
doctor familiar with this injury is not received
immediately.
W-2145-EN-0210

20-40-1 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-5

Removal And Installation (Cont’d)

Figure 20-40-3

S7540

Disconnect the tubeline (Item 1) [Figure 20-40-5] from

S8499 the slew motor.

Figure 20-40-6
Mark all tubes and hoses for ease of assembly [Figure
20-40-3].

Figure 20-40-4

1 1 1

1 1

S7541

Disconnect the tubeline (Item 1) [Figure 20-40-6] from

S8479 the slew motor.

Remove the nine cotter pins and pins (Item 1) [Figure

20-40-4] and disconnect the linkages.

20-40-2 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-9

Removal And Installation (Cont’d)

Figure 20-40-7

1
1

S8482

Disconnect the two tubelines (Item 1) [Figure 20-40-9]

S8480 from the control valve.

Figure 20-40-10
Disconnect the tubeline (Item 1) [Figure 20-40-7] from
the control valve.

Remove the tubeline from the excavator for easy access

to other tubelines and hoses.

Figure 20-40-8

S8483

1
Disconnect the tubeline (Item 1) [Figure 20-40-10] from
the control valve.

S8481

Disconnect the hose (Item 1) [Figure 20-40-8] from the

control valve.

20-40-3 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-13

Removal And Installation (Cont’d)

Figure 20-40-11

S8486

Remove the clamp (Item 1) [Figure 20-40-13] from the

S8484 tubeline.

Figure 20-40-14
Disconnect the tubeline (Item 1) [Figure 20-40-11] from
the swivel joint.

Remove the tubeline from the excavator for easy access

to other tubelines and hoses.

Figure 20-40-12
1

S8488

Disconnect the tubeline (Item 1) [Figure 20-40-14] from

1 the control valve.

S8485

Disconnect the five hoses (Item 1) [Figure 20-40-12]

from the control valve.

20-40-4 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-17

Removal And Installation (Cont’d)

Figure 20-40-15

1
1

S8491

Disconnect the tubeline (Item 1) [Figure 20-40-17] from

S8489 the T-junction.

Remove the tubeline from the excavator for easy access

Disconnect the tubeline (Item 1) [Figure 20-40-15] from to other tubelines and hoses.
the swivel joint.
Figure 20-40-18
Remove the tubeline from the excavator for easy access
to other tubelines and hoses.

Figure 20-40-16

1
1

S8492

Disconnect the tubeline (Item 1) [Figure 20-40-18] from

S8490 the control valve.

Disconnect the tubeline (Item 1) [Figure 20-40-16] from

the control valve.

20-40-5 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-21

Removal And Installation (Cont’d)

Figure 20-40-19

S8495

1
Disconnect the tubeline (Item 1) [Figure 20-40-21] from
S8493 the control valve.

Figure 20-40-22
Disconnect the four hoses (Item 1) [Figure 20-40-19]
from the control valve.

Figure 20-40-20

1 1

2 S8496

Disconnect the tubeline (Item 1) [Figure 20-40-22] from

S8494 the swivel joint.

Remove the tubeline from the excavator.

Disconnect the hose (Item 1) and tubeline (Item 2)
[Figure 20-40-20] from the control valve.

20-40-6 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Removal And Installation (Cont’d)

Figure 20-40-23

1
1

S8497

Remove the three bolts (Item 1) [Figure 20-40-23].

Put the engine speed control assembly (Item 2) [Figure

20-40-23] aside.

Figure 20-40-24

2 2

2 2

S8498

Release the spring tension by moving the lockout handle

(Item 1) [Figure 20-40-24].

Remove the four bolts (Item 2) [Figure 20-40-24].

Remove the control valve from the excavator.

20-40-7 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Parts Identification

Item Description:

1. Left Travel Section

2. Slew Section
3. Arm Section
4. Boom Swing Section
5. Auxiliary Section
6. Blade Section
7. Bucket Section
8. Boom Section
9. Right Travel Section
10. Main Relief - 18,5 MPa (185 bar) (2683 psi)
11. Port Relief - 8,0 MPa (80 bar) (1160 psi)
12. Port Relief - 22,5 MPa (225 bar) (3263 psi)
13. Port Relief - 23,2 MPa (232 bar) (3365 psi)

10
9

12 8
10 11 5 7
6

4
3
1
2

13

11

S8500

20-40-8 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-26

Disassembly

Clean the outside of the hydraulic control valve before 1

disassembly.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly S8500

damage the system.

I-2003-0888
Remove the tie rod nuts and lock washers (Item 1)
[Figure 20-40-26].
Figure 20-40-25

1 2 3 4 5 6 7 8 9

S8501

Remove all the fittings from the control valve. Mark the
valve sections for ease of assembly [Figure 20-40-25].

1. Left Travel Valve

2. Slew Valve
3. Arm Valve
4. Boom Swing Valve
5. Auxiliary Valve
6. Blade Valve
7. Bucket Valve
8. Boom Valve
9. Right Travel Valve

20-40-9 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-28

Left Travel Valve Section Disassembly And Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
2
S8503

Clean all parts in solvent and dry with compressed air.

Remove the bolts (Item 1) and retaining plate (Item 2)
Inspect all parts for wear or damage. Replace any worn [Figure 20-40-28].
or damaged parts.
Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)
Always install new seals and O-rings. Lubricate all seals torque.
and O-rings with clean hydraulic fluid before installation.
Figure 20-40-29
Figure 20-40-27

2
1

1
S8504
S8502

Loosen the bolts (Item 1) and remove cap and screw

Remove the left travel valve (Item 1) [Figure 20-40-27] assembly (Item 2) [Figure 20-40-29].
from the valve assembly.
Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)
torque.

20-40-10 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-32

Left Travel Valve Section Disassembly And Assembly

Cut
(Cont’d)

Figure 20-40-30

11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)

38.1 mm
(1.500”) 19.05 mm
(0.750”)
B-14674

To remove the spring assembly from the spool a holding

2 fixture will have to be made from a 19 mm thick x 38 mm
1
S8505 wide x 51 mm long a (0.750 in thick x 1.500 in wide x 2.0
in long) piece of hardwood. Drill a 11,5 mm (0.45 in) hole
in the center of the hardwood block. Cut the block
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- lengthwise [Figure 20-40-32].
40-30].
Figure 20-40-33
Figure 20-40-31

3 2
1
1 2

S8765
S8767

Using the wood blocks clamp the spool and spring

Remove the spool and spring assembly (Item 1), assembly (Item 1) [Figure 20-40-33] in a vise.
retaining plate (Item 2), seal (Item 3) and O-ring (Item 4)
[Figure 20-40-31]. NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
The spool and valve section are not serviced separately. damaged.

NOTE: When the spool is removed, use care not to Loosen the bolt (Item 2) [Figure 20-40-33].
scratch the spool surface. Do not interchange
spools and valve sections. Installation: Apply Loctite® 243 or equivalent and
tighten the bolt to 6 N•m (53.1 in-lb) torque.

20-40-11 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-36

Left Travel Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-34

1
1
S8075

Remove the O-rings (Item 1) [Figure 20-40-36] from the

plugs.
S8766
Figure 20-40-37

Remove the spring assembly (Item 1) from the spool

(Item 2) [Figure 20-40-34].

Figure 20-40-35

1
1
S8508
2

Remove the O-rings (Item 1) [Figure 20-40-37] from the

1 main relief valve.
S8507

Remove the plug (Item 1) and main relief valve [Figure

20-40-35].

Installation: Tighten the plug and main relief valve to

40 - 45 N•m (29 - 33 ft-lb) torque.

20-40-12 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Left Travel Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-38

S8509

Remove the plug (Item 1) [Figure 20-40-38] from the

main relief valve.

Installation: Tighten the plug to 25 N•m (18 ft-lb) torque.

Figure 20-40-39

S8510

Remove the copper washer (Item 1) [Figure 20-40-39]

from the main relief valve.

20-40-13 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-41

Slew Valve Section Disassembly And Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
S8512

Clean all parts in solvent and dry with compressed air.

Remove the O-ring (Item 1) [Figure 20-40-41] from the
Inspect all parts for wear or damage. Replace any worn slew valve section.
or damaged parts.
Figure 20-40-42
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

Figure 20-40-40

1
1
2

S8513

Loosen the bolts (Item 1) and remove cap and screw

S8511 assembly (Item 2) [Figure 20-40-42].

Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)

Remove the slew valve section (Item 1) [Figure 20-40- torque.
40] from the valve assembly.

20-40-14 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-45

Slew Valve Section Disassembly And Assembly

(Cont’d)
2
Figure 20-40-43
1

4
3

S8768

2 Remove the spool and spring assembly (Item 1),

retaining plate (Item 2), seal (Item 3) and O-ring (Item 4)
1 [Figure 20-40-45].
S8514

The spool and valve section are not serviced separately.

Remove the bolts (Item 1) and retaining plate (Item 2)
[Figure 20-40-43]. NOTE: When the spool is removed, use care not to
scratch the spool surface. Do not interchange
Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb) spools and valve sections.
torque.
Figure 20-40-46
Figure 20-40-44
Cut

11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)

38.1 mm
(1.500”) 19.05 mm
2 (0.750”)
1 B-14674
S8515

To remove the spring assembly from the spool a holding

Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- fixture will have to be made from a 19 mm thick x 38 mm
40-44] from the cap. wide x 51 mm long a (0.750 in thick x 1.500 in wide x 2.0
in long) piece of hardwood. Drill a 11,5 mm (0.45 in) hole
in the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-46].

20-40-15 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-49

Slew Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-47

1 2 1

S8087

Remove the relief valve assemblies (Item 1) [Figure 20-

40-49].
S8765
Installation: Tighten the relief valve assemblies to 40 -
45 N•m (29 - 33 ft-lb) torque.
Using the wood blocks clamp the spool and spring
assembly (Item 1) [Figure 20-40-47] in a vise. Figure 20-40-50

NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged.

Loosen the bolt (Item 2) [Figure 20-40-47].

Installation: Apply Loctite® 243 or equivalent and

tighten the bolt to 6 N•m (53.1 in-lb) torque.

Figure 20-40-48
1

2 S8088

1
Remove the plug (Item 1) [Figure 20-40-50] from both
relief valves.

Installation: Tighten the plugs to 25 N•m (18 ft-lb)

torque.

S8766

Remove the spring assembly (Item 1) from the spool

(Item 2) [Figure 20-40-48].

20-40-16 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-53

Slew Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-51

1
1

S8077

1
Remove the O-ring (Item 1) [Figure 20-40-53] from the
1 check valve.
S8089

Remove the O-rings (Item 1) [Figure 20-40-51].

Figure 20-40-52

S8076

Remove the check valve (Item 1) [Figure 20-40-52].

Installation: Tighten the check valve to 20 N•m (15 ft-lb)

torque.

20-40-17 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-55

Arm Valve Section Disassembly And Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 1
I-2003-0888
S8518

Clean all parts in solvent and dry with compressed air.

Remove the O-ring (Item 1) [Figure 20-40-55] from the
Inspect all parts for wear or damage. Replace any worn arm valve section.
or damaged parts.
Figure 20-40-56
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

Figure 20-40-54

1 1
2

1
S8519

Loosen the bolts (Item 1) and remove cap and screw

S8517 assembly (Item 2) [Figure 20-40-56].

Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)

Remove the arm valve section (Item 1) [Figure 20-40-54] torque.
from the valve assembly.

20-40-18 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-59

Arm Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-57 2
1

4
3

1
S8769

2 Remove the spool and spring assembly (Item 1),

retaining plate (Item 2), seal (Item 3) and O-ring (Item 4)
1 [Figure 20-40-59].
S8520

The spool and valve section are not serviced separately.

Remove the bolts (Item 1) and retaining plate (Item 2)
[Figure 20-40-57]. NOTE: When the spool is removed, use care not to
scratch the spool surface. Do not interchange
Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb) spools and valve sections.
torque.
Figure 20-40-60
Figure 20-40-58
Cut

11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)

38.1 mm
(1.500”) 19.05 mm
(0.750”)
B-14674
2
S8521

To remove the spring assembly from the spool a holding

Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- fixture will have to be made from a 19 mm thick x 38 mm
40-58]. wide x 51 mm long a (0.750 in thick x 1.500 in wide x 2.0
in long) piece of hardwood. Drill a 11,5 mm (0.45 in) hole
in the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-60].

20-40-19 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-63

Arm Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-61

1 2
1
S8097

Remove the plug (Item 1) and port relief valve (Item 2)

[Figure 20-40-63].
S8765
Installation: Tighten the plug to 40 - 45 N•m (29 - 33 ft-
lb) torque.
Using the wood blocks clamp the spool and spring
assembly (Item 1) [Figure 20-40-61] in a vise. Installation: Tighten the port relief valve to 40 - 45 N•m
(29 - 33 ft-lb) torque.
NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be Figure 20-40-64
damaged.

Loosen the bolt (Item 2) [Figure 20-40-61].

1
Installation: Apply Loctite® 243 or equivalent and
tighten the bolt to 6 N•m (53.1 in-lb) torque.

Figure 20-40-62

1
S8098

Remove the O-ring (Item 1) [Figure 20-40-64] from the

plug.

S8766

Remove the spring assembly (Item 1) from the spool

(Item 2) [Figure 20-40-62].

20-40-20 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-67

Arm Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-65

S8076

1
Remove the check valve (Item 1) [Figure 20-40-67].

S8088 Installation: Tighten the check valve to 20 N•m (15 ft-lb)

torque.

Remove the plug (Item 1) [Figure 20-40-65] from the Figure 20-40-68
port relief valve.

Installation: Tighten the plug to 25 N•m (18 ft-lb) torque.

Figure 20-40-66

1
1

S8077

1
Remove the O-ring (Item 1) [Figure 20-40-68] from the
1 check valve.
S8089

Remove the O-rings (Item 1) [Figure 20-40-66].

20-40-21 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-70

Boom Swing Valve Section Disassembly And

Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888 S8100

Clean all parts in solvent and dry with compressed air. Remove the O-ring (Item 1) [Figure 20-40-70] from the
side of the boom swing valve section.
Inspect all parts for wear or damage. Replace any worn
or damaged parts. Figure 20-40-71

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

and O-rings with clean hydraulic fluid before installation.

Figure 20-40-69

1 1

S8101

Remove the bolts (Item 1) and retaining plate (Item 2)

[Figure 20-40-71].
S8523
Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)
torque.
Remove the boom swing valve section (Item 1) [Figure
20-40-69] from the valve assembly.

20-40-22 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-74

Boom Swing Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-72
3

4
1 2
2

S8761

Remove the spool and spring assembly (Item 1),

retaining plate (Item 2), seal (Item 3) and O-ring (Item 4)
1 S8102 [Figure 20-40-74].

The spool and valve section are not serviced separately.

Loosen the bolts (Item 1) and remove cap and screw
assembly (Item 2) [Figure 20-40-72]. NOTE: When the spool is removed, use care not to
scratch the spool surface. Do not interchange
Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb) spools and valve sections.
torque.
Figure 20-40-75
Figure 20-40-73
Cut

11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)
2
1

38.1 mm
(1.500”) 19.05 mm
(0.750”)
B-14674
S8103

To remove the spring assembly from the spool a holding

Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- fixture will have to be made from a 19 mm thick x 38 mm
40-73]. wide x 51 mm long a (0.750 in thick x 1.500 in wide x 2.0
in long) piece of hardwood. Drill a 11,5 mm (0.45 in) hole
in the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-75].

20-40-23 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-78

Boom Swing Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-76

2
1
1 2
S8105

Remove the plug (Item 1) and valve assembly (Item 2)

[Figure 20-40-78].
S8765
Installation: Tighten the plug to 40 - 45 N•m (29 - 33 ft-
lb) torque.
Using the wood blocks clamp the spool and spring
assembly (Item 1) [Figure 20-40-76] in a vise. Installation: Tighten the valve assembly to 40 - 45 N•m
(29 - 33 ft-lb) torque.
NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be Figure 20-40-79
damaged.

Loosen the bolt (Item 2) [Figure 20-40-76].

Installation: Apply Loctite® 243 or equivalent and

tighten the bolt to 6 N•m (53.1 in-lb) torque.

Figure 20-40-77

2 1
1
1
S8106

Remove the O-rings (Item 1) [Figure 20-40-79].

S8766

Remove the spring assembly (Item 1) from the spool

(Item 2) [Figure 20-40-77].

20-40-24 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-82

Boom Swing Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-80

S8109

1
Remove the O-ring (Item 1) [Figure 20-40-82].

S8107 Figure 20-40-83

Remove the plug (Item 1) [Figure 20-40-80] from the

valve assembly.

Installation: Tighten the valve assembly to 25 N•m (18

ft-lb) torque.

Figure 20-40-81

1
1
S8110

Remove the O-rings (Item 1) [Figure 20-40-83].

1 2 3 4

S8108

Remove the bolt (Item 1), washer (Item 2), spring (Item 3)
and valve (Item 4) [Figure 20-40-81].

Installation: Tighten the bolt to 1,5 N•m (13.3 in-lb)

torque.

20-40-25 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Boom Swing Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-84

S8076

Remove the check valve (Item 1) [Figure 20-40-84].

Installation: Tighten the check valve to 20 N•m (15 ft-lb)

torque.

Figure 20-40-85

S8077

Remove the O-ring (Item 1) [Figure 20-40-85] from the

check valve.

20-40-26 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-87

Auxiliary Valve Section Disassembly And Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
S8525

Clean all parts in solvent and dry with compressed air.

Remove the O-ring (Item 1) [Figure 20-40-87] from the
Inspect all parts for wear or damage. Replace any worn auxiliary valve section.
or damaged parts.
Figure 20-40-88
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

Figure 20-40-86

2
1 S8526
1

Remove the bolts (Item 1) and retaining plate (Item 2)

S8524 [Figure 20-40-88].

Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)

Remove the auxiliary valve section (Item 1) [Figure 20- torque.
40-86] from the valve assembly.

20-40-27 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-91

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-89 3

4
2
1
2

S8770

Remove the spool and spring assembly (Item 1),

retaining plate (Item 2), seal (Item 3) and O-ring (Item 4)
1
S8527 [Figure 20-40-91].

The spool and valve section are not serviced separately.

Loosen the bolts (Item 1) and remove cap and screw
assembly (Item 2) [Figure 20-40-89]. NOTE: When the spool is removed, use care not to
scratch the spool surface. Do not interchange
Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb) spools and valve sections.
torque.
Figure 20-40-92
Figure 20-40-90
Cut

11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)

38.1 mm
(1.500”) 19.05 mm
(0.750”)
2 B-14674
1 S8528

To remove the spring assembly from the spool a holding

Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- fixture will have to be made from a 19 mm thick x 38 mm
40-90]. wide x 51 mm long a (0.750 in thick x 1.500 in wide x 2.0
in long) piece of hardwood. Drill a 11,5 mm (0.45 in) hole
in the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-92].

20-40-28 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-95

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)
2
Figure 20-40-93

1 2

S8530

Remove the plug (Item 1) and build-up valve (Item 2)

[Figure 20-40-95].
S8765
Installation: Tighten the plug and build-up valve to
40 - 45 N•m (29 - 33 ft-lb) torque.
Using the wood blocks clamp the spool and spring
assembly (Item 1) [Figure 20-40-93] in a vise. Figure 20-40-96

NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be 1
damaged.
1
Loosen the bolt (Item 2) [Figure 20-40-93].

Installation: Apply Loctite® 243 or equivalent and

tighten the bolt to 6 N•m (53.1 in-lb) torque.

Figure 20-40-94

2 S8158

1
Remove the O-rings (Item 1) [Figure 20-40-96].

S8766

Remove the spring assembly (Item 1) from the spool

(Item 2) [Figure 20-40-94].

20-40-29 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-99

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-97

1
1

S8532

Remove the O-ring (Item 1) [Figure 20-40-99].

S8159 Figure 20-40-100

Remove the O-rings (Item 1) [Figure 20-40-97].

Figure 20-40-98
1

S8160

Remove the check valve (Item 1) [Figure 20-40-100].

S8531 Installation: Tighten the check valve to 20 N•m (15 ft-lb)

torque.

Remove the plug (Item 1) [Figure 20-40-98].

Installation: Tighten the plug to 25 N•m (18 ft-lb) torque.

20-40-30 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Auxiliary Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-101

2
1

S8161

Remove the spring (Item 1) and spring seat (Item 2)

[Figure 20-40-101].

Figure 20-40-102

S8162

Remove the O-ring (Item 1) [Figure 20-40-102].

20-40-31 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-104

Blade Valve Section Disassembly And Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, 1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
S8115

Clean all parts in solvent and dry with compressed air.

Remove the O-ring (Item 1) [Figure 20-40-104] from the
Inspect all parts for wear or damage. Replace any worn blade valve section.
or damaged parts.
Figure 20-40-105
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

Figure 20-40-103

S8116

Remove the O-ring (Item 1) [Figure 20-40-105] from the

S8533 blade valve section.

Remove the blade valve section (Item 1) [Figure 20-40-

103] from the valve assembly.

20-40-32 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-108

Blade Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-106

1 2
1
S8119

Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-

2 40-108].
1 S8117
Figure 20-40-109

Remove the bolts (Item 1) and retaining plate (Item 2)

[Figure 20-40-106].

Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)

torque.
3 2
1
Figure 20-40-107

S8763

1
2
Remove the spool and spring assembly (Item 1),
retaining plate (Item 2), seal (Item 3) and O-ring (Item 4)
[Figure 20-40-109].

The spool and valve section are not serviced separately.

1
S8118
NOTE: When the spool is removed, use care not to
scratch the spool surface. Do not interchange
Loosen the bolts (Item 1) and remove cap and screw spools and valve sections.
assembly [Figure 20-40-107].

Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)

torque.

20-40-33 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-112

Blade Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-110 2

1
Cut

11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)
S8766

38.1 mm Remove the spring assembly (Item 1) from the spool

(1.500”) 19.05 mm (Item 2) [Figure 20-40-112].
(0.750”)
B-14674
Figure 20-40-113

To remove the spring assembly from the spool a holding

fixture will have to be made from a 19 mm thick x 38 mm
wide x 51 mm long a (0.750 in thick x 1.500 in wide x 2.0
in long) piece of hardwood. Drill a 11,5 mm (0.45 in) hole
in the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-110].

Figure 20-40-111
1

S8121

1 2
Remove the check valve (Item 1) [Figure 20-40-113].

Installation: Tighten the check valve to 20 N•m (15 ft-lb)

torque.

S8765

Using the wood blocks clamp the spool and spring

assembly (Item 1) [Figure 20-40-111] in a vise.

NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged.

Loosen the bolt (Item 2) [Figure 20-40-111].

Installation: Apply Loctite® 243 or equivalent and

tighten the bolt to 6 N•m (53.1 in-lb) torque.

20-40-34 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Blade Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-114

S8122

Remove the O-ring (Item 1) [Figure 20-40-114] from the

check valve.

20-40-35 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-116

Bucket Valve Section Disassembly And Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
S8535

Clean all parts in solvent and dry with compressed air.

Remove the O-ring (Item 1) [Figure 20-40-116] from the
Inspect all parts for wear or damage. Replace any worn bucket valve section.
or damaged parts.
Figure 20-40-117
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

Figure 20-40-115

2
1 1 S8536

Remove the bolts (Item 1) and retaining plate (Item 2)

S8534 [Figure 20-40-117].

Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)

Remove the bucket valve section (Item 1) [Figure 20-40- torque.
115] from the valve assembly.

20-40-36 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-120

Bucket Valve Section Disassembly And Assembly

(Cont’d)
3
Figure 20-40-118

3
2

S8771

Remove the spool and spring assembly (Item 1),

2 retaining plate (Item 2), seal (Item 3) and O-ring (Item 4)
1
S8537 [Figure 20-40-120].

The spool and valve section are not serviced separately.

Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-
40-118]. NOTE: When the spool is removed, use care not to
scratch the spool surface. Do not interchange
Figure 20-40-119 spools and valve sections.

Figure 20-40-121

Cut
1
2

11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)

1
S8538 38.1 mm
(1.500”) 19.05 mm
(0.750”)
B-14674
Loosen the bolts (Item 1) and remove cap and screw
assembly [Figure 20-40-119].
To remove the spring assembly from the spool a holding
Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb) fixture will have to be made from a 19 mm thick x 38 mm
torque. wide x 51 mm long a (0.750 in thick x 1.500 in wide x 2.0
in long) piece of hardwood. Drill a 11,5 mm (0.45 in) hole
in the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-121].

20-40-37 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-124

Bucket Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-122

1 2

S8130

Remove the plugs (Item 1) [Figure 20-40-124].

S8765 Installation: Tighten the plugs to 40 - 45 N•m (29 - 33 ft-

lb) torque.

Using the wood blocks clamp the spool and spring Figure 20-40-125
assembly (Item 1) [Figure 20-40-122] in a vise.

NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be 1
damaged. 1

Loosen the bolt (Item 2) [Figure 20-40-122].

Installation: Apply Loctite® 243 or equivalent and

tighten the bolt to 6 N•m (53.1 in-lb) torque.

Figure 20-40-123

S8131

1 Remove the O-rings (Item 1) [Figure 20-40-125] from the

plugs.

S8766

Remove the spring assembly (Item 1) from the spool

(Item 2) [Figure 20-40-123].

20-40-38 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Bucket Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-126

3
2
5
4
S8132

Remove the spring seat (Item 1), spring (Item 2), spring
seat (Item 3), spring (Item 4) and plug (Item 5) [Figure
20-40-126].

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

Figure 20-40-127

S8133

Remove the O-ring (Item 1) [Figure 20-40-127] from the

plug.

20-40-39 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-129

Boom Valve Section Disassembly And Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
1
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
S8541

Clean all parts in solvent and dry with compressed air.

Remove the O-ring (Item 1) [Figure 20-40-129] from the
Inspect all parts for wear or damage. Replace any worn boom valve section.
or damaged parts.
Figure 20-40-130
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

Figure 20-40-128

2
1
1
S8542

Remove the bolts (Item 1) and retaining plate (Item 2)

S8540 [Figure 20-40-130].

Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)

Remove the boom valve section (Item 1) [Figure 20-40- torque.
128] from the valve assembly.

20-40-40 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-133

Boom Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-131 2

4
3
1
2

S8772

Remove the spool and spring assembly (Item 1),

retaining plate (Item 2), seal (Item 3) and O-ring (Item 4)
1
S8543 [Figure 20-40-133].

The spool and valve section are not serviced separately.

Loosen the bolts (Item 1) and remove cap and screw
assembly (Item 2) [Figure 20-40-131]. NOTE: When the spool is removed, use care not to
scratch the spool surface. Do not interchange
Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb) spools and valve sections.
torque.
Figure 20-40-134
Figure 20-40-132
Cut

11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)

38.1 mm
(1.500”) 19.05 mm
(0.750”)
2 B-14674
1 S8544

To remove the spring assembly from the spool a holding

Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- fixture will have to be made from a 19 mm thick x 38 mm
40-132]. wide x 51 mm long a (0.750 in thick x 1.500 in wide x 2.0
in long) piece of hardwood. Drill a 11,5 mm (0.45 in) hole
in the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-134].

20-40-41 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-137

Boom Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-135
1

1 2

S8141

Remove the plug (Item 1) and relief valve (Item 2)

[Figure 20-40-137].
S8765
Installation: Tighten the plug to 40 - 45 N•m (29 - 33 ft-
lb) torque.
Using the wood blocks clamp the spool and spring
assembly (Item 1) [Figure 20-40-135] in a vise. Installation: Tighten the relief valve to 40 - 45 N•m (29 -
33 ft-lb) torque.
NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be Figure 20-40-138
damaged.

Loosen the bolt (Item 2) [Figure 20-40-135].

1
Installation: Apply Loctite® 243 or equivalent and 1
tighten the bolt to 6 N•m (53.1 in-lb) torque.

Figure 20-40-136

1
S8142

Remove the O-rings (Item 1) [Figure 20-40-138].

S8766

Remove the spring assembly (Item 1) from the spool

(Item 2) [Figure 20-40-136].

20-40-42 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-141

Boom Valve Section Disassembly And Assembly

(Cont’d)

Figure 20-40-139

S8145

Remove the check valve (Item 1) [Figure 20-40-141].

S8143 Installation: Tighten the check valve to 20 N•m (15 ft-lb)

torque.

Remove the plug (Item 1) [Figure 20-40-139] from the Figure 20-40-142
relief valve.

Installation: Tighten the plug to 25 N•m (18 ft-lb) torque.

1
Figure 20-40-140

1
1
1

S8146

Remove the O-ring (Item 1) [Figure 20-40-142] from the

check valve.
S8144

Remove the O-rings (Item 1) [Figure 20-40-140].

20-40-43 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-144

Right Travel Valve Section Disassembly And

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 2
damage the system.
I-2003-0888 S8547

Clean all parts in solvent and dry with compressed air. Remove the bolts (Item 1) and retaining plate (Item 2)
[Figure 20-40-144].
Inspect all parts for wear or damage. Replace any worn
or damaged parts. Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)
torque.
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation. Figure 20-40-145

Figure 20-40-143

1
2

1
S8548

S8546
Loosen the bolts (Item 1) and remove cap and screw
assembly (Item 2) [Figure 20-40-145].
Remove the right travel valve section (Item 1) [Figure 20-
40-143] from the tie rods. Installation: Tighten the bolts to 6,5 N•m (57.5 in-lb)
torque.

20-40-44 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-148

Right Travel Valve Section Disassembly And

Cut
Assembly (Cont’d)

Figure 20-40-146

11.43 mm 50.8 mm
(0.45”) dia.
(2.0”)

38.1 mm
(1.500”) 19.05 mm
(0.750”)
B-14674

1
To remove the spring assembly from the spool a holding
2 fixture will have to be made from a 19 mm thick x 38 mm
S8549 wide x 51 mm long a (0.750 in thick x 1.500 in wide x 2.0
in long) piece of hardwood. Drill a 11,5 mm (0.45 in) hole
in the center of the hardwood block. Cut the block
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20- lengthwise [Figure 20-40-148].
40-146].
Figure 20-40-149
Figure 20-40-147

3
1
1 2

4
2

S8765
S8773

Using the wood blocks clamp the spool and spring

Remove the spool and spring assembly (Item 1), assembly (Item 1) [Figure 20-40-149] in a vise.
retaining plate (Item 2), seal (Item 3) and O-ring (Item 4)
[Figure 20-40-147]. NOTE: Do not use anything other than hardwood
blocks to grip the spool, or the spool will be
The spool and valve section are not serviced separately. damaged.

NOTE: When the spool is removed, use care not to Loosen the bolt (Item 2) [Figure 20-40-149].
scratch the spool surface. Do not interchange
spools and valve sections. Installation: Apply Loctite® 243 or equivalent and
tighten the bolt to 6 N•m (53.1 in-lb) torque.

20-40-45 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-152

Right Travel Valve Section Disassembly And

Assembly (Cont’d)
1
Figure 20-40-150 1

S8153

Remove the O-rings (Item 1) [Figure 20-40-152] from the

plug.
S8766
Figure 20-40-153

Remove the spring assembly (Item 1) from the spool

(Item 2) [Figure 20-40-150].

Figure 20-40-151

1 1
1
S8508

Remove the O-rings (Item 1) [Figure 20-40-153] from the

main relief valve.
S8551

Remove the plug (Item 1) and main relief valve (Item 2)

[Figure 20-40-151].

Installation: Tighten the plug and main relief valve to 40

- 45 N•m (29 - 33 ft-lb) torque.

20-40-46 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D)

Right Travel Valve Section Disassembly And

Assembly (Cont’d)

Figure 20-40-154

S8509

Remove the plug (Item 1) [Figure 20-40-154] from the

main relief valve.

Installation: Tighten the plug to 25 N•m (18 ft-lb) torque.

Figure 20-40-155

S8510

Remove the copper washer (Item 1) [Figure 20-40-155]

from the main relief valve.

20-40-47 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-157

Assembly

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

S8541
Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn Install the O-ring (Item 1) [Figure 20-40-157] on the
or damaged parts. boom valve section.

Always install new seals and O-rings. Lubricate all seals Figure 20-40-158
and O-rings with clean hydraulic fluid before installation.

Figure 20-40-156

1 S8540

Install the boom valve section (Item 1) [Figure 20-40-

S8546
158] on the tie rods.

Install the tie rods (Item 1) on the right travel valve

section (Item 2) [Figure 20-40-156].

20-40-48 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-161

Assembly (Cont’d)

Figure 20-40-159

1
S8116

Install the O-ring (Item 1) [Figure 20-40-161] on the

S8535 blade valve section.

Figure 20-40-162
Install the O-ring (Item 1) [Figure 20-40-159] on the
bucket valve section.

Figure 20-40-160

1
S8115

Install the O-ring (Item 1) [Figure 20-40-162] on the

S8534 blade valve section.

Install the bucket valve section (Item 1) [Figure 20-40-

160] on the tie rods.

20-40-49 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-165

Assembly (Cont’d)

Figure 20-40-163

1
S8524

Install the auxiliary valve section (Item 1) [Figure 20-40-

S8533 165] on the tie rods.

Figure 20-40-166
Install the blade valve section (Item 1) [Figure 20-40-
163] on the tie rods.

Figure 20-40-164

1
S8100

Install the O-ring (Item 1) [Figure 20-40-166] on the

S8525 boom swing valve section.

Install the O-ring (Item 1) [Figure 20-40-164] on the

auxiliary valve section.

20-40-50 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-169

Assembly (Cont’d)

Figure 20-40-167

S8517
1

Install the arm valve section (Item 1) [Figure 20-40-169]

S8523 on the tie rods.

Figure 20-40-170
Install the boom swing valve section (Item 1) [Figure 20-
40-167] on the tie rods.

Figure 20-40-168

1
S8512

Install the O-ring (Item 1) [Figure 20-40-170] on the slew

S8518 valve section.

Install the O-ring (Item 1) [Figure 20-40-168] on the arm

valve section.

20-40-51 E08 Service Manual

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-173

Assembly (Cont’d)

Figure 20-40-171 1

1
S8500

Install the washers and nuts (Item 1) [Figure 20-40-173]

1
S8511 on the tie rods, finger tight.

Be sure the valve assembly does not rock on a flat

Install the slew valve section (Item 1) [Figure 20-40-171] surface.
on the tie rods.
Initially tighten the tie rod nuts (Item 1) [Figure 20-40-
Figure 20-40-172 173] to 13 N•m (10 ft-lb) torque in a crisscross manner.

Final tighten the tie rod nuts (Item 1) [Figure 20-40-173]

to 25 N•m (18 ft-lb) torque.
1
The valve assembly must not have any spacing between
the valve sections and the spools must be free when
pushed in and released.

The spools must not stick, if the spools do stick, loosen

the tie rod nuts and tighten per above information.

Recheck the control valve assembly for level settings.

Install the hoses and fittings.

S8502

Install the left travel valve section (Item 1) [Figure 20-40-

172] on the tie rods.

20-40-52 E08 Service Manual

HYDRAULIC PUMP Testing The Hydraulic Pump

Description The hydraulic pump flow is 10 L/min (2.64 U.S. gpm) for
both pump sections at 2370 rpm.
The hydraulic gear pump is attached to the end of the
engine flywheel at the left side of the motor. NOTE: Pump Section 1 is closest to the engine.

The hydraulic gear pump is a double gear pump that The following tool will be needed for the hydraulic pump
provides hydraulic flow to the hydraulic systems. The first test:
gear pump section, located nearest the engine, provides
flow to the right travel, boom, bucket, blade and auxiliary MEL10003 - Hydraulic Tester
functions. The second gear pump section provides flow
to the auxiliary, boom swing, arm, slew and left hand Stop the engine.
travel functions.
Remove the upper left hand side cover. (See Upper Left
Side Cover Removal And Installation on Page 40-210-1.)

Remove the lower left hand side cover. ((See Lower Left
Side Cover Removal And Installation on Page 40-210-2.)

Figure 20-50-1

S8415

Remove the outlet hose, of the section to be tested, from

the hydraulic pump section for testing [Figure 20-50-1].

20-50-1 E08 Service Manual

HYDRAULIC PUMP (CONT’D) Start the engine and run at low rpm until the hydraulic
fluid is warm 66°C (150°F). Make sure the tester is
Testing The Hydraulic Pump (Cont’d) connected correctly. If no flow is indicated at the tester,
the hoses are connected wrong.
Figure 20-50-2
Increase the engine speed to full rpm.

Record the pump free flow L/min (U.S. gpm).

2
Close the flow control knob (Item 1) [Figure 20-50-3]
slowly to approximately 0,689 MPa (6,89 bar) (100 psi)
below the relief valve setting which is 18,0 - 19,0 MPa
1 (180 - 190 bar) (2611 - 2756 psi).

Record the pump high pressure flow L/min (U.S. gpm).

NOTE: The high pressure flow must be at least 80% of

free flow.

S8416 HIGH PRESSURE FLOW (L/MIN) x 100

%=
FREE FLOW (L/MIN)
Connect the hose removed from the pump (Item 1)
[Figure 20-50-2] to the outlet of the tester. If the high pressure flow is less than 80% of free flow,
remove the hydraulic pump for repair or replacement.
Connect the inlet hose of the tester to the fitting on the
pump (Item 2) [Figure 20-50-2]. Repeat the testing procedure for each pump section.

NOTE: The tester connections will be the same for

each pump section.

Figure 20-50-3

P-16671

NOTE: Open the flow control knob on the hydraulic

tester (Item 1) [Figure 20-50-3] fully to prevent
pump damage.

20-50-2 E08 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-4

Removal And Installation

Lower the boom / bucket and blade to the ground.

Relieve hydraulic pressure.

Drain the hydraulic reservoir. (See Replacing Hydraulic 1

Oil on Page 10-120-2.)

IMPORTANT
S8415
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses, Remove the two pressure hoses (Item 1) [Figure 20-50-
tubelines and ports to keep dirt out. Dirt can quickly 4]. Cap and plug the hoses and fittings.
damage the system.
I-2003-0888 Figure 20-50-5

WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by 2
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
doctor familiar with this injury is not received
immediately.
W-2145-EN-0210
1
Remove the upper left hand side cover. (See Upper Left S8417
Side Cover Removal And Installation on Page 40-210-1.)

Remove the lower left hand side cover. (See Lower Left Remove the hose clamp (Item 1) and inlet hose (Item 2)
Side Cover Removal And Installation on Page 40-210-2.) [Figure 20-50-5].

20-50-3 E08 Service Manual

HYDRAULIC PUMP (CONT’D)

Removal And Installation (Cont’d)

Figure 20-50-6

2
1

S8418

Remove the fitting (Item 1) [Figure 20-50-6] from the

pump.

Remove the bolts (Item 2) [Figure 20-50-6] from the

pump flange.

Installation: Tighten the bolts to 71 - 79 N•m (53 - 58 ft-

lb) torque.

Remove the hydraulic pump from the excavator.

20-50-4 E08 Service Manual

HYDRAULIC PUMP (CONT’D)

Parts Identification

1. Body 17. Pin

2. Body 18. Pin
3. Flange
4. Cover
5. Block
6. Gear
7. Gear
8. Gear
9. Plate 12 5 8 11 9
10. Coupling
11. Seal
12. Seal
13. O-ring
14. Seal-up
15. Ring
16. Screw

16 16 4

7 5 12

1 13 11

17 13 14 15

16 16 13

12 18
12 6 5

11 18 13 2 17 3

11 5 10 7

S8236

20-50-5 E08 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-8

Disassembly 1

Clean the outside of the gear pump before disassembly.

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. S7511
I-2003-0888

Put the pump, mounting flange down, in a protected jaw

Figure 20-50-7 vise. Remove the four assembly bolts (Item 1) [Figure
20-50-8].
2 3 4
1 NOTE: The pump has only one inlet port. The pump
5 section with the inlet port is located closest to
the input shaft.

Figure 20-50-9

S7510 2

Mark both sides of each separation point (Items 1 - 4)

[Figure 20-50-7] on the inlet side of the pump, as shown,
with the corresponding separation point number.

Tape the shaft splines (Item 5) [Figure 20-50-7] to make

S7512
sure that the splines will not damage the oil seal when
the shaft is removed.
Remove the end cap (or separating plate) (Item 1)
[Figure 20-50-9].

Remove the O-ring (Item 2) [Figure 20-50-9] from the

top of the gear housing.

20-50-6 E08 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-12

Disassembly (Cont’d)
1
Figure 20-50-10
Remove the O-
1 ring from the end
of the housing

S7515

Remove the drive and idler gears (Item 1) [Figure 20-50-

S7513 12].

Figure 20-50-13
Remove the gear housing (Item 1) [Figure 20-50-10].

Remove the O-ring (Item 2) [Figure 20-50-10] from the

end of the gear housing.

Figure 20-50-11
Back-up Ring O-ring seal
(Black) 2
1

S7516

Remove the lower bearing (Item 1) [Figure 20-50-13].

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

S7514 [Figure 20-50-13] from the bearing.

Remove the upper bearing (Item 1) [Figure 20-50-11].

Remove the back-up ring and O-ring seal from the

bearing.

20-50-7 E08 Service Manual

HYDRAULIC PUMP (CONT’D) Assembly

Disassembly (Cont’d) Clean all parts in solvent and dry with compressed air.

Figure 20-50-14 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 and all O-ring seals
with assembly lube before installation.
1
Use the correct size driver and install the oil seal (seal
lips to the inside of the pump) (Item 4) into the mounting
flange (Item 2). Install the snap ring (Item 1) [Figure 20-
50-15].

Figure 20-50-16

S7517
2

Remove the coupling (Item 1) [Figure 20-50-14].

3
Repeat step [Figure 20-50-9 on Page 6] through step
[Figure 20-50-14] to disassemble the second pump
section. Keep the parts from each section separate from
4
the other section.

NOTE: The gear housing, two bearings, drive gear

and idler gear in each pump section are not 1
serviced separately. These parts are matched
S7518
sets which are run in at the factory. If any part
is damaged, the entire section must be
replaced. Install an O-ring seal (Item 1) [Figure 20-50-16] stepped
side up, into each O-ring seal groove. Push each O-ring
Figure 20-50-15 seal down into the groove.

Install the back-up ring (Item 2) [Figure 20-50-16] into

the groove made by the O-ring seal and bearing. Push
the back-up ring down flush with the O-ring seal.

3 NOTE: There is a notch (Items 3 and 4) [Figure 20-50-

16] in the center of the back-up ring and O-
4 ring seal. When installing the back-up ring,
make sure that these notches are aligned. If
1
the back-up ring or O-ring seal are not
installed correctly the back-up ring will not sit
2
flush with the O-ring seal.

CD-0209

Remove the snap ring (Item 1) from the mounting flange,

(Item 2). Using a seal puller (Item 3), remove the oil seal
(Item 4) [Figure 20-50-15].

20-50-8 E08 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-19
Open side of O-
Assembly (Cont’d)
1 ring seal must go
towards the inlet
Figure 20-50-17
port
Open side of O-
2 ring seal must go
towards the inlet
port
2

S7521

Install the upper bearing (Item 1), seal side up, on the
S7519 drive and idler gears (Item 2) [Figure 20-50-19]. The
open side of the O-ring seal must point toward the inlet
port side (marked side) of the pump.
Put the mounting flange, oil seal side down (Item 1)
[Figure 20-50-17] in a protected jaw vise. Figure 20-50-20
Upper bearing
Install the lower bearing (Item 2) [Figure 20-50-17], seal
must be slightly
side down, on the mounting flange (or separating plate).
lower than
The open side of the O-ring seal must point toward the
housing
inlet port side (marked side) of the pump.

Figure 20-50-18

1 S7522

Install O-rings (Item 1) [Figure 20-50-20] on each end of

the gear housing.

Align the marks made during disassembly on the gear

S7520 housing and mounting flange (or separating plate).
Carefully install the gear housing over the bearings and
gears [Figure 20-50-20].
Tape the splined end (Item 1) [Figure 20-50-18] of the
drive gear to make sure that the splines will not damage NOTE: The upper bearing must be slightly lower than
the oil seal during installation. the gear housing. If the bearing is higher than
the housing, disassemble the pump section to
Apply oil to the drive gear and idler gear and to the side verify that the O-ring seal, back-up ring, or O-
faces of the gears. Install the gears into the lower bearing ring have not moved out of position.
[Figure 20-50-18].

20-50-9 E08 Service Manual

HYDRAULIC PUMP (CONT’D) Figure 20-50-23

Assembly (Cont’d)

Figure 20-50-21 1

2 S7529

Align the marks made during disassembly on the

S7517 separating plate and gear housing. Install the separating
plate (Item 1) [Figure 20-50-23].

Apply oil to the coupling (Item 1) [Figure 20-50-21]. Repeat step [Figure 20-50-16 on Page 8] through Page
20-50-11 step [Figure 20-50-20 on Page 9] to assemble
Install the coupling into the drive gear (Item 2) [Figure pump section 2.
20-50-21].
Figure 20-50-24
Figure 20-50-22
1

Oil passages
must align to
supply to
section one

1 S7512
S7523

Align the marks made during disassembly on the end cap

NOTE: When installing the first section gear housing and gear housing. Install the end cap (Item 1) [Figure
(Item 1) (with inlet port), make sure that the oil 20-50-24].
passage in the housing and the separation
plate align. Section two gear housing (Item 2)
[Figure 20-50-22] must receive oil flow
through this passage from section one gear
housing.

20-50-10 E08 Service Manual

HYDRAULIC PUMP (CONT’D)

Assembly (Cont’d)

Figure 20-50-25

S7511

Install the four assembly bolts (Item 1) [Figure 20-50-25].

Evenly tighten the bolts to a final torque of 52 - 58 N•m

(38 - 43 ft-lb).

Rotate the input shaft periodically while tightening the

bolts to make sure the pump is assembled correctly.

Using a locking plier, rotate the pump shaft to be sure

there is no binding.

NOTE: Use care not to damage the pump shaft.

20-50-11 E08 Service Manual

20-50-12 E08 Service Manual
TRAVEL MOTOR Figure 20-60-2

Description
2
The travel motor is a hydraulic motor which receives
hydraulic fluid from the hydraulic pump through the
hydraulic control valve. The speed that the travel motor
rotates is related to the amount of hydraulic fluid it 1
receives. This travel motor is not equipped with two-
speed.
2
Removal And Installation

Remove the track. (See Track Removal And Installation

on Page 30-20-4.) 2
S7942

Remove the hoses (Item 1) [Figure 20-60-2] from the

IMPORTANT travel motor.

Remove the travel motor mounting bolts (Item 2) [Figure

When repairing hydrostatic and hydraulic systems,
20-60-2].
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Installation: Tighten the bolts to 40 - 50 N•m (29 - 37 ft-
tubelines and ports to keep dirt out. Dirt can quickly
lb) torque.
damage the system.
I-2003-0888
Remove the travel motor.

Figure 20-60-1 The drive sprocket can be removed without removing the
travel motor.

1 If removing the sprocket from a travel motor that has

been removed from the track frame, clamp the motor in a
vise.

1 Figure 20-60-3
1
2
1

S7943

Remove the bolts (Item 1) [Figure 20-60-1] from the

track frame cover.

Installation: Tighten the bolts to 20 - 25 N•m (15 - 18 ft-

lb) torque.
P-59088

Remove the cover.

Remove the sprocket bolts (Item 1) and the sprocket
Mark the hoses for correct installation. (Item 2) [Figure 20-60-3].

Installation: Tighten the bolts to 65 - 75 N•m (48 - 55 ft-

lb) torque.

20-60-1 E08 Service Manual

TRAVEL MOTOR (CONT’D)

Parts Identification

1. Motor 15. Ring 23. Bearing

2. Housing 16. Ring 24. Shim Kit
3. Cover 17. Ring 25. Plug
4. Gear 18. Ring
5. Gear 19. Ring
6. Carrier 20. O-ring
7. Gear 21. Seal
8. Gear 22. Bearing
9. Pin
10. Washer
11. Washer
12. Ring 10 12 5 24 15 20 3 25
9 6 13 11 8 14
13. Ring
14. Roller

19

1 21 18 23 2 17 4 22 16 7

S8473

20-60-2 E08 Service Manual

TRAVEL MOTOR (CONT’D)

Parts Identification (Cont’d)

1. Cover Motor 15. Label 26. Seal 37. Plug

2. Bolt 16. Rivet Screw 27. Shaft 38. Regulator
3. Washer 17. Bearing 28. Valve Plug 39. Pin
4. Distributor 18. Pin 29. O-ring 40. Hub
5. Drum Pumping 19. O-ring 30. Valve Spring
6. Spring 20. Ring Retaining 31. Valve Washer
Pumping 21. Pin 32. Valve Kit Assy
7. Washer 22. Piston 33. Sphere
8. Plate Piston 23. Ring 34. Rubber Band
9. Block Sliding 24. Ring 35. Spring
10. Swash Plate 25. Bearing 36. O-ring
11. Support 9 10 12 27 24 23 25 23 26 40
17 4 20 7 6 7 5 21 11 8 22
Piston
12. Pin
13. O-ring
14. Plastic Plug

2 3 14 13 33 34 35

28
16 19

15 30
31
37
30 31 37 36 35
36
29 39

19
18
28
1
38
32

33

34

S8474

20-60-3 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-5

Disassembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-62502

Clean the outside of the travel motor before disassembly.

Figure 20-60-6
Drain the lubricant from the travel motor.

Figure 20-60-4

2
1

P-62503

P-62500 To remove the cover, lift the cover up using screwdrivers

in the upper groove [Figure 20-60-5] or install two
threaded pins in the drain holes and lift the cover off
Remove the drain plugs (Item 1) and snap ring (Item 2) [Figure 20-60-6].
[Figure 20-60-4] securing the reduction gear cover.

Drain the excess oil into a container.

20-60-4 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-9

Disassembly (Cont’d) 1
2
Figure 20-60-7
3

P-62506

Remove the retaining rings (Item 1), anti-rotation washer

1
P-62504 (Item 2), planetary gears (Item 3), needle bearings (Item
4) and thrust washer (Item 5) [Figure 20-60-9] from the
first stage planetary carrier assembly.
Remove the O-ring (Item 1) [Figure 20-60-7] from the
cover. Figure 20-60-10

Figure 20-60-8
1
1
2
3

P-62507

P-62505
Remove the retaining ring (Item 1) from the second
reduction sun gear (Item 2) [Figure 20-60-10] and push
Remove the retaining ring (Item 1), shims (Item 2) and the gear down to remove from planetary carrier.
sun gear (Item 3) [Figure 20-60-8].

Remove the first stage planetary carrier (Item 4) [Figure

20-60-8] using your hands.

20-60-5 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-13

Disassembly (Cont’d)
1
Figure 20-60-11

P-62510

Remove the retaining ring (Item 1) [Figure 20-60-13]

P-62508 from the hub to free the bearing, rotation housing and
motor hub.

Remove the second stage planetary carrier (Item 1) Figure 20-60-14

[Figure 20-60-11] using your hands.

Figure 20-60-12

4 1
2

S8057

P-62509 Remove the hub (Item 1) [Figure 20-60-14] from the ring
gear.

Remove the retaining rings (Item 1), anti-rotation washer

(Item 2), planetary gears (Item 3), needle bearings (Item
4) and thrust washer (Item 5) [Figure 20-60-12] from the
second stage planetary carrier assembly.

20-60-6 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-17

Disassembly (Cont’d) 4
4 3
Figure 20-60-15
3

1
1 2

1 2

S8054

Remove the plugs (Item 1), O-rings (Item 2), springs

S8055 (Item 3), washers (Item 4) [Figure 20-60-17].

Figure 20-60-18
Remove the front seal (Item 1) [Figure 20-60-15] from
the ring gear.

Figure 20-60-16
1

S8058

Remove the counterbalance valve (Item 1) [Figure 20-

S8056 60-18] from the motor cover.

Remove the retaining ring (Item 1) [Figure 20-60-16]

from the ring gear.

Remove the ball bearing (Item 2) [Figure 20-60-16] by

pushing from underneath.

20-60-7 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-21

Disassembly (Cont’d)

Figure 20-60-19

2 1
2
2

P-62520

3
Remove the valve plate (Item 1) and dowel pins (Item 2)
S8059 [Figure 20-60-21].

NOTE: Removal of dowel pins (Item 2) [Figure 20-60-

Remove the six screws and washers (Item 1) [Figure 20- 21] is optional.
60-19].
Figure 20-60-22
Remove the cover (Item 2) and dowel pin (Item 3)
[Figure 20-60-19].

NOTE: Removal of dowel pin (Item 3) [Figure 20-60- 1

19] is optional.

Figure 20-60-20 2

3
1 2
2

B-14820

Remove the rotating block (Item 1) and the three dowel

pins (Item 2) [Figure 20-60-22].

S8060

Remove the O-ring (Item 1), needle bearing (Item 2) and

dowel pin (Item 3) [Figure 20-60-20] from the cover.

NOTE: Removal of dowel pin (Item 3) [Figure 20-60-

20] is optional.

20-60-8 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-25

Disassembly (Cont’d)
1
Figure 20-60-23

S8062

Remove the retaining ring (Item 1) [Figure 20-60-25].

B-14821
Figure 20-60-26

Remove the piston assembly (Item 1) [Figure 20-60-23].

NOTE: The rotating group components are not

available separately. Service as a complete
assembly only. 2
Figure 20-60-24
1

S8063

2
Remove the bearing / drive shaft assembly (Item 1)
[Figure 20-60-26].

Remove the oil seal (Item 2) [Figure 20-60-26].

S8061

Remove the swash plate (Item 1) [Figure 20-60-24] by

using your hands.

Remove the dowel pin (Item 2) [Figure 20-60-24].

NOTE: Removal of dowel pin (Item 2) [Figure 20-60-

24] is optional.

20-60-9 E08 Service Manual

TRAVEL MOTOR (CONT’D)

Disassembly (Cont’d)

Figure 20-60-27

2
1

3
P-62524

Remove the retaining ring (Item 1), ball bearing (Item 2)

and the second retaining ring (Item 3) [Figure 20-60-27].

20-60-10 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-30

Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts and replace any that are damaged. If
any of the planetary gears (first or second) are damaged,
replace the damaged planetary stage assembly (first or 1
second) complete with the sun gear that the damaged
gear is from. One damaged gear can cause microscopic
fatigue cracks in mating gear teeth and cause premature
failure after servicing. Apply oil to all O-rings and light
grease to the ball and roller bearings before installation.

Figure 20-60-28
S8065
3

Install the bearing / drive shaft assembly (Item 1) [Figure

2 20-60-30].
1
Figure 20-60-31

P-62525

Install the retaining ring (Item 1) [Figure 20-60-28] on the

drive shaft.

Install the ball bearing (Item 2) and the retaining ring

(Item 3) [Figure 20-60-28]. S8066

Figure 20-60-29
Install the retaining ring (Item 1) [Figure 20-60-31].

S8064

Install the oil seal (Item 1) [Figure 20-60-29] in the hub.

20-60-11 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-34

Assembly (Cont’d)

Figure 20-60-32

2
2

1
1

B-14833

Tip the motor housing on its side. Make sure the thick
S8061 side of the swash plate (Item 1) [Figure 20-60-34] is
towards the bottom.

Install the dowel pin (Item 1) and swash plate (Item 2) Install the rotating block assembly (Item 2) [Figure 20-
[Figure 20-60-32]. 60-34] in the hub.

Figure 20-60-33 NOTE: The rotating group components are not

available separately. Service as a complete
assembly only.

Figure 20-60-35

1 1
1 2
2

B-14832

Install the dowel pins (Item 1) [Figure 20-60-33] in the

rotating block.
P-62520

Apply oil to the piston assembly (Item 2) [Figure 20-60-

33] and install the piston assembly in the rotating block. Install the valve plate (Item 1) and dowel pins (Item 2)
[Figure 20-60-35].

20-60-12 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-38

Assembly (Cont’d)

Figure 20-60-36 1
2

1
3

S8058

Install the counterbalance valve (Item 1) [Figure 20-60-

S8060 38] in the motor cover.

Figure 20-60-39
Install the needle bearing (Item 1) [Figure 20-60-36] in
the cover so the bearing edge extends 2,5 - 2,8 mm (0.98 1
- 0.110 in) from the face of the cover. 1 2

Install the O-ring (Item 2) and dowel pin (Item 3) [Figure 2

20-60-36] in the cover.

Figure 20-60-37 4
3

1 4 3

3 S8054

Install the washers (Item 1), springs (Item 2), O-rings

(Item 3) and plugs (Item 4) [Figure 20-60-39].

S8059

Install the cover (Item 1) and dowel pin (Item 2) [Figure

20-60-37].

Install the six screws and washers (Item 3) [Figure 20-

60-37].

Tighten the screws in a crisscross manner to 25 - 28 N•m

(18.5 - 20.6 ft-lb) torque.

20-60-13 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-42

Assembly (Cont’d)

Figure 20-60-40

1
2

S8067

Install the front seal (Item 1) [Figure 20-60-42] on the

S8056 hub as indicated in the installation procedure (See
[Figure 20-60-43] to [Figure 20-60-46].

Install the ball bearing (Item 1) [Figure 20-60-40] in its Figure 20-60-43
seat on the rotating housing.

Install the retaining ring (Item 2) [Figure 20-60-40].

2
Figure 20-60-41 1

P-62550

Install the O-ring (Item 1) [Figure 20-60-43] on the seal

ring (Item 2) [Figure 20-60-43].
S8068
NOTE: Inspect the seal ring for burrs before installing
the O-ring. Install the seal ring making sure it
Install the front seal (Item 1) [Figure 20-60-41] on the is not twisted. To remove any twists, gently
rotating housing as indicated in the installation procedure pull a section of the O-ring and let it snap
(See [Figure 20-60-43] to [Figure 20-60-46]. back.

The O-ring, seal ring and motor assembly must be clean

and free of any dust, oil film or foreign matter.

20-60-14 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-46

Assembly (Cont’d)

Figure 20-60-44

P-62557

After the seal ring is installed, check the stand out height
P-62555 [Figure 20-60-46] in four places, 90° apart.
The seal ring assembly [Figure 20-60-44] must be The stand out height is 1,00 mm (0.04 in).
lubricated with alcohol, so the O-ring will slip past the
housing retaining ring and seal uniform in the motor NOTE: If the seal ring does not meet the height
housing radius. specifications inspect the torque ring for
twists or obvious bulges.
The O-ring [Figure 20-60-44] on the seal ring assembly
must be lubricated with alcohol. Apply a light film of oil to the seal ring and lapped face of
the bearing.
This will allow the O-ring to slide on the motor housing
sealing surface without twisting.
NOTE: Do not get any oil on the O-ring.
Dip the O-ring [Figure 20-60-44] and seal ring assembly
in a pan of alcohol. Figure 20-60-47

Shake off the excess alcohol and install the seal ring
assembly on the motor [Figure 20-60-44].

Figure 20-60-45

S8057

Press the reduction unit and motor assembly into the

seat of the bearings [Figure 20-60-47].
B-14594

Use firm even pressure on the installation tool

(MEL1468) to pop the O-ring into the motor housing
[Figure 20-60-45].

20-60-15 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-50

Assembly (Cont’d)

Figure 20-60-48 1

P-62542

Install the second stage planetary carrier assembly (Item

P-62510 1) [Figure 20-60-50].

Figure 20-60-51
Install the external retaining ring (Item 1) [Figure 20-60-
48] in the motor reduction unit.

Figure 20-60-49
2

5
4
3

1 1

P-62543

Install the sun gear (Item 1) into the planetary carrier and
P-62541 lock with the retaining ring (Item 2) [Figure 20-60-51].

Install the thrust washers (Item 1), planetary gears (Item

2), needle bearing (Item 3), anti-rotation washers (Item 4)
and external snap rings (Item 5) [Figure 20-60-49] on
the second stage planetary carrier assembly.

NOTE: Install the snap rings so the opening of the

snap ring is towards the outside.

20-60-16 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-54

Assembly (Cont’d) 3
2
1
Figure 20-60-52

5
4

P-62505

Install the sun gear (Item 1), shims (theoretical shimming

P-62544 0,5 mm [0.02 in] (Item 2) and retaining ring (Item 3)
[Figure 20-60-54].

Install the thrust washers (Item 1), planetary gears (Item Figure 20-60-55
2), needle bearings (Item 3), anti-rotation washers (Item
4) and external snap rings (Item 5) [Figure 20-60-52] on
the primary stage planetary carrier assembly.

NOTE: Install the snap rings so the opening of the

snap ring is towards the outside.

Figure 20-60-53

2
P-62504

Install the O-ring (Item 1) [Figure 20-60-55] on the cover.

P-62545

Install the primary planetary assembly (Item 1) [Figure

20-60-53].

20-60-17 E08 Service Manual

TRAVEL MOTOR (CONT’D) Figure 20-60-58

Assembly (Cont’d)
1
Figure 20-60-56

P-62605

Add 0,5 L (0.53 qt) of gear lube 90W to the top plug hole
P-62548 (Item 1) until the gear lube is at the bottom of the plug
hole (Item 2) [Figure 20-60-58].

Install the cover (Item 1) [Figure 20-60-56] in the Install and tighten the two plugs (Item 2) [Figure 20-60-
housing. 57].

Figure 20-60-57

1
2

P-62500

Install the snap ring (Item 1) [Figure 20-60-57] securing

the reduction gear cover.

20-60-18 E08 Service Manual

SWIVEL JOINT (S/N A4BP11673 & ABOVE AND S/N
B4PC11001 & ABOVE)

Description WARNING
The swivel joint is located under the floor panels and
mounted to the upperstructure. The swivel joint directs Hydraulic fluid escaping under pressure can have
hydraulic fluid to the undercarriage components while sufficient force to enter a person’s body by
allowing the upperstructure to rotate. penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
Removal And Installation doctor familiar with this injury is not received
immediately.
W-2145-EN-0210
Expand the track frame fully.

Figure 20-70-1 Mark all hoses and tubelines for ease of assembly.

Figure 20-70-2

1
1

S8352

S8354
Place blocks under the excavator tracks and blade
[Figure 20-70-1].
Remove the two tubelines (Item 1) [Figure 20-70-2] from
Lower the boom / bucket to the ground. the top of the swivel joint.

Relieve hydraulic pressure.

Remove the muffler. (See MUFFLER on Page 60-20-1.)

Remove the floor panels. (See FLOOR PANELS on Page

40-120-1.)

Drain the hydraulic reservoir. (See Replacing Hydraulic

Oil on Page 10-120-2.)

20-70-1 E08 Service Manual

SWIVEL JOINT (S/N A4BP11673 & ABOVE AND S/N Figure 20-70-5
B4PC11001 & ABOVE) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-70-3

1
1 S8357

Remove the tubeline (Item 1) [Figure 20-70-5] from the

side of the swivel joint.
S8355
Figure 20-70-6

Remove the two tubelines (Item 1) [Figure 20-70-3] from

the top of the swivel joint.

Figure 20-70-4

1 1

S8358

Remove the two tubelines (Item 1) [Figure 20-70-6] from

the side of the swivel joint.
S8356
Remove the track frame expansion cylinder. (See
Removal And Installation on Page 20-25-2.)
Remove the tubeline (Item 1) [Figure 20-70-4] from the
side of the swivel joint.

20-70-2 E08 Service Manual

SWIVEL JOINT (S/N A4BP11673 & ABOVE AND S/N
B4PC11001 & ABOVE) (CONT’D)

Removal And Installation (Cont’d)

Figure 20-70-7

1
2

1
2
2

S8263

Remove the five hoses (Item 1) [Figure 20-70-7] from

the left side of the swivel joint.

Remove the five hoses (Item 2) [Figure 20-70-7] from

the right side of the swivel joint.

NOTE: Support the swivel joint on the bottom side of

the excavator to prevent the swivel joint from
falling when the three nuts are being
removed.

Figure 20-70-8

2
1
1

NA9179

While supporting the swivel joint, remove the nuts (Item

1) [Figure 20-70-8].

20-70-3 E08 Service Manual

SWIVEL JOINT (S/N A4BP11673 & ABOVE AND S/N B4PC11001 & ABOVE) (CONT’D)

Parts Identification

1. Seal
2. Seal
3. Back-up Seal
4. Snap Ring
5. Washer
6. Barrel
7. Plug
8. Spool
9. Stop

1
9 5

5 2

3
6

5
1

7
NA8994S

20-70-4 E08 Service Manual

SWIVEL JOINT (S/N A4BP11673 & ABOVE AND S/N Figure 20-70-11
B4PC11001 & ABOVE) (CONT’D)

Disassembly

Figure 20-70-9

1
P-59180

Tap the end of the rotor (Item 1) [Figure 20-70-11] with a

1 rubber mallet to drive the rotor out of the housing.
P-59178
Figure 20-70-12

Remove the snap ring (Item 1) [Figure 20-70-9] from the

bottom of the swivel joint. 1

Figure 20-70-10

P-59181

1
Remove the outer and inner seals (Item 1) [Figure 20-
70-12].
P-59179

Remove the nylon washer (Item 1) [Figure 20-70-10].

20-70-5 E08 Service Manual

SWIVEL JOINT (S/N A4BP11673 & ABOVE AND
B4PC11001 & ABOVE) (CONT’D)

Disassembly (Cont’d)

Figure 20-70-13

1 1 1 1
1

P-59184

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

[Figure 20-70-13].

Figure 20-70-14

2
P-59184

Remove the outer and inner seals (Item 1). Remove the
nylon washer (Item 2) [Figure 20-70-14].

20-70-6 E08 Service Manual

SWIVEL JOINT (S/N A4BP11673 & ABOVE AND S/N Figure 20-70-17
B4PC11001 & ABOVE) (CONT’D)

Assembly 1 1 1 1
1

Clean all parts in solvent and dry with compressed air.

Inspect the rotor and housing for scratches or wear that

could cause internal leakage. Always install new seals
and back-up seals. Lubricate all seals and back-up seals
with clean hydraulic fluid before installation.

Figure 20-70-15

P-62345
P-59184

Install the O-rings under the seals (Item 1) [Figure 20-

70-17].

Heat the seals in hydraulic fluid for 3 minutes at 54°C

(130°F).

Install the seals and back-up seals (Item 1) [Figure 20-

70-17].
1
P-59184 NOTE: The seal and O-ring are serviceable as one
part number.

Install the nylon washer (Item 1) [Figure 20-70-15]. Figure 20-70-18

Figure 20-70-16
1

P-62346 P-59181

P-62345 P-59184
Heat the seals in hydraulic fluid for 3 minutes at 54°C
(130°F).
Heat the seals in hydraulic fluid for 3 minutes at 54°C
(130°F). Install the inner and outer seals (Item 1) [Figure 20-70-
18].
Install the inner and outer seals (Item 1) [Figure 20-70-
16]. NOTE: The inner and outer seal are serviceable as
one part number.
NOTE: The inner and outer seal are serviceable as
one part number.

20-70-7 E08 Service Manual

SWIVEL JOINT (S/N A4BP11673 & ABOVE AND S/N Figure 20-70-21
B4PC11001 & ABOVE) (CONT’D)

Assembly (Cont’d)

Figure 20-70-19

P-59179

Install the nylon washer (Item 1) [Figure 20-70-21].

P-59185 Figure 20-70-22

NOTE: A ring compressor (Item 1) [Figure 20-70-19]

may be used to install the seals into the seal
grove. Compress the seals for 3 minutes.

Figure 20-70-20

1
P-59178

Remove the snap ring (Item 1) [Figure 20-70-22] from

the bottom of the swivel joint.
1
P-59180

Apply hydraulic fluid to the rotor. Install the rotor (Item 1)

[Figure 20-70-20] in the housing.

20-70-8 E08 Service Manual

SWIVEL JOINT (S/N A4BP11468 - A4BP11672)

Description
IMPORTANT
The swivel joint is located under the floor panels and
mounted to the upperstructure. The swivel joint directs When repairing hydrostatic and hydraulic systems,
hydraulic fluid to the undercarriage components while clean the work area before disassembly and keep all
allowing the upperstructure to rotate. parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
Removal And Installation damage the system.
I-2003-0888
Expand the track frame fully.
Mark all hoses and tubelines for ease of assembly.
Figure 20-71-1
Figure 20-71-2

1
1

S8352

S8354

Place blocks under the excavator tracks and blade

[Figure 20-71-1]. Remove the two tubelines (Item 1) [Figure 20-71-2] from
the top of the swivel joint.
Lower the boom / bucket to the ground.

Relieve hydraulic pressure.

Remove the muffler. (See MUFFLER on Page 60-20-1.)

Remove the floor panels. (See FLOOR PANELS on Page

40-120-1.)

Drain the hydraulic reservoir. (See Replacing Hydraulic

Oil on Page 10-120-2.)

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
doctor familiar with this injury is not received
immediately.
W-2145-EN-0210

20-71-1 E08 Service Manual

SWIVEL JOINT (S/N A4BP11468 - A4BP11672) Figure 20-71-5
(CONT’D)

Removal And Installation (Cont’d)

Figure 20-71-3

1
1 S8357

Remove the tubeline (Item 1) [Figure 20-71-5] from the

side of the swivel joint.
S8355
Figure 20-71-6

Remove the two tubelines (Item 1) [Figure 20-71-3] from

the top of the swivel joint.

Figure 20-71-4

1 1

S8358

Remove the two tubelines (Item 1) [Figure 20-71-6] from

the side of the swivel joint.
S8356
Remove the track frame expansion cylinder. (See
Removal And Installation on Page 20-25-2.)
Remove the tubeline (Item 1) [Figure 20-71-4] from the
side of the swivel joint.

20-71-2 E08 Service Manual

SWIVEL JOINT (S/N A4BP11468 - A4BP11672)
(CONT’D)

Removal And Installation (Cont’d)

Figure 20-71-7

1
2

1
2
2

S8263

Remove the five hoses (Item 1) [Figure 20-71-7] from

the left side of the swivel joint.

Remove the five hoses (Item 2) [Figure 20-71-7] from

the right side of the swivel joint.

NOTE: Support the swivel joint on the bottom side of

the excavator to prevent the swivel joint from
falling when the three nuts are being
removed.

Figure 20-71-8

S8359

Remove the bolt and nut (Item 1) [Figure 20-71-8].

20-71-3 E08 Service Manual

SWIVEL JOINT (S/N A4BP11468 - A4BP11672) (CONT’D)

Parts Identification

1. Seal
2. Seal
3. Back-up Seal
4. Snap Ring
5. Washer
6. Barrel
7. Plug
8. Washer 2
9. Spool 11
10. Washer
10 1
11. Stop

3
1
9
3
1
3

3
1
3

3
8
1
3

3
1
3
6
3
1
3

3
5 1
3

4 1
3

2
7
NA8006

20-71-4 E08 Service Manual

SWIVEL JOINT (S/N A4BP11468 - A4BP11672) Figure 20-71-11
(CONT’D)

Disassembly

Figure 20-71-9

1
P-59180

Tap the end of the rotor (Item 1) [Figure 20-71-11] with a

1 rubber mallet to drive the rotor out of the housing.
P-59178
Figure 20-71-12

Remove the snap ring (Item 1) [Figure 20-71-9] from the

bottom of the swivel joint. 1

Figure 20-71-10

P-59181

1
Remove the outer and inner seals (Item 1) [Figure 20-
71-12].
P-59179

Remove the nylon washer (Item 1) [Figure 20-71-10].

20-71-5 E08 Service Manual

SWIVEL JOINT (S/N A4BP11468 - A4BP11672)
(CONT’D)

Disassembly (Cont’d)

Figure 20-71-13

1 1 1 1
1

P-59184

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

[Figure 20-71-13].

Figure 20-71-14

2
P-59184

Remove the outer and inner seals (Item 1). Remove the
nylon washer (Item 2) [Figure 20-71-14].

20-71-6 E08 Service Manual

SWIVEL JOINT (S/N A4BP11468 - A4BP11672) Figure 20-71-17
(CONT’D)

Assembly 1 1 1 1
1

Clean all parts in solvent and dry with compressed air.

Inspect the rotor and housing for scratches or wear that

could cause internal leakage. Always install new seals
and back-up seals. Lubricate all seals and back-up seals
with clean hydraulic fluid before installation.

Figure 20-71-15

P-62345
P-59184

Install the O-rings under the seals (Item 1) [Figure 20-

71-17].

Heat the seals in hydraulic fluid for 3 minutes at 54°C

(130°F).

Install the seals and back-up seals (Item 1) [Figure 20-

71-17].
1
P-59184 NOTE: The seal and O-ring are serviceable as one
part number.

Install the nylon washer (Item 1) [Figure 20-71-15]. Figure 20-71-18

Figure 20-71-16
1

P-62346 P-59181

P-62345 P-59184
Heat the seals in hydraulic fluid for 3 minutes at 54°C
(130°F).
Heat the seals in hydraulic fluid for 3 minutes at 54°C
(130°F). Install the inner and outer seals (Item 1) [Figure 20-71-
18].
Install the inner and outer seals (Item 1) [Figure 20-71-
16]. NOTE: The inner and outer seal are serviceable as
one part number.
NOTE: The inner and outer seal are serviceable as
one part number.

20-71-7 E08 Service Manual

SWIVEL JOINT (S/N A4BP11468 - A4BP11672) Figure 20-71-21
(CONT’D)

Assembly (Cont’d)

Figure 20-71-19

P-59179

Install the nylon washer (Item 1) [Figure 20-71-21].

P-59185 Figure 20-71-22

NOTE: A ring compressor (Item 1) [Figure 20-71-19]

may be used to install the seals into the seal
grove. Compress the seals for 3 minutes.

Figure 20-71-20

1
P-59178

Remove the snap ring (Item 1) [Figure 20-71-22] from

the bottom of the swivel joint.
1
P-59180

Apply hydraulic fluid to the rotor. Install the rotor (Item 1)

[Figure 20-71-20] in the housing.

20-71-8 E08 Service Manual

SWIVEL JOINT (S/N A4BP11117 - A4BP11467)

Description
WARNING
The swivel joint is located under the floor panels and
mounted to the upperstructure. The swivel joint directs
Hydraulic fluid escaping under pressure can have
hydraulic fluid to the undercarriage components while
sufficient force to enter a person’s body by
allowing the upperstructure to rotate.
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
Removal And Installation
doctor familiar with this injury is not received
immediately.
Expand the track frame fully. W-2145-EN-0210

Figure 20-72-1
Mark all hoses and tubelines for ease of assembly.

Figure 20-72-2

1
1

S8352

Place blocks under the excavator tracks and blade S8354

[Figure 20-72-1].

Lower the boom / bucket to the ground. Remove the two tubelines (Item 1) [Figure 20-72-2] from
the top of the swivel joint.
Relieve hydraulic pressure.

Remove the muffler. (See Removal And Installation on

Page 60-20-1.)

Remove the floor panels. (See FLOOR PANELS on Page

40-120-1.)

Drain the hydraulic reservoir. (See Replacing Hydraulic

Oil on Page 10-120-2.)

20-72-1 E08 Service Manual

SWIVEL JOINT (S/N A4BP11117 - A4BP11467) Figure 20-72-5
(CONT’D)

Removal And Installation (Cont’d)

Figure 20-72-3

1
1 S8357

Remove the tubeline (Item 1) [Figure 20-72-5] from the

side of the swivel joint.
S8355
Figure 20-72-6

Remove the two tubelines (Item 1) [Figure 20-72-3] from

the top of the swivel joint.

Figure 20-72-4

1 1

S8358

Remove the two tubelines (Item 1) [Figure 20-72-6] from

the side of the swivel joint.
S8356
Remove the track frame expansion cylinder. (See
Removal And Installation on Page 20-25-2.)
Remove the tubeline (Item 1) [Figure 20-72-4] from the
side of the swivel joint.

20-72-2 E08 Service Manual

SWIVEL JOINT (S/N A4BP11117 - A4BP11467) Figure 20-72-9
(CONT’D)

Removal And Installation (Cont’d) 1

Figure 20-72-7

1
2

1
2
2
S8360

Remove the bolt and nut (Item 1) [Figure 20-72-9].

S8263 Figure 20-72-10

Remove the five hoses (Item 1) [Figure 20-72-7] from

the left side of the swivel joint.

Remove the five hoses (Item 2) [Figure 20-72-7] from

the right side of the swivel joint.

NOTE: Support the swivel joint on the bottom side of

the excavator to prevent the swivel joint from
falling when the three nuts are being 1
removed.

Figure 20-72-8
S8266

Remove the bolt and nut (Item 1) [Figure 20-72-10].

1 Slide the swivel joint out through the bottom of the
excavator.

S8359

Remove the bolt and nut (Item 1) [Figure 20-72-8].

20-72-3 E08 Service Manual

SWIVEL JOINT (S/N A4BP11117 - A4BP11467) (CONT’D)

Parts Identification

1. Seal and O-ring

2. Back-up Seal
3. O-ring
4. Inner / Outer Seals
5. Washer 8
6. Snap Ring
7. Housing
8. Rotor
9. Plug

5
3

9
4

1
2
1
2
1
2
2
4
1
2
2
1
2
2
7 1
2
2
1
2
2
5 1
2
1
6 2

MS-2041

20-72-4 E08 Service Manual

SWIVEL JOINT (S/N A4BP11117 - A4BP11467) Figure 20-72-13
(CONT’D)

Disassembly

Figure 20-72-11

1
1

1
P-59178

Remove the snap ring (Item 1) [Figure 20-72-13] from

the bottom of the swivel joint.
S6083
Figure 20-72-14

Mark fitting position. Remove the fittings (Item 1) [Figure

20-72-11].

Figure 20-72-12

1 1

2
1
1

P-59179

Remove the nylon washer (Item 1) [Figure 20-72-14].

S6084

Remove the three bolts (Item 1). Remove the mount

(Item 2) [Figure 20-72-12].

20-72-5 E08 Service Manual

SWIVEL JOINT (S/N A4BP11117 - A4BP11467) Figure 20-72-17
(CONT’D)

Disassembly (Cont’d) 1 1 1 1
1

Figure 20-72-15

P-59184

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

[Figure 20-72-17].
P-59180
Figure 20-72-18

Tap the end of the rotor (Item 1) [Figure 20-72-15] with a

rubber mallet to drive the rotor out of the housing. 1

Figure 20-72-16

2
P-59184

Remove the outer and inner seals (Item 1). Remove the
nylon washer (Item 2) [Figure 20-72-18].
P-59181

Remove the outer and inner seals (Item 1) [Figure 20-

72-16].

20-72-6 E08 Service Manual

SWIVEL JOINT (S/N A4BP11117 - A4BP11467) Figure 20-72-21
(CONT’D)

Assembly 1 1 1 1
1

Clean all parts in solvent and dry with compressed air.

Inspect the rotor and housing for scratches or wear that

could cause internal leakage. Always install new seals
and back-up seals. Lubricate all seals and back-up seals
with clean hydraulic fluid before installation.

Figure 20-72-19

P-62345
P-59184

Install the O-rings under the seals (Item 1) [Figure 20-

72-21].

Heat the seals in hydraulic fluid for 3 minutes at 54°C

(130°F).

Install the seals and back-up seals (Item 1) [Figure 20-

72-21].
1
P-59184 NOTE: The seal and O-ring are serviceable as one
part number.

Install the nylon washer (Item 1) [Figure 20-72-19]. Figure 20-72-22

Figure 20-72-20
1

P-62346 P-59181

P-62345 P-59184
Heat the seals in hydraulic fluid for 3 minutes at 54°C
(130°F).
Heat the seals in hydraulic fluid for 3 minutes at 54°C
(130°F). Install the inner and outer seals (Item 1) [Figure 20-72-
22].
Install the inner and outer seals (Item 1) [Figure 20-72-
20]. NOTE: The inner and outer seal are serviceable as
one part number.
NOTE: The inner and outer seal are serviceable as
one part number.

20-72-7 E08 Service Manual

SWIVEL JOINT (S/N A4BP11117 - A4BP11467) Figure 20-72-25
(CONT’D)

Assembly (Cont’d)

Figure 20-72-23

P-59179

Install the nylon washer (Item 1) [Figure 20-72-25].

P-59185 Figure 20-72-26

NOTE: A ring compressor (Item 1) [Figure 20-72-23]

may be used to install the seals into the seal
grove. Compress the seals for 3 minutes.

Figure 20-72-24

1
P-59178

Remove the snap ring (Item 1) [Figure 20-72-26] from

the bottom of the swivel joint.
1
P-59180

Apply hydraulic fluid to the rotor. Install the rotor (Item 1)

[Figure 20-72-24] in the housing.

20-72-8 E08 Service Manual

SWIVEL JOINT (S/N A4BP11117 - A4BP11467)
(CONT’D)

Assembly (Cont’d)

Figure 20-72-27

2
2

S6084

Install the mount (Item 1) [Figure 20-72-27] on the swivel

joint.

Apply Loctite® 242 to each bolt (Item 2) [Figure 20-72-

27].

Install the bolts (Item 2) [Figure 20-72-27]. Tighten the

bolts to 43 - 47 N•m (32 - 35 ft-lb) torque.

Figure 20-72-28

1
1

S6083

Install the fittings (Item 1) [Figure 20-72-28] and position

accordingly.

20-72-9 E08 Service Manual

20-72-10 E08 Service Manual
SWIVEL JOINT (S/N A4BP11001 - A4BP11117) Mark all hoses and tubelines for ease of assembly.

Description Figure 20-73-2

The swivel joint is located under the floor panels and

mounted to the upperstructure. The swivel joint directs
hydraulic fluid to the undercarriage components while 1
allowing the upperstructure to rotate. 1

Removal And Installation

Expand the track frame fully.

Figure 20-73-1

S8354

Remove the two tubelines (Item 1) [Figure 20-73-2] from

the top of the swivel joint.

S8352

Place blocks under the excavator tracks and blade

[Figure 20-73-1].

Lower the boom / bucket to the ground.

Relieve hydraulic pressure.

Remove the muffler. (See MUFFLER on Page 60-20-1.)

Remove the floor panels. (See FLOOR PANELS on Page

40-120-1.)

Drain the hydraulic reservoir. (See Replacing Hydraulic

Oil on Page 10-120-2.)

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
doctor familiar with this injury is not received
immediately.
W-2145-EN-0210

20-73-1 E08 Service Manual

SWIVEL JOINT (S/N A4BP11001 - A4BP11117) Figure 20-73-5
(CONT’D)

Removal And Installation (Cont’d)

Figure 20-73-3

1
1 S8357

Remove the tubeline (Item 1) [Figure 20-73-5] from the

side of the swivel joint.
S8355
Figure 20-73-6

Remove the two tubelines (Item 1) [Figure 20-73-3] from

the top of the swivel joint.

Figure 20-73-4

1 1

S8358

Remove the two tubelines (Item 1) [Figure 20-73-6] from

the side of the swivel joint.
S8356
Remove the track frame expansion cylinder. (See
Removal And Installation on Page 20-25-2.)
Remove the tubeline (Item 1) [Figure 20-73-4] from the
side of the swivel joint.

20-73-2 E08 Service Manual

SWIVEL JOINT (S/N A4BP11001 - A4BP11117) Figure 20-73-9
(CONT’D)

Removal And Installation (Cont’d) 1

Figure 20-73-7

1
2

1
2
2
S8360

Remove the bolt and nut (Item 1) [Figure 20-73-9].

S8263 Figure 20-73-10

Remove the five hoses (Item 1) [Figure 20-73-7] from

the left side of the swivel joint.

Remove the five hoses (Item 2) [Figure 20-73-7] from

the right side of the swivel joint.

NOTE: Support the swivel joint on the bottom side of

the excavator to prevent the swivel joint from
falling when the three nuts are being 1
removed.

Figure 20-73-8
S8266

Remove the bolt and nut (Item 1) [Figure 20-73-10].

1 Slide the swivel joint out through the bottom of the
excavator.

S8359

Remove the bolt and nut (Item 1) [Figure 20-73-8].

20-73-3 E08 Service Manual

SWIVEL JOINT (S/N A4BP11001 - A4BP11117) (CONT’D)

Parts Identification

1. Seal and O-ring

2. Back-up Seal
3. O-ring
4. Inner / Outer Seals
5. Washer 8
6. Snap Ring
7. Housing
8. Rotor
9. Plug

5
3

9
4

1
2
1
2
1
2
2
4
1
2
2
1
2
2
7 1
2
2
1
2
2
5 1
2
1
6 2

MS-2041

20-73-4 E08 Service Manual

SWIVEL JOINT (S/N A4BP11001 - A4BP11117) Figure 20-73-13
(CONT’D)

Disassembly

Figure 20-73-11

1
1

1
P-59178

Remove the snap ring (Item 1) [Figure 20-73-13] from

the bottom of the swivel joint.
S6083
Figure 20-73-14

Mark fitting position. Remove the fittings (Item 1) [Figure

20-73-11].

Figure 20-73-12

1 1

2
1
1

P-59179

Remove the nylon washer (Item 1) [Figure 20-73-14].

S6084

Remove the three bolts (Item 1). Remove the mount

(Item 2) [Figure 20-73-12].

20-73-5 E08 Service Manual

SWIVEL JOINT(S/N A4BP11001 - A4BP11117) Figure 20-73-17
(CONT’D)

Disassembly (Cont’d) 1 1 1 1
1

Figure 20-73-15

P-59184

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

[Figure 20-73-17].
P-59180
Figure 20-73-18

Tap the end of the rotor (Item 1) [Figure 20-73-15] with a

rubber mallet to drive the rotor out of the housing. 1

Figure 20-73-16

2
P-59184

Remove the outer and inner seals (Item 1). Remove the
nylon washer (Item 2) [Figure 20-73-18].
P-59181

Remove the outer and inner seals (Item 1) [Figure 20-

73-16].

20-73-6 E08 Service Manual

SWIVEL JOINT(S/N A4BP11001 - A4BP11117) Figure 20-73-21
(CONT’D)

Assembly 1 1 1 1
1

Clean all parts in solvent and dry with compressed air.

Inspect the rotor and housing for scratches or wear that

could cause internal leakage. Always install new seals
and back-up seals. Lubricate all seals and back-up seals
with clean hydraulic fluid before installation.

Figure 20-73-19

P-62345
P-59184

Install the O-rings under the seals (Item 1) [Figure 20-

73-21].

Heat the seals in hydraulic fluid for 3 minutes at 54°C

(130°F).

Install the seals and back-up seals (Item 1) [Figure 20-

73-21].
1
P-59184 NOTE: The seal and O-ring are serviceable as one
part number.

Install the nylon washer (Item 1) [Figure 20-73-19]. Figure 20-73-22

Figure 20-73-20
1

P-62346 P-59181

P-62345 P-59184
Heat the seals in hydraulic fluid for 3 minutes at 54°C
(130°F).
Heat the seals in hydraulic fluid for 3 minutes at 54°C
(130°F). Install the inner and outer seals (Item 1) [Figure 20-73-
22].
Install the inner and outer seals (Item 1) [Figure 20-73-
20]. NOTE: The inner and outer seal are serviceable as
one part number.
NOTE: The inner and outer seal are serviceable as
one part number.

20-73-7 E08 Service Manual

SWIVEL JOINT (S/N A4BP11001 - A4BP11117) Figure 20-73-25
(CONT’D)

Assembly (Cont’d)

Figure 20-73-23

P-59179

Install the nylon washer (Item 1) [Figure 20-73-25].

P-59185 Figure 20-73-26

NOTE: A ring compressor (Item 1) [Figure 20-73-23]

may be used to install the seals into the seal
grove. Compress the seals for 3 minutes.

Figure 20-73-24

1
P-59178

Remove the snap ring (Item 1) [Figure 20-73-26] from

the bottom of the swivel joint.
1
P-59180

Apply hydraulic fluid to the rotor. Install the rotor (Item 1)

[Figure 20-73-24] in the housing.

20-73-8 E08 Service Manual

SWIVEL JOINT(S/N A4BP11001 - A4BP11117)
(CONT’D)

Assembly (Cont’d)

Figure 20-73-27

2
2

S6084

Install the mount (Item 1) [Figure 20-73-27] on the swivel

joint.

Apply Loctite® 242 to each bolt (Item 2) [Figure 20-73-

27].

Install the bolts (Item 2) [Figure 20-73-27]. Tighten the

bolts to 43 - 47 N•m (32 - 35 ft-lb) torque.

Figure 20-73-28

1
1

S6083

Install the fittings (Item 1) [Figure 20-73-28] and position

accordingly.

20-73-9 E08 Service Manual

20-73-10 E08 Service Manual
SLEW MOTOR Figure 20-80-2

Description

The slew motor is a hydraulic motor that receives

hydraulic fluid from the gear pump through the control
valve to swing the upperstructure left or right. The speed
that the slew motor rotates is related to the amount of
hydraulic fluid it receives.

Removal And Installation

IMPORTANT 1
S7541

When repairing hydrostatic and hydraulic systems,

Mark and remove the tubeline (Item 1) [Figure 20-80-2].
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
Figure 20-80-3
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

Remove the floor panels. (See FLOOR PANELS on Page

40-120-1.)
1
Remove the instrument panel. (See Removal And
Installation on Page 40-220-1.)

Figure 20-80-1

S8426

Remove the two fittings (Item 1) [Figure 20-80-3] from

1 the slew motor.

S7540

Mark and remove the tubeline (Item 1) [Figure 20-80-1].

20-80-1 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-6

Removal And Installation (Cont’d)

Figure 20-80-4

S8554
1

Mark and remove the tubeline (Item 1) [Figure 20-80-6].

S8552
Figure 20-80-7

Mark and remove the tubeline (Item 1) [Figure 20-80-4]

from the swivel joint.

Figure 20-80-5

1
S8555

Mark and remove the tubeline (Item 1) [Figure 20-80-7]

from the control valve.
S8553

Mark and remove the tubeline (Item 1) [Figure 20-80-5].

20-80-2 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-10

Removal And Installation (Cont’d)

Figure 20-80-8
1

S7545
1

Remove the three bolts (Item 1) [Figure 20-80-10] from

S8556 the slew motor.

Installation: Tighten the bolts to 71 - 79 N•m (52.5 - 58.5

Mark and remove the tubeline (Item 1) [Figure 20-80-8]. ft-lb) torque.

Figure 20-80-9 Figure 20-80-11

S7571 S7546

Mark and remove the tubeline (Item 1) [Figure 20-80-9] Remove the three bolts (Item 1) [Figure 20-80-11] from
from the track expand valve. the slew motor.

Installation: Tighten the bolts to 71 - 79 N•m (52.5 - 58.5

ft-lb) torque.

Remove the slew motor from the excavator.

20-80-3 E08 Service Manual

SLEW MOTOR (CONT’D)

Parts Identification

1. Bearing Housing 24. Steel Ball

2. Pinion Gear 25. Plug
3. Ball Bearing 26. O-ring
4. Ball Bearing 27. Plug 23 30 31 29
5. Plug 28. O-ring
6. Seal 29. Hexagon Bolt
7. Retaining Ring 30. Name Plate
8. O-ring 31. Rivet
9. Shaft Face Seal 32. Plug
10. Wear Plate 33. O-ring
11. Valve Plate
12. O-ring 7 20 8 21 11 12 13 14 17 15
13. Valve
14. Balancing Ring
15. Spring
16. Inner Seal
17. Pin
18. Outer Seal
19. Drive 24 26 25
20. Housing Motor
16 18 22 28 27
21. Valve Drive
22. O-ring
23. Valve Housing

22

5 32 33

19 9 10 22 8

2 3 1 6 4 8

S8448

20-80-4 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-14

Disassembly

Clean the outside of the slew motor before disassembly.

Mark the outside of the slew motor for ease of assembly.

1
1
Figure 20-80-12

1 1

S7686

Remove the balls (Item 1) [Figure 20-80-14].

Figure 20-80-15

S7684

Remove the plugs (Item 1) [Figure 20-80-12] from the

slew motor.

Figure 20-80-13
1

S7687

Remove the plug (Item 1) [Figure 20-80-15] from the

slew motor.

S7685

Remove the O-ring (Item 1) [Figure 20-80-13] from the

plugs.

20-80-5 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-18

Disassembly (Cont’d)

Figure 20-80-16
1

S7690

Remove the O-ring (Item 1) [Figure 20-80-18] from the

S7688 plug.

Figure 20-80-19
Remove the O-ring (Item 1) [Figure 20-80-16] from the
plug.
2
Figure 20-80-17
1 1

1 1

S7691
1

Remove the bolts (Item 1) [Figure 20-80-19].

S7689

Remove the plug (Item 1) [Figure 20-80-17] from the

slew motor.

20-80-6 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-22

Disassembly (Cont’d) 1
1
2
Figure 20-80-20
2

1
1
2
2

3
S6421

Remove the springs (Item 1) and pins (Item 2) [Figure

20-80-22].
S6419

Figure 20-80-23
Remove the top of the motor (Item 2) [Figure 20-80-19]
by lifting straight up. If done carefully, the springs (Item
1), pins (Item 2) and balance ring assembly (Item 3) 1
[Figure 20-80-20] will remain on the valve for easy
removal.

Figure 20-80-21

1
S6422

Remove the balance ring (Item 1) [Figure 20-80-23].

Figure 20-80-24

S7692 2
1

Remove the O-ring (Item 1) [Figure 20-80-21].

S6423

Remove the inner seal (Item 1) and outer seal (Item 2)

[Figure 20-80-24].

20-80-7 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-27

Disassembly (Cont’d)

Figure 20-80-25 1

S6426

Remove the valve plate (Item 1) [Figure 20-80-27].

S6424
Figure 20-80-28

Remove the valve (Item 1) [Figure 20-80-25].

1
Figure 20-80-26

P-59820

Remove the O-ring (Item 1) [Figure 20-80-28] from the

S6425 valve plate.

Remove the drive (Item 1) [Figure 20-80-26].

20-80-8 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-31

Disassembly (Cont’d)

Figure 20-80-29 1

S6430

Remove the seal (Item 1) [Figure 20-80-31] from the

S6428 valve plate.

Figure 20-80-32
Remove the Geroler® (Item 1) [Figure 20-80-29].
1
NOTE: Do not disassemble the Geroler®.

Figure 20-80-30
2
3

1
2

S6431

Remove the drive (Item 1) and O-ring (Item 2) [Figure

20-80-32].
S6429
Remove the snap ring (Item 3) [Figure 20-80-32].

Remove the O-ring (Item 1) [Figure 20-80-30].

Remove the valve plate (Item 2) [Figure 20-80-30].

20-80-9 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-35

Disassembly (Cont’d)

Figure 20-80-33
1

S6433

Remove the bearing (Item 1) [Figure 20-80-35] from the

S6432 housing.

Figure 20-80-36
Press the shaft out of the housing [Figure 20-80-33].

Figure 20-80-34
1

S6434

P-59827 Remove the seal (Item 1) [Figure 20-80-36] from the

housing.

Press the bearing (Item 1) [Figure 20-80-34] off of the

shaft.

20-80-10 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-39

Assembly

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage. Replace any worn

or damaged parts.
1
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.

Figure 20-80-37 2

S6435
1
Press the shaft (Item 1) [Figure 20-80-39] in the housing.

Apply assembly lube to the bearing and press the

bearing (Item 2) [Figure 20-80-39] in the housing.

Figure 20-80-40

S6434

2
Install the seal (Item 1) [Figure 20-80-37] in the housing. 1

Figure 20-80-38

S6431
1

Install the snap ring (Item 1) and O-ring (Item 2) [Figure

20-80-40].

Install the drive (Item 3) [Figure 20-80-40].

P-59830

Press the bearing (Item 1) [Figure 20-80-38] on the

shaft.

20-80-11 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-43

Assembly (Cont’d)
1
Figure 20-80-41

S6428

Install the Geroler® (Item 1) [Figure 20-80-43].

S6430
Figure 20-80-44

Install the seal (Item 1) [Figure 20-80-41] in the valve

1
plate.

Figure 20-80-42

2
1

P-59820

Install the O-ring (Item 1) [Figure 20-80-44] on the valve

plate.
S6429

Install the valve plate (Item 1) [Figure 20-80-42].

Install the O-ring (Item 2) [Figure 20-80-42].

20-80-12 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-47

Assembly (Cont’d) 1

Motor Timing

The direction that the output shaft rotates is determined

by timing. Time the motor as follows:

Figure 20-80-45

S6425

Install the drive (Item 1) [Figure 20-80-47].

Figure 20-80-48

S6428
1
Locate the largest open pocket in the Geroler® (Item 1)
[Figure 20-80-45].

Figure 20-80-46

S6424

NOTE: Picture position has changed 180°.

Align one of the side openings (Item 1) [Figure 20-80-48]

in the valve with the valve plate slot that is over the
largest open Geroler® pocket.

Engage the valve with the valve drive by rotating it 15

S6426 clockwise until the spline teeth mesh.

NOTE: If the valve is turned clockwise the motor will

Install the valve plate and locate the open slot (Item 1) rotate in the opposite direction.
[Figure 20-80-46] that is over the largest open Geroler®
pocket.

20-80-13 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-51

Assembly (Cont’d)

Figure 20-80-49 2
1

2 1

S6423

Figure 20-80-52
S7693

Install the O-ring (Item 1) [Figure 20-80-49].

3
Apply assembly lube to the springs, and install the 1
2
springs (Item 2) [Figure 20-80-49].

Figure 20-80-50

Balance Ring
1
B-13495A

Install the inner (Item 1) and outer (Item 2) [Figure 20-

1 80-51] and [Figure 20-80-52] face seals on the balance
ring as shown.

S7694

Install the pins (Item 1) [Figure 20-80-50].

20-80-14 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-55

Assembly (Cont’d)

Figure 20-80-53 1

1 2

S7697

Install the housing (Item 1) [Figure 20-80-55] on the

S7695 motor.

Remove the screwdriver (Item 2) [Figure 20-80-55].

Install the balance ring (Item 1) [Figure 20-80-53]. Make
sure the pins engage the pin notches (Item 3) [Figure Figure 20-80-56
20-80-52] in the balance ring.

Figure 20-80-54

1 1

S7691

S7696 Install the bolts (Item 1) [Figure 20-80-56]. Tighten the

bolts to 50 N•m (37 ft-lb) torque in a crisscross pattern.

Insert a small screw driver through the port in the Installation: Tighten bolts to 53 N•m (39.1 ft-lb) torque.
housing. Apply pressure to the side of the balance ring
assembly until the valve housing is in place [Figure 20-
80-54].

20-80-15 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-59

Assembly (Cont’d)

Figure 20-80-57
1

S7688

Install the O-ring (Item 1) [Figure 20-80-59] on the plug.

S7690
Figure 20-80-60

Install the O-ring (Item 1) [Figure 20-80-57] on the plug.

Figure 20-80-58

S7687

Install the plug (Item 1) [Figure 20-80-60].

S7689
Installation: Tighten to 10 N•m (7.5 ft-lb) torque.

Install the plug (Item 1) [Figure 20-80-58].

Installation: Tighten to 10 N•m (88.50 in-lb) torque.

20-80-16 E08 Service Manual

SLEW MOTOR (CONT’D) Figure 20-80-63

Assembly (Cont’d)

Figure 20-80-61

1
1

S7684

Install the plugs (Item 1) [Figure 20-80-63].

S7686
Installation: Tighten to 10 N•m (7.5 ft-lb) torque.

Install the balls (Item 1) [Figure 20-80-61]. Clamp the motor in a vise.

Figure 20-80-62 Figure 20-80-64

S7685 S7977

Install the O-ring (Item 1) [Figure 20-80-62] on the plugs. Turn the shaft (Item 1) [Figure 20-80-64] in a clockwise
direction.

If the motor is correctly timed, there will be suction at the

top port (Item 2) [Figure 20-80-64].

20-80-17 E08 Service Manual

20-80-18 E08 Service Manual
HYDRAULIC RESERVOIR Figure 20-90-3

Description

The hydraulic reservoir is a storage container for the

excavators hydraulic fluid. The reservoir contains a
vented fill cap.

The hydraulic reservoir is located behind the radiator on

the right side of the excavator.

Removal And Installation

1
Open the tailgate.

Remove the radiator. (See Radiator Removal And S8435

Installation on Page 60-40-1.)

Figure 20-90-1 Put a hose clamp (Item 1) [Figure 20-90-3] on the lower
reservoir hose.

Figure 20-90-4

S8399 2
1

Mark and remove the tubeline (Item 1) [Figure 20-90-1] S7602

from the back side of the hydraulic reservoir.

Figure 20-90-2 Remove the hose clamp (Item 1) and lower reservoir
hose (Item 2) [Figure 20-90-4].

NOTE: There still can be a small amount of hydraulic

fluid in the lower reservoir hose. Use a
container when removing lower reservoir
hose.

2 Recycle or dispose of the used hydraulic fluid in an

environmentally safe manner.

S8434

Remove the hose clamp (Item 1) and hose (Item 2)

[Figure 20-90-2].

20-90-1 E08 Service Manual

HYDRAULIC RESERVOIR (CONT’D)

Removal And Installation (Cont’d)

Figure 20-90-5

1
1

S7603

Remove the four bolts (Item 1) [Figure 20-90-5] and

remove the fan.

NOTE: Fan belt will become loose when removing

bolts.

Figure 20-90-6

S8709

Gently pull hydraulic reservoir towards you and slide it

out of its positioning bracket.

20-90-2 E08 Service Manual

OIL COOLER Figure 20-100-2

Description
1
The oil cooler is needed for breaker applications and is
not included with the excavator. If using the excavator for
breaker applications, the oil cooler kit needs to be
installed. See your dealer for kit.

The oil cooler is used to cool the excavators hydraulic

fluid. Oil passages are coiled into a heat exchanger. The
air is forced around these passages cooling the oil.

Removal And Installation

Drain hydraulic reservoir. (See Replacing Hydraulic Oil S8407

on Page 10-120-2.)
Remove the tubeline (Item 1) [Figure 20-100-2] from the
Remove the upper right hand side cover. (See Upper
bottom of the oil cooler.
Right Side Cover Removal And Installation on Page 40-
210-1.)
Figure 20-100-3
Remove the lower right hand side cover. (See Lower
Right Side Cover Removal And Installation on Page 40-
210-3.)

Figure 20-100-1 1

S8406

Remove the bolt (Item 1) [Figure 20-100-3] from the oil

cooler frame.

S8405

Remove the tubeline (Item 1) [Figure 20-100-1] from the

top of the oil cooler.

20-100-1 E08 Service Manual

OIL COOLER (CONT’D)

Removal And Installation (Cont’d)

Figure 20-100-4

S8408

Remove the bolt (Item 1) [Figure 20-100-4] from the oil

cooler frame.

Remove the oil cooler from the frame.

20-100-2 E08 Service Manual

BLADE / TRACK EXPAND VALVE Figure 20-110-1

Description

The blade / track expand valve diverts hydraulic fluid to

either the blade or track expansion function with the
control handle situated in the middle of the floor panels.

The blade / track expand valve is located directly

underneath the floor panels in the middle of the
excavator.

Block Removal And Installation 1

Lower the boom / bucket and blade to the ground.

S8412
With the engine off, turn the start key to the ON position
and move blade lever to relieve hydraulic pressure.
Disconnect the tubeline (Item 1) [Figure 20-110-1] from
the underside of the valve.

IMPORTANT Figure 20-110-2

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
Remove the floor panels. (See FLOOR PANELS on Page
40-120-1.)

WARNING S8413

Disconnect the tubelines (Item 1) [Figure 20-110-2].

Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
doctor familiar with this injury is not received
immediately.
W-2145-EN-0210

20-110-1 E08 Service Manual

BLADE / TRACK EXPAND VALVE (CONT’D) Control Handle Removal And Installation

Block Removal And Installation (Cont’d) Lower the boom / bucket and blade to the ground.

Figure 20-110-3 With the engine off, turn the start key to the ON position
and move blade lever to relieve hydraulic pressure.

Remove the floor panels. (See FLOOR PANELS on Page

40-120-1.)

Figure 20-110-4

1
2

S8414

Remove the nuts and bolts (Item 1) [Figure 20-110-3]. 1

Remove the blade / track expand valve.

S8413

Remove the bolt (Item 1) and washer (Item2) [Figure 20-

110-4] from the control handle.

Remove the control handle.

20-110-2 E08 Service Manual

BLADE / TRACK EXPAND VALVE (CONT’D) Figure 20-110-6

Block Disassembly And Assembly

IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 2
I-2003-0888 1
S7525

Clean all parts in solvent and dry with compressed air.

Remove the washer (Item 1) and control handle (Item 2)
Inspect all parts for wear or damage. Replace any worn [Figure 20-110-6].
or damaged parts.
Figure 20-110-7
Always install new O-rings and back-up rings. Lubricate
all O-rings and back-up rings with clean hydraulic fluid
before installation.

Figure 20-110-5 1

1 S7528

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

20-110-7] from the valve.
S7524

Remove the bolt (Item 1) [Figure 20-110-5].

20-110-3 E08 Service Manual

BLADE / TRACK EXPAND VALVE (CONT’D)

Block Disassembly And Assembly (Cont’d)

Figure 20-110-8

S7527

Remove the spool (Item 1) [Figure 20-110-8] from the

valve.

Figure 20-110-9

1
1

2
2 S7526

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

[Figure 20-110-9] from the spool.

20-110-4 E08 Service Manual

ELECTRIC BLADE / TRACK EXPAND VALVE Figure 20-111-1

Description

The blade / track expand valve diverts hydraulic fluid to

either the blade or track expansion function with the 2
control handle situated in the middle of the floor panels.

The blade / track expand valve is located directly

underneath the floor panels in the middle of the
excavator.
1
Block Removal And Installation

Lower the boom / bucket and blade to the ground.

S9734
With the engine off, turn the Start key to the ON position
and move blade lever to relieve hydraulic pressure.
Disconnect the track expansion valve harness (Item 1)
from the mainframe harness (Item 2) [Figure 20-111-1].

IMPORTANT Figure 20-111-2

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
1
damage the system. 3
I-2003-0888

Remove the floor panels. (See FLOOR PANELS on Page

40-120-1.) 2
1

WARNING P116552

Hydraulic fluid escaping under pressure can have Mark all tubelines and hoses for ease of assembly.
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury Disconnect the tubelines (Item 1) [Figure 20-111-2].
and possible death if proper medical treatment by a
physician familiar with this injury is not received Remove the two bolts (Item 2) and the blade / track
immediately. expansion valve (Item 3) [Figure 20-111-2] from the
W-2145-0290 excavator.

20-111-1 E08 Service Manual

ELECTRIC BLADE / TRACK EXPAND VALVE Figure 20-111-3
(CONT’D)

Solenoid Removal And Installation

Lower the boom / bucket and blade to the ground.

With the engine off, turn the start key to the ON position
and move blade lever to relieve hydraulic pressure.

IMPORTANT 1

When repairing hydrostatic and hydraulic systems,

clean the work area before disassembly and keep all S9734
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Disconnect the wire harness (Item 1) [Figure 20-111-3]
I-2003-0888 from the excavator harness.

Remove the blade / track expand valve.

WARNING Figure 20-111-4

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 2 1
immediately.
W-2145-0290

P116552

Remove the solenoid nut (Item 1), O-ring and coil (Item
2) [Figure 20-111-4] from the expansion block.

20-111-2 E08 Service Manual

LECTRIC BLADE / TRACK EXPAND VALVE (CONT’D) Block Disassembly And Assembly

Solenoid Removal And Installation (Cont’d)

Figure 20-111-5
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
1
damage the system.
I-2003-0888

Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear or damage.

Replace any worn or damaged parts.

P122534
Always install new O-rings and back-up rings. Lubricate
all O-rings and back-up rings with clean hydraulic fluid
Remove the solenoid stem (Item 1) [Figure 20-111-5].
before installation.
Installation: Tighten the solenoid stem to 50 N•m (37 ft-
Figure 20-111-7
lb) torque.

Figure 20-111-6

2 2

P-66866
1

P-62378 Remove the nut (Item 1) [Figure 20-111-7] from the

solenoid.
Remove the O-rings (Item 1) and back-up rings (Item 2)
[Figure 20-111-6].

20-111-3 E08 Service Manual

BLADE / TRACK EXPAND VALVE (CONT’D) Figure 20-111-10

Block Disassembly And Assembly (Cont’d)

1
Figure 20-111-8
2

1
2
2 P-62378

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

P-66867 [Figure 20-111-10] from the solenoid stem.

Remove the O-ring (Item 1) and solenoid (Item 2)

[Figure 20-111-8].

Figure 20-111-9

1
P-66868

Remove the solenoid stem (Item 1) [Figure 20-111-9]

from the block.

Installation: Tighten the solenoid stem to 50 N•m (37 ft-

lb) torque.

20-111-4 E08 Service Manual

UNDERCARRIAGE

BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Extension Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Blade Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2

TRACK UNDERCARRIAGE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Track Lug Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Checking Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
Adjusting Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-3
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4
Idler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-5
Idler Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6
Idler Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-7
Idler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-9
Track Tensioner Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-10
Track Tensioner Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-11
Roller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-11
Removal And Installation Of Expandable Track Frame . . . . . . . . . . . . . . . . . . . . . . 30-20-12

TRACK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

SWING CIRCLE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

30-01 E08 Service Manual

30-02 E08 Service Manual
BLADE Extension Removal And Installation

Description Figure 30-10-2

The blade extensions are used to match the track width

to the blade width. Retract the blade extensions when
transporting the excavator or when a narrow operating
width is needed. Under normal operating conditions, the 2
blade width should match the track width. 1

Figure 30-10-1

1 2

S7677

2 Put a block (Item 1) [Figure 30-10-2] under the blade.

Fully lower the blade to the block.

Stop the engine.

S7675
Remove the pin (Item 2) [Figure 30-10-2] from the blade
extensions.
The blade extensions (Items 1 and 2) [Figure 30-10-1]
are located on the blade. Figure 30-10-3

S7676

Remove the blade extensions (Item 1) [Figure 30-10-3]

from the blade.

30-10-1 E08 Service Manual

BLADE (CONT’D)

Blade Removal And Installation

Expand the tracks.

Lower the blade to the ground.

Remove the blade cylinder. (See Removal And

Installation on Page 20-24-2.)

Figure 30-10-4

S7658

Figure 30-10-5

2
1

S7657

Remove the snap ring (Item 1) [Figure 30-10-4] and

[Figure 30-10-5] and washer from the blade arm pivot
pins (both sides).

Remove the blade arm pivot pins (Item 2) [Figure 30-10-

4] and [Figure 30-10-5].

Remove the blade from the excavator.

30-10-2 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS Track Lug Height

Description Rubber Track

The track undercarriage components consist of the front The lug height of a new rubber track is 25,0 mm (0.984
idler, rollers, drive motor and track frame. in).

Figure 30-20-1

Straight Edge

B-14489

To find the percentage of wear on an excavator track,

measure the height of the lug by placing a straight edge
across the top of three lugs and measure the distance
from the base of the track to the bottom of the straight
edge [Figure 30-20-1].

Divide this measurement by the new track height and

multiply by 100. This will give the percentage of track lug
left.

Example: lug height 20,0 mm (0.787 in)

0.787
0.984 x 100 = 80

80% of the track lug is remaining with 20% wear on the

track lugs.

The rubber track should be replaced when lug height

measures 6,25 mm (0.246 in) from the base of the track
to the top of the lug.

30-20-1 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D)

Checking Tension
WARNING
NOTE: The wear of undercarriage parts vary with
working conditions and types of soil
AVOID INJURY
conditions. Maintain the correct track tension
Keep fingers and hands out of pinch points when
by inspecting regularly. (See SERVICE
checking the track tension.
SCHEDULE on Page 10-70-1.) W-2142-0903

Figure 30-20-2
Figure 30-20-4

S8452 S7954

Raise one side of the machine (approximately 102 mm [4

in]) using the boom and arm as shown in [Figure 30-20- Figure 30-20-5
2].
RUBBER
Figure 30-20-3 Track Frame

Rubber
Track Sag
0.33-0.53 inch
(8-13 mm) Track
1 Roller

1
S8756 S8757
Rubber
Track S8710
Raise the blade fully and install wooden blocks (Item 1)
[Figure 30-20-3] or jackstands under the blade and the
track frame. Lower the machine until all machine weight Measure the rubber track sag at the middle track roller
is on the wooden blocks or jackstands. [Figure 30-20-4]. Do not get your fingers into pinch
points between the track and the track roller. Use material
Stop the engine. of appropriate size to check the gap between the contact
edge of the roller and top edge of the track guide lug
[Figure 30-20-4] and [Figure 30-20-5].

30-20-2 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Figure 30-20-8

Adjusting Tension

Figure 30-20-6 1

1 1

S8887

Use tool MEL1560 (Item 1) [Figure 30-20-8] to loosen

S7954 the bleed fitting (Item 2) [Figure 30-20-7] (one turn
maximum) to release tension from the track.

Loosen the two bolts (Item 1) [Figure 30-20-6] on the Repeat the procedure for the other side.
cover. Pivot the cover downward.
If the track tension is still loose after adjusting to the
Figure 30-20-7 mentioned limit, it indicates the track is worn.

WARNING
AVOID INJURY OR DEATH
Do not loosen the grease fitting more than one
complete rotation. Also, be careful not to loosen any
1 2 part other than the grease fitting. If the grease fitting
or any part is loosened too much, it can fly off under
high pressure. If the grease does not ooze smoothly,
try moving the machine back and forth for a short
distance.
W-2143-0189
S7953

Add grease to the fitting (Item 1) [Figure 30-20-7] until

the track tension is correct.

30-20-3 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Figure 30-20-11

Track Removal And Installation

Lift and block the side of the machine where the track will 1
be removed. (See Procedure on Page 10-10-1.)

Figure 30-20-9

1 1
S8887

Use tool MEL1560 (Item 1) [Figure 30-20-11] to loosen

the bleed fitting (Item 1) [Figure 30-20-10] (one turn
maximum) to release tension from the track.

S7954 NOTE: Apply additional pressure to the track by

standing on the lower track span so all the
tension is released from the grease cylinder
Loosen the two bolts (Item 1) [Figure 30-20-9] on the for easier removal of the track.
cover. Pivot the cover downward.
Figure 30-20-12
Figure 30-20-10

S7952
S7953

Install a round bar (Approximately 30 mm [1.25 in]

diameter) between the drive lugs [Figure 30-20-12].

30-20-4 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Idler Removal And Installation

Track Removal And Installation (Cont’d) Remove the track. (See Track Removal And Installation
on Page 30-20-4.)
Figure 30-20-13
Figure 30-20-14

S7951

S7950

Turn the track until the bar contacts the frame [Figure 30-
20-13]. Slide the front track idler out of the track frame to remove
it [Figure 30-20-14].
Pry the track off the idler wheel.

Remove the track from the drive sprocket.

To install the rubber track:

Put the track over the rear drive sprocket lugs.

Put the front of the track onto the front idler wheel.

(See Checking Tension on Page 30-20-2.) for adding

grease to the grease spring and for checking track
tension.

30-20-5 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D)

Idler Parts Identification

1. Washer
2. Tensioner
3. Idler
4. Shaft
5. Seal
6. Bearing
7. Pin
8. Ring

7 1 2

8
7

S8280

30-20-6 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Figure 30-20-17

Idler Disassembly
1
The following tools must be fabricated for this procedure:

Figure 30-20-15

90 mm
70 mm (3.5”)
(2.75”)
S7939

Remove the seal (Item 1) [Figure 30-20-17] from both

0,75 mm 30 mm sides of the idler.
(0.03”) (1.18”) Dia.
Chamfer Figure 30-20-18
3 Places 46 mm
(1.81”) Dia. B-14204

1. Driver Tool - see [Figure 30-20-15].

1
Figure 30-20-16

1
S7937

Remove the snap ring (Item 1) [Figure 30-20-18] from

both sides of the idler.

S7940

Remove the roll pin (Item 1) [Figure 30-20-16] from each

end of the shaft.

Using a suitable driver, gently tap the shaft (Item 2)

[Figure 30-20-16] out of the track idler and bracket.

Remove the track idler from the bracket.

30-20-7 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D)

Idler Disassembly (Cont’d)

Figure 30-20-19

S7936

Using a suitable bearing puller, remove the bearing (Item

1) [Figure 30-20-19] from both sides of the idler.

30-20-8 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Figure 30-20-22

Idler Assembly

Clean all parts in solvent and dry with compressed air.

Figure 30-20-20

S7933

Using a press or driving tool, install the bearing in the

idler [Figure 30-20-22] on both sides of the idler.
1 2 1
S7935 Figure 30-20-23

Inspect the bearings (Item 1) and shaft (Item 2) [Figure

30-20-20] for wear or damage. Replace any worn or
damaged parts.

The bearings are sealed. If the bearings do not roll

smoothly, or if the seals are damaged, replace the 1
bearings.

Figure 30-20-21

S7937

Install the snap ring (Item 1) [Figure 30-20-23] on both

sides of the idler.

S7934

Remove all paint and corrosion from the bearing and seal
surface (Item 1) [Figure 30-20-21] on both sides of the
idler. If necessary, replace the track idler.

NOTE: Left-Hand Side Idler and Right-Hand Side Idler

are different. For ordering, a different P/N
exists for each side.

30-20-9 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Figure 30-20-26

Idler Assembly (Cont’d)

Figure 30-20-24
1

2
1

S7940

2
Apply assembly lube to the shaft.
S7932
Using a soft faced hammer, gently tap the shaft (Item 1)
[Figure 30-20-26] in the idler and bracket.
Apply assembly lube to the inside diameter (Item 1)
[Figure 30-20-24] of the seal. Install the roll pin (Item 2) [Figure 30-20-26] on each end
of the shaft.
Apply a small bead of high temperature silicone sealant
around the flange surface (Item 2) [Figure 30-20-24] of Track Tensioner Removal And Installation
the seal.
Figure 30-20-27
Figure 30-20-25

S7949
S7939

Slide the grease cylinder forward and remove it from the

Using the driving tool, install the seal (Item 1) [Figure 30- track frame [Figure 30-20-27].
20-25] on both sides of the idler.

30-20-10 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Roller Removal And Installation

Track Tensioner Disassembly And Assembly Figure 30-20-30

Figure 30-20-28

1 S7948

S7945
Loosen the nuts (Item 1) [Figure 30-20-30] from the
track roller on both sides of the track frame.
Remove the rod (Item 1) [Figure 30-20-28] from the
grease cylinder. Installation: Tighten the nuts to 170 - 190 N•m (125 -
140 ft-lb) torque.
Figure 30-20-29
Remove the track roller (Item 2) [Figure 30-20-30].

2
P-15318

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

ring (Item 3) [Figure 30-20-29] from the cylinder.

30-20-11 E08 Service Manual

TRACK UNDERCARRIAGE COMPONENTS (CONT’D) Figure 30-20-33

Removal And Installation Of Expandable Track Frame

Remove the track expansion cylinder. (See Removal And

Installation on Page 20-25-2.)

Remove the track. (See Track Removal And Installation

on Page 30-20-4.)

Figure 30-20-31

1 1
2
S7946

Remove the nut (Item 1) [Figure 30-20-33] from the track

1 expansion stop rod.

Figure 30-20-34

1
S7943

Remove the bolts (Item 1) and the travel motor cover

(Item 2) [Figure 30-20-31] from the travel motor.

Figure 30-20-32

S7944

Install a chain hoist on the track frame [Figure 30-20-34].

1
Lift the frame a small amount while pulling the frame
away from the excavator.

Using a 10 X 1,5 mm tap, clean the track frame bolt holes

to remove the old thread locking compound.
1
P-59087

Remove the hoses (Item 1) [Figure 30-20-32] from the

travel motor.

30-20-12 E08 Service Manual

TRACK MAINTENANCE Figure 30-30-3

Track Damage Identification

Cutting Of The Steel Cords

Damage:

Figure 30-30-1

PI-13035

When the rubber track is detracking, the idler or sprocket

rides on the projections of the embedded metal [Figure
30-30-3].

When the rubber track is detracted, projections of rubber

P-03864 tracks get stuck between the frame of the undercarriage.

The rubber track is clogged with stones or foreign

Figure 30-30-2 obstacles.

When moisture penetrates through a cut on the lug side

rubber surface, the embedded steel cords will corrode.
The deterioration of the design strength may lead to the
breaking off of the steel cords.

Prevention

The following preventions should be taken to minimize

the risk of this damage:

Periodically check on site, recommended track tension.

Steel Cords (See Adjusting Tension on Page 30-20-3.)

PI-13034 Avoid quick turns on bumpy and rocky fields.

Drive carefully to avoid having stones and other articles

Embedded steel cords are cut off [Figure 30-30-1] and clog the rubber tracks.
[Figure 30-30-2].
Avoid driving over sharp objects. If this is impossible, do
Replacement: not make turns while driving over sharp objects.
Replacement is required [Figure 30-30-1] and [Figure
30-30-2].

Causes Of The Damage

When applied to rubber tracks under the following

circumstances, tension in excess of the breaking strength
of the embedded steel cords causes steel cords to be
cut:

30-30-1 E08 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
rubber track abrasion:
Damage:
Rubber tracks are driven with an extraordinary heavy
Figure 30-30-4 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

In proportion to the service time, embedded metals will

gradually wear away by friction [Figure 30-30-4].

Replacement:

Figure 30-30-5

Abrasion

D D1 = 0.67D
PI-13037

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 E08 Service Manual

TRACK MAINTENANCE (CONT’D) When the idler continually rides on the projections of
embedded metals, the embedded metals will eventually
Track Damage Identification (Cont’d) peel off [Figure 30-30-7].

Separation Of Embedded Metals Figure 30-30-8

Damage:

Figure 30-30-6 Guide

PI-13040

When a rubber track is detracted, it becomes stuck

P-04379 between the guide or the undercarriage frame, causing
the separation of embedded metals [Figure 30-30-8].
Extraordinary outer forces applied to embedded metals
Figure 30-30-9
cause their separation from the rubber track's body
[Figure 30-30-6].

Replacement:

Even a partial separation of embedded metals requires

replacement of the track.
Abrasion
Causes Of The Damage:

Embedded metals adhere between the steel cords and

the rubber body. The following cases generate external
forces greater than the adhesion strength, causing
separation of the embedded metals:

Figure 30-30-7
PI-13041

Abnormally worn sprockets as shown will pull embedded

Idler metals out [Figure 30-30-9].

Prevention:

Similar to the prevention against the cutting of the steel

Rubber cords:
Track
Periodically check on site, recommended track tension.
(See Adjusting Tension on Page 30-20-3.)

PI-13039

30-30-3 E08 Service Manual

TRACK MAINTENANCE (CONT’D) Causes Of The Damage

Track Damage Identification (Cont’d) Figure 30-30-11

Separation Of Embedded Metals (Cont’d) Embedded metal

Quick turns on bumpy and rocky fields should be

avoided.
Good
If abnormal wear of sprockets is observed, they should
be immediately replaced.

Separation Of Embedded Metals Due To Corrosion

Separation of bonded
Damage: rubber cover
Figure 30-30-10
PI-13043

Embedded metals are bonded to the rubber body. The

following operating conditions cause embedded metals to
corrode, causing deterioration of the bonding, and finally
resulting in separation of the embedded metals from the
rubber body [Figure 30-30-11].

Excessively salty fields, like the sea shore.

Strong acidic or alkali soil conditions

Compost spread grounds

P-04378
On tracks that are out of adjustment, the track rollers,
idlers and sprockets will gradually wear the rubber
Due to corrosion of embedded metals, the adhesion to surface at track roller side, causing exposure of the
the rubber body deteriorates, resulting in complete embedded metals. Consequently the embedded metals
separation [Figure 30-30-10]. will corrode resulting in their separation from the rubber
body.
Replacement:
Prevention:
Even a partial separation of embedded metals requires a
rubber track replacement. If rubber tracks are used under such field conditions as
described under (Causes Of The Damage), they 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.

30-30-4 E08 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

Damage: Cuts

Figure 30-30-12

PI-13045

When rubber tracks drive over projections or sharp

stones in the fields, the concentrated forces applied
cause cuts on the lug side rubber surface. In case of
P-04377 making turns on projections, the lug side rubber surface
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 breakage of steel cords due to 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].
Replacement:
Prevention:
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately repaired Machine operators should drive with great attention to the
with cold vulcanization rubber. ground 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, quick

high speed turns and overloading should be avoided.

30-30-5 E08 Service Manual

TRACK MAINTENANCE (CONT’D) Replacement:

Track Damage Identification (Cont’d) When the cracks become deep enough to expose the
steel cords, track replacement is required.
Cracks On The Lug Side Rubber Due To Fatigue
Causes Of The Damage:
Damage:
Because of wound stress applied to rubber tracks around
Figure 30-30-14 the undercarriage parts during operation, the fatigue
especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
even small external cracks.

Also 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. However,
external damage on the lug side rubber, increases the
possibility of cracking. Machine operators should observe
P-04382 soil conditions when driving, to prevent external damage
to the lug side rubber. In order to minimize the
occurrence of ozone cracks, follow these maintenance
Figure 30-30-15 instructions:

Avoid exposing stored tracks to direct sun light.

Avoid exposing stored tracks to direct rain and snowfall.

Store tracks in well ventilated warehouses.

Use the tracks at least once a month.

P-4380

Small cracks around the root of the lug are a result from
operation fatigue [Figure 30-30-14] and [Figure 30-30-
15].

30-30-6 E08 Service Manual

TRACK MAINTENANCE (CONT’D) Replacement:

Track Damage Identification (Cont’d) No replacement is required.

Lug Abrasion Causes Of The Damage:

Damage: Lug abrasion will occur as operation time increases.

Even as lug abrasion increases, the rubber track can be
Figure 30-30-16 used. However, as the traction performance deteriorates,
it is highly recommended to replace the abraded tracks
with new ones when the lug height becomes less than 5
mm (0.196 in).

Prevention:

In order to prevent the rubber track from abnormal or

premature abrasion, the following operating conditions
should be avoided:

Making quick and repeated turns on concrete and

asphalt roads.

Driving up and down hilly paths with slippage.

P-04381
Making frequent turns on paths covered with rocks and
wood.
Figure 30-30-17

Lug abrasion
t

PI-13049

As operation time increases, the lug side undergoes

abrasion [Figure 30-30-16] and [Figure 30-30-17].

30-30-7 E08 Service Manual

TRACK MAINTENANCE (CONT’D) Causes Of The Damage:

Track Damage Identification (Cont’d) Figure 30-30-19

Cracks And Cuts On The Lug Side Rubber

Damage:

Figure 30-30-18
Crack at the edge of Cut on lug side
embedded metal rubber

PI-13051

When rubber tracks drive over sharp projections,

intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
CD-13050 cracks and cuts in the area around the embedded metals
[Figure 30-30-19].

Sometimes cracks and cuts on the lug side rubber at the Prevention:
edges of the embedded metals can be observed [Figure
30-30-18]. To avoid extensive stress applied to the lug root where
metals are embedded, machine operators should avoid
Replacement: driving over stumps and ridges.

Basically, 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.

30-30-8 E08 Service Manual

TRACK MAINTENANCE (CONT’D) Causes Of The Damage:

Track Damage Identification (Cont’d) Figure 30-30-21

Abrasion Of The Track Roller Side

Damage:
Track roller
Figure 30-30-20
Abrasion

PI-13053

The abrasion of the track roller side rubber surface

occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
P-04383 rollers. The stress pushes the sand and gravel against
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 result in the exposure of the embedded The level of abrasion is highly dependent on terrain
metals [Figure 30-30-20]. conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
Replacement: stones and gravel. Small stones hardened with mud,
stuck to the track rollers increase the abrasion level. 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.

30-30-9 E08 Service Manual

TRACK MAINTENANCE (CONT’D) Figure 30-30-24

Track Damage Identification (Cont’d)

Cuts On The Edges Of The Track Roller Side

Cut
Damage:

Figure 30-30-22

Tear
Edge Edge

PI-13057

Both edges of a rubber track [Figure 30-30-22] have no

special reinforcement. During operation the edges may
become cut or torn off [Figure 30-30-23] and [Figure 30-
30-24].

PI-13055 Replacement:

In such case, the rubber track does not have to be

Figure 30-30-23 replaced.

Causes Of The Damage:

This damage is caused by objects on the ground or by

interference with the machine frame.

In case of damage by objects on the operating ground:

The edges of rubber track are often deformed largely due

to a bumpy ground surface, stones and other objects.
This causes extensive stress on the edges resulting in
the damage.

When driving a machine over concrete ridges, this type of

P-04384 damage easily occurs.

In case of damage by interference with the machine

frame.

30-30-10 E08 Service Manual

TRACK MAINTENANCE (CONT’D)

Track Damage Identification (Cont’d)

Cuts On The Edges Of The Track Roller Side (Cont’d)

Figure 30-30-25

PI-13056

If a machine continues operating with rubber tracks being

detracked, the rubber tracks may get caught up in the
machine frame or undercarriage parts resulting in
damage. Furthermore, when a machine travels along
side slopes, the rubber tracks are deformed so much that
they come into contact with the machine frame and
undercarriage parts, which causes cutting, gouging and
rubbing of rubber tracks in the end [Figure 30-30-25].

Prevention:

When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for detracking.

30-30-11 E08 Service Manual

30-30-12 E08 Service Manual
SWING CIRCLE GEAR Figure 30-40-3

Removal And Installation

Remove the upperstructure from the swing circle gear.

(See Removal on Page 40-10-1.) 1

S
Figure 30-40-1

S
2
S

1 S8299
S

Remove the bolts and nuts from the swing circle gear
[Figure 30-40-3].

Installation: Tighten the bolts and nuts to 105 - 115 N•m

S8299 (78 - 85 ft-lb) torque.

Figure 30-40-2

S
2

1
S

S8298

The swing gear and outer ring both have a soft zone. The
swing gear soft zone is identified with an S (Item 1)
stamped in the swing gear. The outer ring soft zone is
identified with an S (Item 2) [Figure 30-40-1] and [Figure
30-40-2] stamped in the outer ring.

The soft zones of both the swing gear and outer ring
must be positioned 180° of each other.

30-40-1 E08 Service Manual

30-40-2 E08 Service Manual
UPPERSTRUCTURE & SWING

UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-5

TOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

RIGHT CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

LEFT CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
Horn Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-5

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
Cable Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-3
Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-5

BLADE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-3

UPPERSTRUCTURE SLEW LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

RIGHT PEDAL AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Control Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Control Linkage Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-3

TRAVEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1

Right Hand Travel Control Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 40-100-1
Right Hand Travel Control Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 40-100-1
Left Hand Travel Control Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-2
Left Hand Travel Control Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . 40-100-3

LEFT PEDAL AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1

Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1
Control Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1
Control Linkage Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-3

40-01 E08 Service Manual

FLOOR PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Left Floor Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Right Floor Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1

HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1

SWING FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1
Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-2
Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-3
Boom Pivot Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-4
Boom Pivot Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-4

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1

ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Arm To Boom Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-2
Arm To Bucket And Bucket Link Bushing Removal And Installation . . . . . . . . . . . . 40-170-2

BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1

TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-2

COUNTERWEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1
Rear Counterweight Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1
Left Side Counterweight Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-2
Right Side Counterweight Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 40-200-3

SIDE COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1

Upper Left Side Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1
Upper Right Side Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1
Lower Left Side Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-2
Lower Right Side Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-3

INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-220-2

40-02 E08 Service Manual

UPPERSTRUCTURE Figure 40-10-1

Description

The upperstructure includes all the components in or

attached to the frame and connects to the slew bearing.
The slew bearing divides the upperstructure from the
undercarriage, which includes the track frame
components.

Removal 1

Fully extend the cylinders of the bucket and arm. Fully

1
retract the cylinder of the boom.

Lower the blade to the ground. S8361

Remove the battery. (See Removal And Installation on

Page 50-20-4.) Remove the two tubelines (Item 1) [Figure 40-10-1] from
the swivel joint.
Remove the TOPS. (See Removal And Installation on
Page 40-20-1.) Figure 40-10-2

Drain the hydraulic reservoir. (See Replacing Hydraulic

Oil on Page 10-120-2.) 1

Remove the seat. (See Removal And Installation on

Page 40-30-1.)

Remove the floor panels. (See FLOOR PANELS on Page

40-120-1.) 1
Remove the slew motor. (See Removal And Installation
on Page 20-80-1.)

Remove the track expand valve. (See Block Removal

And Installation on Page 20-111-1.) S8362

Remove the muffler. (See Removal And Installation on

Page 60-20-1.) Remove the two tubelines (Item 1) [Figure 40-10-2] from
the swivel joint.
Remove the lower right hand side cover. (See Lower
Right Side Cover Removal And Installation on Page 40-
210-3.)

40-10-1 E08 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-5

Removal (Cont’d)
1
Figure 40-10-3

S8364

Disconnect the tubeline (Item 1) [Figure 40-10-5] from

S8363 the swivel joint.

Remove the tubeline from the excavator for easy access

Disconnect the tubeline (Item 1) [Figure 40-10-3] from to the swing circle gear bolts.
the control valve.
Figure 40-10-6
Figure 40-10-4

1
1

S8365
S8324

Disconnect the tubeline (Item 1) [Figure 40-10-6] from

Disconnect the tubeline (Item 1) [Figure 40-10-4] from the swivel joint.
the control valve.
Remove the tubeline from the excavator for easy access
to the swing circle gear bolts.

40-10-2 E08 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-9

Removal (Cont’d)

Figure 40-10-7 1

1 S8400

Disconnect the tubeline (Item 1) [Figure 40-10-9] from

S8398 the swivel joint.

Remove the tubeline from the excavator for easy access

Remove the two bolts (Item 1) and fan apron (Item 2) to the swing circle gear bolts.
[Figure 40-10-7].
Figure 40-10-10
Figure 40-10-8

1
1
1

S8401
S8399

Remove the bolt and nut (Item 1) [Figure 40-10-10] from

Disconnect the tubeline (Item 1) [Figure 40-10-8] from the cable bracket.
the hydraulic reservoir.
Move the cable bracket aside for easy access to swing
circle gear bolts.

40-10-3 E08 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-12

Removal (Cont’d)

Figure 40-10-11

S8275

Mark the upperstructure to the swing bearing and to the

S8402 track frame for ease of assembly [Figure 40-10-12].

Figure 40-10-13
Install eye bolts (Item 1) [Figure 40-10-11] in the rear
TOPS mounting holes.

Fasten chains to the eye bolts and up to the chain hoist.

Fasten a chain (Item 2) [Figure 40-10-11] through the

rod at the top of the boom. 1

WARNING
AVOID INJURY OR DEATH
• Use a lifting fixture with sufficient capacity for S8404
the weight of the excavator plus any added
attachments.
• Maintain centre of gravity and balance when Remove the three swivel joint mount nuts (Item 1)
lifting. [Figure 40-10-13].
• Do not swing boom or upperstructure. Engage
the upperstructure slew lock.
• Never lift with operator on machine.
W-2202-EN-0909

40-10-4 E08 Service Manual

UPPERSTRUCTURE (CONT’D) Installation

Removal (Cont’d) Figure 40-10-16

Figure 40-10-14

S
1

S
1

S8299

S8403
Figure 40-10-17
Figure 40-10-15

S
2

1 1

S
1

S8298

S8404
The swing gear and outer ring both have a soft zone. The
swing gear soft zone is identified with an S (Item 1)
Remove the 18 bolts (Item 1) [Figure 40-10-14] and stamped in the swing gear. The outer ring soft zone is
[Figure 40-10-15] from the upperstructure. identified with an S (Item 2) [Figure 40-10-16] and
[Figure 40-10-17] stamped in the outer ring.
Lift the upperstructure off the swing bearing. Position the
upperstructure onto supporting stands or blocks. The soft zones of both the swing gear and outer ring
must be positioned 180° of each other.
NOTE: Keep tension on the chain hoist to support the
boom and arm when the upperstructure is NOTE: Clean out the old excess Loctite® from all the
supported on stands or blocks. 18 threaded holes in the slew bearing prior to
installing the upperstructure.

40-10-5 E08 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-20

Installation (Cont’d)

Figure 40-10-18

1 1

S8403

Figure 40-10-21
S8775

Lower the upperstructure frame onto the swing bearing

aligning the two pins (Item 1) [Figure 40-10-18]. Maintain
a slight amount of weight on the hoist.

Figure 40-10-19 1

S8404

Apply Loctite® 242 (Blue) to bolts and install the 18 bolts

and washers (Item 1) [Figure 40-10-20] and [Figure 40-
10-21] through the upperstructure frame and into the
swing bearing.

S8275 Tighten the bolts to 57 - 63 N•m (42 - 46.5 ft-lb) torque.

Check that upperstructure is properly aligned to the

swing bearing and track frame [Figure 40-10-19].

40-10-6 E08 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-24

Installation (Cont’d)

Figure 40-10-22
1

S8400

Connect the tubeline (Item 1) [Figure 40-10-24] to the

S8404 swivel joint.

Figure 40-10-25
Install the three swivel joint mount nuts (Item 1) [Figure
40-10-22].

Figure 40-10-23

1 S8399
1

Connect the tubeline (Item 1) [Figure 40-10-25] to the

S8401
hydraulic reservoir.

Install the bolt and nut (Item 1) [Figure 40-10-23] from

the cable bracket.

40-10-7 E08 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-28

Installation (Cont’d)
1
Figure 40-10-26

2 S8364

Connect the tubeline (Item 1) [Figure 40-10-28] to the

S8398 swivel joint.

Figure 40-10-29
Install the fan apron (Item 1) and two bolts (Item 2)
[Figure 40-10-26].

Figure 40-10-27
1

S8324

Connect the tubeline (Item 1) [Figure 40-10-29] to the

S8365 control valve.

Connect the tubeline (Item 1) [Figure 40-10-27] to the

swivel joint.

40-10-8 E08 Service Manual

UPPERSTRUCTURE (CONT’D) Figure 40-10-32

Installation (Cont’d)

Figure 40-10-30

1
1

S8361

Connect the two tubelines (Item 1) [Figure 40-10-32] to

S8363 the swivel joint.

Install the lower right hand side cover. (See Lower Right
Connect the tubeline (Item 1) [Figure 40-10-30] to the Side Cover Removal And Installation on Page 40-210-3.)
control valve.
Install the muffler. (See Removal And Installation on
Figure 40-10-31 Page 60-20-1.)

1 Install the track expand valve. (See Block Removal And

Installation on Page 20-111-1.)

Install the slew motor. (See Removal And Installation on

Page 20-80-1.)

Install the floor panels. (See FLOOR PANELS on Page

1 40-120-1.)

Install the seat. (See Removal And Installation on Page

40-30-1.)

Fill the hydraulic reservoir. (See Replacing Hydraulic Oil

S8362 on Page 10-120-2.)

Install the TOPS. (See Removal And Installation on Page

Connect the two tubelines (Item 1) [Figure 40-10-31] to 40-20-1.)
the swivel joint.
Install the battery. (See Removal And Installation on
Page 50-20-4.)

40-10-9 E08 Service Manual

40-10-10 E08 Service Manual
TOPS

Removal And Installation

Figure 40-20-1

S8001

Put a strap around the TOPS to support while removing

[Figure 40-20-1].

Figure 40-20-2

1
2

S8319

Remove the pin (Item 1), bolt and nut (Item 2) [Figure
40-20-2] from both sides of the TOPS.

Installation: Tighten the bolts to 215 N•m (159 ft-lb)

torque.

Remove the TOPS from the excavator.

40-20-1 E08 Service Manual

40-20-2 E08 Service Manual
SEAT Figure 40-30-3

Removal And Installation

Move the seat to the rear most position using the seat
adjustment lever.

Open the tailgate.

Figure 40-30-1

1 1

2 2
S8220

Open the tailgate.

Remove the two nuts (Item 2) [Figure 40-30-1] and bolts

(Item1) [Figure 40-30-3].
1 1
Remove the seat and seat rails from the tailgate.
S6737
Figure 40-30-4

Figure 40-30-2

1 1

1
1

S8221

Remove the two bolts (Item 1) [Figure 40-30-4].

Remove the two nuts (Item 1) [Figure 40-30-1] and bolts

(Item1) [Figure 40-30-2].

Close the tailgate and move the seat completely forward

using the seat adjustment lever.

40-30-1 E08 Service Manual

SEAT (CONT’D)

Removal And Installation (Cont’d)

Figure 40-30-5

1 1

S8222

Remove the two bolts (Item 1) [Figure 40-30-5].

Remove the seat rails from the seat.

40-30-2 E08 Service Manual

RIGHT CONTROL HANDLE Disassembly And Assembly

Removal And Installation Figure 40-40-3

Remove the instrument panel. (See Removal And 1

Installation on Page 40-220-1.)

Figure 40-40-1

2
3
2

S8368

1
Loosen the two nuts (Item 1) and remove the linkages
(Item 2) [Figure 40-40-3].
S8366
Figure 40-40-4

Remove the cotter pins (Item 1) and pins (Item 2) [Figure

40-40-1].

Disconnect the linkages (Item 3) [Figure 40-40-1] from 2

the control valve. 1

Figure 40-40-2

1
S8369

Loosen the nut (Item 1) [Figure 40-40-4].

Remove the rod and nut (Item 2) [Figure 40-40-4] from

the bracket.

S8367

Remove the snap ring (Item 1) [Figure 40-40-2].

Remove the right control handle.

40-40-1 E08 Service Manual

RIGHT CONTROL HANDLE (CONT'D) Figure 40-40-7

Disassembly And Assembly (Cont’d)

Figure 40-40-5

S8372

Remove the two bushings (Item 1) [Figure 40-40-7] from

S8370 the bracket.

Figure 40-40-8
Remove the snap ring (Item 1) [Figure 40-40-5].

Figure 40-40-6

2
1
1
1

2
S8373

S8371 Remove the nut (Item 1) and dust boot (Item 2) [Figure
40-40-8] from the rod.

Remove the two bushings (Item 1) and shaft (Item 2)

[Figure 40-40-6].

40-40-2 E08 Service Manual

RIGHT CONTROL HANDLE (CONT'D)

Disassembly And Assembly (Cont’d)

Figure 40-40-9

S8374

Loosen the nut (Item 1) [Figure 40-40-9].

Remove the handle (Item 2) and nut (Item 1) [Figure 40-

40-9] from the rod.

40-40-3 E08 Service Manual

40-40-4 E08 Service Manual
LEFT CONTROL HANDLE Figure 40-50-3

Removal And Installation

Remove the instrument panel. (See Removal And

Installation on Page 40-220-1.)

Figure 40-50-1
1

S8377

1
Remove the snap ring (Item 1) [Figure 40-50-3].

Remove the left control handle.

S8375

Disconnect the connector (Item 1) [Figure 40-50-1] from

the wire harness.

Figure 40-50-2

3 2

S8376

Remove the cotter pins (Item 1) and pins (Item 2) [Figure

40-50-2].

Disconnect the linkages (Item 3) [Figure 40-50-2] from

the control valve.

40-50-1 E08 Service Manual

LEFT CONTROL HANDLE (CONT'D) Figure 40-50-6

Disassembly And Assembly

Figure 40-50-4

1 1

S8380

2
Remove the snap ring (Item 1) [Figure 40-50-6].
S8378
Figure 40-50-7

Loosen the two nuts (Item 1) and remove the linkages

(Item 2) [Figure 40-50-4].

Figure 40-50-5 1 2

S8381

Remove the two bushings (Item 1) and shaft (Item 2)

[Figure 40-50-7].
S8379

Loosen the nut (Item 1) [Figure 40-50-5].

Remove the rod and nut (Item 2) [Figure 40-50-5] from

the bracket.

40-50-2 E08 Service Manual

LEFT CONTROL HANDLE (CONT'D) Figure 40-50-10

Disassembly And Assembly (Cont’d)

Figure 40-50-8

2
1

1
S8384

Loosen the nut (Item 1) [Figure 40-50-10].

S8382
Remove the handle (Item 2) and nut (Item 1) [Figure 40-
50-10] from the rod.
Remove the two bushings (Item 1) [Figure 40-50-8] from
the bracket. Figure 40-50-11

Figure 40-50-9

1
2

S8385

S8383
Remove the end cap (Item 1) [Figure 40-50-11] from the
handle.
Remove the nut (Item 1) and dust boot (Item 2) [Figure
40-50-9] from the rod.

40-50-3 E08 Service Manual

LEFT CONTROL HANDLE (CONT'D) Figure 40-50-14

Disassembly And Assembly (Cont’d)

Figure 40-50-12

S8388

Pull the microswitch assembly (Item 1) [Figure 40-50-14]

S8386 out of the handle.

Figure 40-50-15
Remove the pin (Item 1) [Figure 40-50-12] from the
handle.
1
Figure 40-50-13

1
2 S8389

Remove the spacers (Item 1) [Figure 40-50-15] from the

S8387 microswitch.

Remove the cap (Item 1) and spring (Item 2) [Figure 40-

50-13] from the handle.

40-50-4 E08 Service Manual

LEFT CONTROL HANDLE (CONT'D) Horn Switch Removal And Installation

Disassembly And Assembly (Cont’d) Figure 40-50-18

Figure 40-50-16 1

S8392

S8390
Remove the end cap (Item 1) [Figure 40-50-18] from the
handle.
Mark and disconnect the connectors (Item 1) [Figure 40-
50-16] from the microswitch. Figure 40-50-19

Figure 40-50-17

S8393

S8391
Remove the pin (Item 1) [Figure 40-50-19] from the
handle.
Remove the electrical cable and connectors (Item 1)
[Figure 40-50-17] from the handle.

40-50-5 E08 Service Manual

LEFT CONTROL HANDLE (CONT'D) Figure 40-50-22

Horn Switch Removal And Installation (Cont’d)

Figure 40-50-20

1
S8396
2

Remove the spacers (Item 1) [Figure 40-50-22] from the

S8394 microswitch.

Figure 40-50-23
Remove the cap (Item 1) and spring (Item 2) [Figure 40-
50-20] from the handle.

Figure 40-50-21

S8397

Mark and disconnect the connectors (Item 1) [Figure 40-

S8395 50-23] from the microswitch.

Remove the microswitch (Item 2) [Figure 40-50-23].

Pull the microswitch assembly (Item 1) [Figure 40-50-21]
out of the handle.

40-50-6 E08 Service Manual

ENGINE SPEED CONTROL Figure 40-60-3

Removal And Installation

Figure 40-60-1
1

1
1

S8292

Remove the three bolts (Item 1) [Figure 40-60-3] from

S8291 the right side of the instrument panel.

Figure 40-60-4
Remove the two bolts (Item 1) [Figure 40-60-1] from the
throttle lever.

Installation: Tighten the two bolts (Item 1) [Figure 40-

60-1] evenly until the throttle lever moves back and forth
at a comfortable tension. 1

Figure 40-60-2

1 3
2
1

S8293

Remove the three bolts (Item 1) [Figure 40-60-4] from

the left side of the instrument panel.

Move the instrument panel to one side to provide extra

clearance for easy access to engine speed control.
S7924

Remove the lever (Item 1), the two wave washers (Item
2) and the spacer (Item 3) [Figure 40-60-2].

40-60-1 E08 Service Manual

ENGINE SPEED CONTROL (CONT’D)

Removal And Installation (Cont’d)

Figure 40-60-5

1
2

S8323

Remove the bolt (Item 1) and bracket (Item 2) [Figure

40-60-5].

Disconnect the throttle cable (Item 3) [Figure 40-60-5]

from the throttle linkage.

Remove the spacer (Item 4) [Figure 40-60-5] from the

throttle lever.

40-60-2 E08 Service Manual

ENGINE SPEED CONTROL (CONT’D) Figure 40-60-8

Cable Removal

Figure 40-60-6

1
1

S8292

Remove the three bolts (Item 1) [Figure 40-60-8] from

S8291 the right side of the instrument panel.

Figure 40-60-9
Remove the two bolts (Item 1) [Figure 40-60-6] from the
throttle lever.

Figure 40-60-7
1
1 3
2

S8293

Remove the three bolts (Item 1) [Figure 40-60-9] from

S7924 the left side of the instrument panel.

Move the instrument panel to one side to provide extra

Remove the lever (Item 1), the two wave washers (Item clearance for easy access to engine speed control.
2) and the spacer (Item 3) [Figure 40-60-7].

40-60-3 E08 Service Manual

ENGINE SPEED CONTROL (CONT’D) Figure 40-60-12

Cable Removal (Cont’d)

Figure 40-60-10

1 1 2

1 S7581

Loosen the nuts (Item 1) [Figure 40-60-12] fastening the

S8323 cable to the bracket.

Disconnect the linkage (Item 2) [Figure 40-60-12] from

Remove the throttle cable (Item 1) [Figure 40-60-10] the bracket.
from the throttle linkage.
Move the cable away from the engine.
Figure 40-60-11
Figure 40-60-13

1
2

S8324

S8325

Remove the bolt and nut (Item 1) and bracket (Item 2)

[Figure 40-60-11]. Pull the cable (Item 1) [Figure 40-60-13] out the back of
the excavator.

40-60-4 E08 Service Manual

ENGINE SPEED CONTROL (CONT’D) Figure 40-60-16

Cable Installation

Figure 40-60-14

2
1

1 S8323

Insert the throttle cable (Item 1) [Figure 40-60-16]

S8325 through the throttle linkage.

Install the nut (Item 2) [Figure 40-60-16].

Position the throttle cable (Item 1) [Figure 40-60-14].
Figure 40-60-17
Figure 40-60-15

2
1

S8293
S8324

Install the three bolts (Item 1) [Figure 40-60-17] on the

Install the bracket (Item 1) and bolt and nut (Item 2) left side of the instrument panel.
[Figure 40-60-15].

40-60-5 E08 Service Manual

ENGINE SPEED CONTROL (CONT’D) Figure 40-60-20

Cable Installation (Cont’d)

Figure 40-60-18

1
1

S8291
1
Install the two bolts (Item 1) [Figure 40-60-20] and
S8292 tighten evenly until the throttle lever moves back and forth
at a comfortable tension.

Install the three bolts (Item 1) [Figure 40-60-18] on the Figure 40-60-21
right side of the instrument panel.

Figure 40-60-19

3 1
2

2 2 1

S7581

S7924 Connect the linkage (Item 1) [Figure 40-60-21] to the

injection pump control lever.

Install the spacer (Item 1), the two wave washers (Item 2) Slightly tighten the nuts (Item 2) [Figure 40-60-21] by
and lever (Item 3) [Figure 40-60-19]. hand.

40-60-6 E08 Service Manual

ENGINE SPEED CONTROL (CONT’D) Figure 40-60-23

Cable Installation (Cont’d)

Figure 40-60-22

2
2

1 2
1

S8777

Figure 40-60-24
S8291

Check if throttle lever (Item 1) does not interfere with

space in front of 12V socket (Item 2) [Figure 40-60-22].

1 1

S7581

Move throttle lever (Item 1) [Figure 40-60-22] and check

if injection pump control lever (Item 1) reaches both end
positions (Item 2) [Figure 40-60-23].

If not, set the correct end position of the throttle lever by

using the nuts (Item 1) [Figure 40-60-24].

When correct setting is obtained fully tighten the nuts

(Item 1) [Figure 40-60-24].

40-60-7 E08 Service Manual

40-60-8 E08 Service Manual
BLADE CONTROL Figure 40-70-3

Removal And Installation

1
Remove the instrument panel. (See Removal And
Installation on Page 40-220-1.)

Figure 40-70-1 2

3
1

S8327

1 Remove the cotter pin (Item 1) and pin (Item 2) [Figure

40-70-3].

1 Disconnect the linkage (Item 3) [Figure 40-70-3] from

S8335 the control valve.

Figure 40-70-4
Remove the four bolts (Item 1) [Figure 40-70-1] from the
cover.
1
Figure 40-70-2

1 1
2

S8328
1
Remove the cotter pins (Item 1) [Figure 40-70-4].
S8336
Remove the pin (Item 2) and remove the linkage (Item 3)
[Figure 40-70-4] from the control valve.
Remove the bolts (Item 1) [Figure 40-70-2] from the
cover.

Remove the cover from the excavator.

40-70-1 E08 Service Manual

BLADE CONTROL (CONT’D) Figure 40-70-7

Removal And Installation (Cont’d)

Figure 40-70-5

2
1
2

S8331

1 Remove the pin (Item 1) [Figure 40-70-7].

S8329
Remove the bell-crank (Item 2) [Figure 40-70-7].

Remove the bolts and nuts (Item 1) [Figure 40-70-5]. Figure 40-70-8

Remove the travel control and blade control (Item 2)

[Figure 40-70-5].

Figure 40-70-6
2

1
S8332

Remove the pin (Item 1) [Figure 40-70-8].

S8330 Remove the blade control handle (Item 2) [Figure 40-70-

8].

Remove the two bearings (Item 1) [Figure 40-70-6].

40-70-2 E08 Service Manual

BLADE CONTROL (CONT’D)

Disassembly And Assembly

Figure 40-70-9

S8333

Remove the two bushings (Item 1) [Figure 40-70-9] from

the blade control handle.

Figure 40-70-10

S8334

Remove the screws (Item 1) [Figure 40-70-10] and

plastic handle halves.

40-70-3 E08 Service Manual

40-70-4 E08 Service Manual
UPPERSTRUCTURE SLEW LOCK Disassembly And Assembly

Removal And Installation Figure 40-80-2

Remove the right floor panel. (See Right Floor Panel

Removal And Installation on Page 40-120-1.) 2

Remove the instrument panel. (See Removal And 1

Installation on Page 40-220-1.)

Figure 40-80-1 3

S8003
1

Remove the nut (Item 1) from the swing lock lever (Item
2). Remove the pin (Item 3) [Figure 40-80-2].

S8002

Remove the upperstructure slew lock lever (Item 1)

[Figure 40-80-1] from the upperstructure.

40-80-1 E08 Service Manual

40-80-2 E08 Service Manual
RIGHT PEDAL AND LINKAGE Control Linkage Removal And Installation

Pedal Removal And Installation Remove the instrument panel. (See Removal And
Installation on Page 40-220-1.)
Figure 40-90-1
Figure 40-90-2

4
2 1

1
1

S8034 1
S8335

Remove the cotter pin (Item 1) and washer (Item 2)

[Figure 40-90-1] from the pedal assembly. Remove the four bolts (Item 1) [Figure 40-90-2] from the
cover.
Remove the pin (Item 3) and remove the auxiliary pedal
(Item 4) [Figure 40-90-1]. Figure 40-90-3

S8336

Remove the bolts (Item 1) [Figure 40-90-3] from the

cover.

Remove the cover.

40-90-1 E08 Service Manual

RIGHT PEDAL AND LINKAGE (CONT’D) Figure 40-90-5

Control Linkage Removal And Installation (Cont’d)

Remove the right floor panel. (See Right Floor Panel

Removal And Installation on Page 40-120-1.)

Remove the lower right hand side cover. (See Lower

Right Side Cover Removal And Installation on Page 40-
210-3.)

Figure 40-90-4
1

1 S8340

Remove the nut (Item 1) [Figure 40-90-5].

2
Remove the control linkage assembly from the excavator.

S8339

Remove the cotter pin (Item 1) and the pin (Item 2)

[Figure 40-90-4].

Disconnect the linkage from the bellcrank.

Remove the nut (Item 3) [Figure 40-90-4].

40-90-2 E08 Service Manual

RIGHT PEDAL AND LINKAGE (CONT’D) Figure 40-90-8

Control Linkage Disassembly And Assembly

1 1
Figure 40-90-6

S8029
1

Remove the two pivot pins (Item 1) [Figure 40-90-8].

S8031
Figure 40-90-9

Remove the nut (Item 1) and linkage (Item 2) [Figure 40-

90-6].

Installation: Tighten the nut to 5,5 N•m (48.68 in-lb)

torque.

Figure 40-90-7

1
1 S8028

Remove the nut (Item 1) [Figure 40-90-9].

1 Installation: Tighten the nut to 5,5 N•m (48.68 in-lb)

torque.

S8030

Remove the two nuts (Item 1) [Figure 40-90-7].

Installation: Tighten the nuts to 5,5 N•m (48.68 in-lb)

torque.

40-90-3 E08 Service Manual

RIGHT PEDAL AND LINKAGE (CONT’D) Figure 40-90-12

Control Linkage Disassembly And Assembly (Cont’d)

Figure 40-90-10

1
3 3
1

S8025

4 4 Remove the pivot pin (Item 1) [Figure 40-90-12].

S8027
Figure 40-90-13

Remove the lever (Item 1), pedal assembly (Item 2),

spacers (Item 3) and bolts (Item 4) [Figure 40-90-10].

Figure 40-90-11

2
S8024

1 2
Remove the cotter pin (Item 1) and washer (Item 2)
[Figure 40-90-13].
S8026

Remove the cotter pin (Item 1) and washer (Item 2)

[Figure 40-90-11].

40-90-4 E08 Service Manual

RIGHT PEDAL AND LINKAGE (CONT’D)

Control Linkage Disassembly And Assembly (Cont’d)

Figure 40-90-14

S8023

Remove the pin (Item 1) and pedal (Item 2) [Figure 40-

90-14] from the bracket.

40-90-5 E08 Service Manual

40-90-6 E08 Service Manual
TRAVEL CONTROLS Right Hand Travel Control Disassembly And
Assembly
Right Hand Travel Control Removal And Installation
Figure 40-100-2
Remove the blade control. (See Removal And Installation
on Page 40-70-1.)

Figure 40-100-1

1 S7917

Remove the right hand control knob (Item 1) [Figure 40-

S7916 100-2].

Remove the pin (Item 1) [Figure 40-100-1] from the right

hand travel control.

40-100-1 E08 Service Manual

TRAVEL CONTROLS (CONT’D) Figure 40-100-5

Left Hand Travel Control Removal And Installation

Remove the instrument panel. (See Removal And

Installation on Page 40-220-1.)

Figure 40-100-3 1

2
1

S8337

1 Remove the cotter pin (Item 1) and pin (Item 2) [Figure

40-100-5].

1 Disconnect the linkage (Item 3) [Figure 40-100-5] from

S8335 the control valve.

Figure 40-100-6
Remove the four bolts (Item 1) [Figure 40-100-3] from
the cover.

Figure 40-100-4 1

2
1
1

S8338

1
Remove the bolts and nuts (Item 1) [Figure 40-100-6].
S8336
Remove the left hand travel control (Item 2) [Figure 40-
100-6].
Remove the bolts (Item 1) [Figure 40-100-4] from the
cover.

Remove the cover from the excavator.

40-100-2 E08 Service Manual

TRAVEL CONTROLS (CONT’D) Left Hand Travel Control Disassembly And Assembly

Left Hand Travel Control Removal And Installation Figure 40-100-9

(Cont’d)

Figure 40-100-7

S7917

S7920 Remove the left hand control knob (Item 1) [Figure 40-
100-9].

Remove the two bearings (Item 1) [Figure 40-100-7].

Figure 40-100-8

S7921

Remove the pin (Item 1) [Figure 40-100-8].

Remove the bellcrank (Item 2) [Figure 40-100-8].

40-100-3 E08 Service Manual

40-100-4 E08 Service Manual
LEFT PEDAL AND LINKAGE Control Linkage Removal And Installation

Pedal Removal And Installation Remove the instrument panel. (See Removal And
Installation on Page 40-220-1.)
Figure 40-110-1
Figure 40-110-2

4
1

3
2
S8010
1
S8335

Remove the cotter pin (Item 1) and washer (Item 2)

[Figure 40-110-1]. Remove the four bolts (Item 1) [Figure 40-110-2] from
the cover.
Remove the pin (Item 3) and remove the boom swing
pedal (Item 4) [Figure 40-110-1]. Figure 40-110-3

S8336

Remove the bolts (Item 1) [Figure 40-110-3] from the

cover.

Remove the cover.

40-110-1 E08 Service Manual

LEFT PEDAL AND LINKAGE (CONT’D) Figure 40-110-6

Control Linkage Removal And Installation (Cont’d)

Figure 40-110-4

3 1 S8342

Disconnect the tubeline (Item 1) [Figure 40-110-6] from

S8341 the control valve.

Remove the left floor panel. (See Left Floor Panel

Remove the cotter pin (Item 1) and pin (Item 2) [Figure Removal And Installation on Page 40-120-1.)
40-110-4].
Figure 40-110-7
Disconnect the linkage from the bellcrank.

Remove the bolts and nuts (Item 3) [Figure 40-110-4].

Figure 40-110-5

1
1

S8343

Disconnect the tubeline (Item 1) [Figure 40-110-7] from

the swivel joint.
S8012
Reposition the tubeline for easy removal of the control
linkage assembly.
Remove the bolts and nuts (Item 1) [Figure 40-110-5].
Remove the control linkage assembly.

40-110-2 E08 Service Manual

LEFT PEDAL AND LINKAGE (CONT’D) Figure 40-110-10

Control Linkage Disassembly And Assembly

Figure 40-110-8

1 1

S8017

Remove the cotter pin (Item 1) and washer (Item 2)

S8015 [Figure 40-110-10] from the shaft.

Figure 40-110-11
Remove the bearing (Item 1) [Figure 40-110-8] from the
shaft.

Figure 40-110-9
2

1
1

2 S8018

Remove the pin (Item 1) and pedal (Item 2) [Figure 40-

S8016 110-11].

Remove the pin (Item 1) and bellcrank (Item 2) [Figure

40-110-9] from the shaft.

40-110-3 E08 Service Manual

LEFT PEDAL AND LINKAGE (CONT’D)

Linkage Disassembly And Assembly (Cont’d)

Figure 40-110-12

1
2

S8019

Remove the bearing (Item 1) and pin (Item 2) [Figure 40-

110-12] from the shaft.

40-110-4 E08 Service Manual

FLOOR PANELS Right Floor Panel Removal And Installation

Description Figure 40-120-3

The floor of the excavator is divided into two floor panels.

Both floor panels provide accessibility to the hydraulic
components, electrical components and the fuel tank.

Left Floor Panel Removal And Installation

Figure 40-120-1 1

S6726

1 Remove the nut and bolt (Item 1) [Figure 40-120-3].

Figure 40-120-4

S6717

Remove the nut and bolt (Item 1) [Figure 40-120-1].

Figure 40-120-2
1

S6719

1 1 Remove the bolts (Item 1) [Figure 40-120-4] from the

right floor panel.

Remove the right floor panel.

S6717

Remove the bolts (Item 1) [Figure 40-120-2] from the left

floor panel.

Remove the left floor panel.

40-120-1 E08 Service Manual

40-120-2 E08 Service Manual
FUEL TANK Figure 40-130-3

Removal And Installation

Drain the fuel tank. (See Draining The Fuel Tank on Page
10-100-3.)

Remove the left floor panel. (See Left Floor Panel

Removal And Installation on Page 40-120-1.)

Figure 40-130-1

S8317

1 Remove the bolt (Item 1) [Figure 40-130-3] from the

mounting bracket.

Figure 40-130-4

S6756

1
Remove the hose (Item 1) [Figure 40-130-1] from the
fuel tank.

Remove the upper left hand side cover. (See Upper Left
Side Cover Removal And Installation on Page 40-210-1.)

Remove the lower left hand side cover. (See Lower Left
2
Side Cover Removal And Installation on Page 40-210-2.)

Figure 40-130-2
S6761

Remove the bolt (Item 1) and mounting bracket (Item 2)

[Figure 40-130-4].

Remove the fuel tank.

1

S8296

Disconnect the fuel level sender (Item 1) [Figure 40-130-

2] from the fuel tank.

Remove the hose (Item 2) [Figure 40-130-2] from the

fuel tank.

40-130-1 E08 Service Manual

40-130-2 E08 Service Manual
HORN

Removal And Installation

Remove the right floor panel. (See Right Floor Panel

Removal And Installation on Page 40-120-1.)

Figure 40-140-1

S8318

Remove the wire (Item 1) [Figure 40-140-1] from the

horn.

Remove the bolt and nut (Item 2) [Figure 40-140-1].

Remove the horn.

40-140-1 E08 Service Manual

40-140-2 E08 Service Manual
SWING FRAME Figure 40-150-2

Description

The swing frame is the casting connected to the boom

swing cylinder and the boom with top mounted boom
cylinder. The swing casting provides the pivot point for
the boom in the offset function and the up down motion of
the boom. The swing frame is connected to the 2
upperstructure by a top and bottom pivot pin.
1
Removal And Installation

Remove the bucket.

Remove the arm. (See Removal And Installation on Page S7672

40-170-1.)

Remove the boom. (See Removal And Installation on Install the pivot pin (Item 1), nut and bolt (Item 2) [Figure
Page 40-160-1.) 40-150-2].

Figure 40-150-1 Install a chain hoist on the swing frame [Figure 40-150-
2].

Figure 40-150-3
2

S6782 2

Remove the nut and bolt (Item 1) [Figure 40-150-1] from S7673
the rod end pivot pin.

Remove the pivot pin (Item 2) [Figure 40-150-1] from the Remove the bolt, washers and spacer (Item 1) [Figure
rod end of the cylinder. 40-150-3] from the top pivot pin.

Remove the top pivot pin (Item 2) [Figure 40-150-3] from

the swing frame.

40-150-1 E08 Service Manual

SWING FRAME (CONT’D) Bushing Removal

Removal And Installation (Cont’d) Figure 40-150-5

Figure 40-150-4

S7973
1
2 S7674
Remove the bottom bushing (Item 1) [Figure 40-150-5]
and top bushing (Item 2) [Figure 40-150-5] from the
Remove the bolt and washers (Item 1) [Figure 40-150-4] upperstructure by using a bolt, washers and nut.
from the bottom pivot pin.
The following parts will be needed for removal and
Remove the bottom pivot pin (Item 2) [Figure 40-150-4] installation of the bushings.
from the swing frame.
Bolt - 0.625 x 4.5 in long
Remove the swing frame from the excavator.
Nut - 0.625 in
Washer - 0.625 in I.D. x1.496 in O.D. x 0.25 in thick
Washer - 0.625 in I.D. x 2.925 in O.D. x 0.25 in thick
Spacer - 2.600 in I.D. x 2.925 in O.D. x 1.575 in thick

40-150-2 E08 Service Manual

SWING FRAME (CONT’D) Bushing Installation

Bushing Removal (Cont’d) Apply a film of grease to the outer diameter of the
bushing and the inner diameter of the casting.
Figure 40-150-6
Center the bushing in the casting hole.
2
NOTE: Make sure the bushing is centered into the
3 casting hole and is started in the hole evenly
and square.

Put the washer (Item 3) over the flanged end of the

bushing. Put the washer (Item 2) [Figure 40-150-6] over
the bushing hole casting, center the washer over the
bushing hole.

5 4 Install the bolt (Item 4) through the washers and the

bushing and install the nut (Item 5) [Figure 40-150-6].
1
S7972 Tighten the bolt and nut until the bushing is seated in the
casting.
Install the spacer (Item 1) and washer (Item 2) [Figure
40-150-6] over the flanged end of the bushing.

The spacer (Item 1) [Figure 40-150-6] must be centered

over the bushing to avoid contact between the bushing
and the spacer during removal.

Install the washer (Item 3) [Figure 40-150-6] on the

opposite end of the bushing. This washer must be
centered on the bushing and must not contact the
casting.

Install the bolt (Item 4) and the nut (Item 5) [Figure 40-
150-6] through the washers and spacer.

Tighten the bolt and nut to remove the bushing from the
casting.

Install the bushing so the flanged edge of bushing is

seated in the casting. The flanged edge of the bushings
must be installed from the top and bottom of the
upperstructure casting.

40-150-3 E08 Service Manual

SWING FRAME (CONT’D) Boom Pivot Bushing Installation

Boom Pivot Bushing Removal Apply a film of grease to the outer diameter of the
bushing and the inner diameter of the casting.
The following parts will be needed for removal and
installation of the boom pivot bushings. Center the bushing in the casting hole.

Bolt - 0.625 x 4.5 in long NOTE: Make sure the bushing is centered into the
Nut - 0.625 in casting hole and is started in the hole evenly
and square.
Washer - 0.625 in I.D. x1.375 in O.D. x 0.25 in thick
Washer - 0.625 in I.D. x 2.625 in O.D. x 0.25 in thick Put the washer (Item 3) over the flanged end of the
Spacer - 2.250 in I.D. x 2.625 in O.D. x 1.5 in thick bushing. Put the washer (Item 2) [Figure 40-150-7] over
the bushing hole casting, center the washer over the
bushing hole.
Figure 40-150-7
Install the bolt (Item 4) through the washers and the
2 bushing and install the nut (Item 5) [Figure 40-150-7].

3 Tighten the bolt and nut until the bushing is seated in the
casting.

5 4

1
S7972

Install the spacer (Item 1) and washer (Item 2) [Figure

40-150-7] over the flanged end of the bushing.

The spacer (Item 1) [Figure 40-150-7] must be centered

over the bushing to avoid contact between the bushing
and the spacer during removal.

Install the washer (Item 3) [Figure 40-150-7] on the

opposite end of the bushing. This washer must be
centered on the bushing and must not contact the
casting.

Install the bolt (Item 4) and the nut (Item 5) [Figure 40-
150-7] through the washers and spacer.

Tighten the bolt and nut to remove the bushing from the
casting.

40-150-4 E08 Service Manual

BOOM Figure 40-160-2

Description

The boom is the section that is connected to the swing

frame and the arm. The boom has the boom and arm
cylinders mounted on the top of the boom.

Removal And Installation

Figure 40-160-1 2

1
S7665

Remove the tie strap (Item 1) on the light wire harness.

Disconnect the harness (Item 2) [Figure 40-160-2].

Figure 40-160-3

S7660

Install a chain hoist on the boom [Figure 40-160-1]. 1

Remove the bucket. (See Removal And Installation on

Page 40-180-1.)
2
Remove the arm cylinder. (See Removal And Installation
on Page 20-21-3.) 1

Remove the arm. (See Removal And Installation on Page S7659

20-21-3.)

Remove the boom cylinder. (See Removal And Remove the nut and bolt (Item 1) [Figure 40-160-3] from
Installation on Page 20-20-2.) the pivot pin.

Remove the pivot pin (Item 2) [Figure 40-160-3].

40-160-1 E08 Service Manual

BOOM (CONT’D)

Removal And Installation (Cont’d)

Figure 40-160-4

S7671

Mark and remove the two hoses (Item 1) [Figure 40-160-

4] from the fittings.

Figure 40-160-5

S7666

Lift the boom from the swing frame [Figure 40-160-5].

Carefully move the boom while removing the hoses from
the center of the boom.

Installation: Feed the two arm cylinder hoses, the two

boom cylinder hoses and the two auxiliary hoses (Item 1)
through the inside of the boom and come out at the base
pivot of the arm cylinder. Continue feeding the two bucket
cylinder hoses (Item 2) through the end of the boom
(Item 3) [Figure 40-160-5].

40-160-2 E08 Service Manual

ARM Figure 40-170-2

Description
1
The arm is the section that is connected to the end of the
boom section and the bucket / bucket link. The excavator
comes with a standard length but has an optional long
arm.

Removal And Installation

2
Figure 40-170-1

S7661

Remove the nut and bolt (Item 1) [Figure 40-170-2] from

the rod end pivot pin.

Remove the pivot pin (Item 2) [Figure 40-170-2].

Remove the rod end of the cylinder from the arm.

Figure 40-170-3
S7660

Support the boom with a chain hoist [Figure 40-170-1].

2
1
Remove the bucket. (See Removal And Installation on
Page 40-180-1.)

Remove the bucket cylinder. (See Removal And

Installation on Page 20-23-2.) 3

4
IMPORTANT S7663

When repairing hydrostatic and hydraulic systems,

Install a strap (Item 1) [Figure 40-170-3] to support the
clean the work area before disassembly and keep all
arm.
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
Move the bucket cylinder hoses (Item 2) [Figure 40-170-
damage the system.
I-2003-0888
3] away from the arm.

Remove the nut and bolt (Item 3) [Figure 40-170-3] from

the arm pivot pin.

Remove the pivot pin (Item 4) [Figure 40-170-3].

Remove the arm.

40-170-1 E08 Service Manual

ARM (CONT’D) Arm To Bucket And Bucket Link Bushing Removal
And Installation
Arm To Boom Bushing Removal And Installation
Figure 40-170-6
Figure 40-170-4

1 1

P-60648
S7664

Remove the dust seals and bushings (Item 1) [Figure 40-

Remove the dust seals and bushings (Item 1) [Figure 40- 170-6] from both sides of the arm.
170-4] from both sides of the arm.
Figure 40-170-7
Figure 40-170-5

1
1

P-60650
P-60650

5 mm (0.197”)
5 mm (0.197”) TS-01614
TS-01614

Install the bushings until they are seated 5 mm (0.197 in)

Install the new bushings until they are seated 5 mm in the pin boss [Figure 40-170-7].
(0.197 in) in the pin boss [Figure 40-170-5].
NOTE: Install the new bushings with the tapered end
NOTE: Install the new bushings with the tapered end first (Item 1) [Figure 40-170-7].
first (Item 1) [Figure 40-170-5].
Install new dust seals with the lip facing out.
Install new dust seals with the lip facing out.

40-170-2 E08 Service Manual

BUCKET Figure 40-180-2

Removal And Installation

WARNING
2
AVOID INJURY OR DEATH
Adjust locking tabs on control linkage so that lift and
tilt control pedals or (Mechanical Hand Controls) are
locked in neutral when the seat bar is up. 1
W-2104-0199

2 S6228
Park the excavator on a flat level surface. Put the bucket
on the ground.
Remove the washer (Item 1) [Figure 40-180-2].
Figure 40-180-1
Remove the pivot pins (Item 2) [Figure 40-180-2].

Keep the pins clean. Do not damage the dust seals in the
arm when removing the bucket.

Install the arm into the bucket and align the hole.

Install the pivot pin.

Extend the bucket cylinder until the connecting link aligns

with the other bucket pin hole and install the pivot pin.
1
Install the washer (Item 1) [Figure 40-180-2].

S6227 Install the pin retainer clips (Item 1) [Figure 40-180-1].

Add grease to the pivot pins before operation.

Remove the pin retainer clips (Item 1) [Figure 40-180-1].

WARNING
AVOID INJURY OR DEATH
Never use attachments or buckets which are not
approved by Bobcat Company. Buckets and
attachments for safe loads of specified densities are
approved for each model. Unapproved attachments
can cause injury or death.
W-2052-0907

40-180-1 E08 Service Manual

40-180-2 E08 Service Manual
TAILGATE Figure 40-190-3

Removal And Installation

Remove the seat. (See Removal And Installation on

Page 40-30-1.)
1
Open the tailgate.

Figure 40-190-1

S8308

1 1 Remove the nuts and bolts (Item 1) [Figure 40-190-3]

from the hinges.

Move the tailgate slightly to the right to free it from the

support, then remove it from the excavator.

S8226 S8224 Figure 40-190-4

Install and tighten two C-clamps (Item 1) [Figure 40-190-

1] equally spaced from the sides on the top of the
2
tailgate.

NOTE: To prevent paint damage use rubber pads on

the c-clamps. 1

Figure 40-190-2

S8309

Remove the cotter pins and washers (Item 1) [Figure 40-

190-4] from the support.

Remove the support (Item 2) [Figure 40-190-4] from the

excavator.

S8307

Install chains to the c-clamps and chain hoist [Figure 40-

190-2].

40-190-1 E08 Service Manual

TAILGATE (CONT’D)

Latch Removal And Installation

Open the tailgate.

Figure 40-190-5

1 2

S8228

Remove the bolt (Item 1) and bracket (Item 2) [Figure

40-190-5].

Remove the key lock assembly (Item 3) [Figure 40-190-

5] from the tailgate.

40-190-2 E08 Service Manual

COUNTERWEIGHTS

Rear Counterweight Removal And Installation

Open the tailgate.

Figure 40-200-1

S8310

Remove the nuts and bolts (Item 1) [Figure 40-200-1]

from the rear counterweight.

Installation: Tighten the bolts and nuts to 105 - 115 N•m

(78 - 85 ft-lb) torque.

Remove the rear counterweight.

NOTE: Approximate weight of the rear counterweight

is 20 kg (44 lb).

40-200-1 E08 Service Manual

COUNTERWEIGHTS (CONT’D) Figure 40-200-3

Left Side Counterweight Removal And Installation

Remove the rear counterweight. (See Rear

1
Counterweight Removal And Installation on Page 40-
200-1.)

Remove the lower left hand side cover. (See Lower Left
Side Cover Removal And Installation on Page 40-210-2.)

Figure 40-200-2

P103123
1

NOTE: For S/N A4BP11130 & Below, the top bolt has
a spacer (Item 1) [Figure 40-200-3] between
the counterweight and frame. Failure to install
the spacer could result in cracking of the
counterweight
2

S7556

Remove the bolt (Item 1) and nut (Item 2) [Figure 40-

200-2] from the counterweight.

Installation: Tighten the bolts and nuts to 105 - 115 N•m

(78 - 85 ft-lb) torque.

Remove the left hand counterweight.

NOTE: Approximate weight of the left hand

counterweight is 20 kg (44 lb).

40-200-2 E08 Service Manual

COUNTERWEIGHTS (CONT’D) Figure 40-200-5

Right Side Counterweight Removal And Installation

Remove the rear counterweight. (See Rear

1
Counterweight Removal And Installation on Page 40-
200-1.)

Remove the lower right hand side cover. (See Lower

Right Side Cover Removal And Installation on Page 40-
210-3.)

Figure 40-200-4

P103123

1 NOTE: For S/N A4BP11130 & Below, the top bolt has
a spacer (Item 1) [Figure 40-200-5] between
the counterweight and frame. Failure to install
the spacer could result in cracking of the
counterweight.

S7558

Remove the bolt (Item 1) and nut (Item 2) [Figure 40-

200-4] from the counterweight.

Installation: Tighten the bolts and nuts to 215 N•m (159

ft-lb).

Remove the right hand counterweight.

NOTE: Approximate weight of the right hand

counterweight is 20 kg (44 lb).

40-200-3 E08 Service Manual

40-200-4 E08 Service Manual
SIDE COVERS Upper Right Side Cover Removal And Installation

Upper Left Side Cover Removal And Installation Figure 40-210-2

Figure 40-210-1
1
1
2
1

S7956

S7974
Remove the bolts (Item 1) [Figure 40-210-2] from the
upper right hand side cover.
Remove the fuel fill cap (Item 1) [Figure 40-210-1] from
the fuel tank. Remove the upper right hand side cover.

Remove the bolts (Item 2) [Figure 40-210-1] from the

upper left hand side cover.

Remove the upper left hand side cover.

40-210-1 E08 Service Manual

SIDE COVERS (CONT’D) Figure 40-210-5

Lower Left Side Cover Removal And Installation

Figure 40-210-3

1
S6781

Remove the bolt (Item 1) [Figure 40-210-5] from the

S6717 undercarriage.

Figure 40-210-6
Remove the three bolts (Item 1) [Figure 40-210-3] from
the floorplate.

Figure 40-210-4

1 1

S7975

Remove the nut (Item 1) [Figure 40-210-6] from the

S6715 lower cover.

Remove the lower left hand side cover.

Remove the bolt (Item 1) [Figure 40-210-4] from the
front of the lower cover.

40-210-2 E08 Service Manual

SIDE COVERS (CONT’D) Figure 40-210-9

Lower Right Side Cover Removal And Installation

Figure 40-210-7

1
1
1

1 S7976

Remove the nut (Item 1) [Figure 40-210-9] from the

S6719 lower cover.

Remove the lower right hand side cover.

Remove the three bolts (Item 1) [Figure 40-210-7] from
the floorplate.

Figure 40-210-8

S6716

Remove the bolt (Item 1) [Figure 40-210-8] from the

undercarriage.

40-210-3 E08 Service Manual

40-210-4 E08 Service Manual
INSTRUMENT PANEL Figure 40-220-3

Removal And Installation

Figure 40-220-1 1

1
1

S8292

Remove the three bolts (Item 1) [Figure 40-220-3] from

S8291 right hand side of the instrument panel.

Figure 40-220-4
Remove the two bolts (Item 1) [Figure 40-220-1] from
the throttle lever.

Installation: Tighten the two bolts (Item 1) [Figure 40- 1

220-1] evenly until the throttle lever moves back and forth
at a comfortable tension.

Figure 40-220-2
1

1 3
2
1
S8293

Remove the three bolts (Item 1) [Figure 40-220-4] from

the left hand side of the instrument panel.

S7924

Remove the lever (Item 1), the two wave washers (Item
2) and the spacer (Item 3) [Figure 40-220-2].

40-220-1 E08 Service Manual

INSTRUMENT PANEL (CONT’D) Disassembly And Assembly

Removal And Installation (Cont’d) Figure 40-220-6

Figure 40-220-5 4

1 2 3

S8953

S7997
Remove the light switch (Item 1), switch plug (Item 2),
battery light (Item 3) and temperature light (Item 4)
Pull back the instrument panel, mark and disconnect all [Figure 40-220-6] from the instrument panel.
connectors [Figure 40-220-5].
Figure 40-220-7
Remove the instrument panel.

1 1

S8573

Remove the two nuts (Item 1) and bracket (Item 2)

[Figure 40-220-7] from the fuel gauge.

Remove the fuel gauge from the instrument panel.

40-220-2 E08 Service Manual

INSTRUMENT PANEL (CONT’D) Figure 40-220-10

Disassembly And Assembly (Cont’d)

Figure 40-220-8

1
S8316

Remove the accessory socket (Item 1) [Figure 40-220-

S8575 10] from the instrument panel.

Remove the nut (Item 1) [Figure 40-220-8] from the key

switch.

Remove the key switch from the instrument panel.

Figure 40-220-9

1 1

S8315

Remove the two nuts (Item 1) [Figure 40-220-9] from the

hourmeter.

Remove the hourmeter from the instrument panel.

40-220-3 E08 Service Manual

40-220-4 E08 Service Manual
ELECTRICAL SYSTEM

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-5
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-5
Fuel Timer Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-6

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Maintaining Battery Charge Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Battery Service During Machine Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-3
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-4
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-5

ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Full Field Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Alternator Regulator Test With Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-7

STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Light Bulb Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Light Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2

FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

50-01 E08 Service Manual

50-02 E08 Service Manual

3$1(/
*5281'

5(' :+7

%/8 5('
%/. %/.

35,17('0$<

*

1710 1345

1345
1710
2875
1340
1640
1471 1470
1590

6010 2210 8090

6000 6000 1330

2000 2000

3010
1380

1400

3030
2020
2300 1590

2310
6310 1440 3000

2210
2300
1340 2310

6310 1450 8080

2320
2870

2890
2870 2220

2220 1460 8060

1440
1450
1460
2320

6020
3040
1490
1430 8040
2090 1430
1610 1490 1350

1670 1630
1660
2110
1670
1610

1520
1630

6020
1660 6000 1510 GROUND PANEL
6010
2110 2190
2090 2200

1650 1510 GLOW PLUGS

1620

1520
1600

START
1300 BATTERY
1620 2200 1300
1500
RUN
1500

2890
1330
1500
1590

6000
1350
3040
1300
1510
1520
8040
8060
8080
8090
3000
2190
1600

1500
1590

6000
1350
3040
1300
1510
1520
8040
8060
8080
8090
3000
2100
2190
1600

2895
1640 2070 2070
2890
1390 1700

2940
1335
1360
1330

1700
1360

1000
1640 1640

1500
1590
1390
1480 1470
1410 1410
1550 1550 1550

1330
1500
1590
2890
1340 1340 1010
1640 1640 1640 8010
1470 1470 1470
1590 1590 1590
1550 1550 1550
1380

1400

1560 1560 1560 1010

1020 2230
1350
8020 8020 2020
1420

3000
2190

2170
1590
1600

2180

2890
1560

2010
2900
1570
8090
2170
8000 2000

2950

2160
1580
2180 2050
8060 8080
3020 8070 8070
8050 3010 2040

3030
2910
2030

1475 1475 1470 2080

1680 1680 1640 8040
1485

8050
1690

3040 1310 RED WHT 8030 8030

2160 1320 BLU RED 8100 8100
2080 BLK BLK 2880 2880
1690
1020
2950

1130 1110
1370
1140

1120

2010
1370

1300

1310

1340

1420

1485

1320

1330

1130 1120 1110

1150 8000 8010

1500 2050 1540 2040 1530 2030

1060

1100
1040
1030

1050

1070

1090
1080

(PRINTED APRIL 2019)

1140

1150

1510
1540
1520
1530
7330650 (0)
ELECTRICAL SYSTEM INFORMATION

Glossary Of Electrical Symbols

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107

3520 C C 3520 harness to a component. The internally grounded.

3510 B B 3510
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector LIGHT -
pins can be numbered alphabetical
C107
A A (shown) or numerical (1, 2, 3 etc.).
3500 3500
3520
C C
3520
The harness wires numbers are
B B
3510 3510 called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or
connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.

COMPONENTS

- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ when released.)
POSITIVE ELECTRICAL CIRCUIT -
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT -
Indicates battery ground circuit.
on switch application.)

SWITCH - Double Pole - Double

Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
electrical current to supply voltage to on switch application.
G the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.

GROUND - Used to represent an

external ground connection.

50-10-1 E08 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION SYMBOL DESCRIPTION

COMPONENTS SOLENOID - Fuel and Traction Lock -

HOLD PULL
15 ohm B Dual solenoids. (The ohm rating of
I
SWITCH - Ignition - Multi position the solenoid coils are listed next to
B
switch to activate various start 0.5 ohm A the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.

HORN - Audible alarm. Sound is

START
RUN activated manually by a switch to
OFF
warn personnel.

BUZZER - Audible alarm. Sounds at a

1 SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
positions.
3

4 5 RESISTOR - Limits current flow.

6

DIODE - Allows electrical current to

ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD

87A 87 86 RELAY - Uses a low amp switch to MOTOR - Wiper - Single or multi
control a high amp component. A speed motor.
30 85 B

FUSE - Used to protect the wire MOTOR - Washer - Single speed.

harness from an overloaded circuit. M
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL

3700 3710
SPLICE (•) - Used to show when
3110 multiple wires are connected together
on the schematic. HOURMETER - Records the time the
+
H - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
7.7 o h m - +
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.

SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7 .5 o h m magnetically. (The ohm rating and gauge are marked with a icon that
12V S
voltage of the solenoid coil is listed I
represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

50-10-2 E08 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION

SENDERS AND SENSORS

+ PRESSURE SENDER - Provides a

A
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B listed to show volt at high and low
0.5 - 7.5 V
setting.)

B PRESSURE SWITCH - Switch opens

A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)

to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000ohm ohm rating is listed to show ohms at
high and low setting.)

A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)

FUEL SENDER - Provides a variable

B
resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)

C
HALL EFFECT SENSOR - Detects
B linear or rotary position and provides
A a proportional variable voltage.

A SPEED SENSOR - magnetic pickup -

detects rpm.
B

50-10-3 E08 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual 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-EN-0614

PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn engine. 2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE

1. Engine accessory drive belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

50-10-4 E08 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse And Relay Location / Identification

Description Figure 50-10-2

Figure 50-10-1
8 7

1
6 5

2 4 3

2 1
B14855

S8281
1. Power Socket - 15 A
2. Ignition - 10 A (SW)
The excavator has a 12 volt, negative ground electrical
system. The electrical system is controlled by fuses and 3. Timer - 25 A (UNSW)
relays located on top of the engine compartment (items 1 4. Beacon - 10 A
and 2) [Figure 50-10-1] The fuses will protect the 5. Switch Power - 10 A
electrical system when there is an electrical overload. 6. Valves horn - 10 A
The reason for the overload must be found before
starting the engine again. 7. Switched timer - 10 A
8. Light - 10 A
Always replace fuses using the same type and capacity.

The three electrical relays (Item 2) [Figure 50-10-1] are

located in the engine compartment below the tailgate to
the right. The three relays control the starter, glow plugs
and switched power circuits.

50-10-5 E08 Service Manual

ELECTRICAL SYSTEM INFORMATION (CONT’D)

Fuel Timer Location / Identification

Figure 50-10-3

S8282

The fuel shutoff timer (Item 1) [Figure 50-10-3] is located

on top of the engine compartment.

Figure 50-10-4

S0915

There are two diodes in the harness behind the starter

(Item 1) [Figure 50-10-4]. The starter is located next to
the cleaner, behind the access panel under the seat. The
diodes are for alternator feedback protection and the
glow plug during start function.

50-10-6 E08 Service Manual

BATTERY

Location

Figure 50-20-1

S8283

The battery (Item 1) [Figure 50-20-1] is located behind

the upper left hand side cover.

Figure 50-20-2

S8284

Battery cables (Item 1) [Figure 50-20-2] are accessible

by opening the tailgate.

50-20-1 E08 Service Manual

BATTERY (CONT’D)

Servicing
WARNING
See the SERVICE SCHEDULE for the correct service
interval. (See SERVICE SCHEDULE on Page 10-70-1.)
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
The Bobcat brand battery supplied with your machine is
contact. Wear goggles, protective clothing and
sealed and does not require watering. Proper charging
rubber gloves to keep acid off body.
and storage are important to maximize the life of all
batteries.
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
Figure 50-20-3
and wash eye with clean, cool water for at least 15
minutes.

If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

Maintaining Battery Charge Level

All batteries will self-discharge over time. This machine

has features that require battery power even when the
machine is not being used. Use of a quality battery
maintainer is highly recommended to ensure that your
P9589 P9590
machine is ready to start when you need it and avoid
costly battery replacement.

Simple steps for reliability and long battery life: Battery Maintainers

• Keep battery posts and terminals clean [Figure 50- Use a good quality battery maintainer to keep the battery
20-3]. above 12.4 volts for machines that are not frequently
used. Batteries below 12.4 volts must first be charged
• Keep terminals tight. using a battery charger. Solar maintainers should have a
• Remove corrosion from battery and terminals with minimum capacity of 10 watts to be effective.
sodium bicarbonate (baking soda) and water solution.
Battery Service During Machine Storage
• Put Bobcat Battery Saver or grease on the battery
terminals and cable ends to prevent corrosion.
Remove the battery if storing the machine for an
• Operate the machine for at least 15 minutes to extended period of time. Fully charge the battery. Store
recover from the battery drain caused by engine the battery in a cool dry place above freezing and boost
startup whenever practical. charge periodically. If battery removal is not desired, a
• Maintain the battery charge level. This is a key factor good quality battery maintainer must be used to
for long battery life. compensate for battery self-discharge and parasitic loads
• Charge a severely discharged battery with a battery from machine controllers, accessories, and features such
charger instead of relying on the machine charging as connected machine intelligence.
system. (See Battery Charging on Page 50-20-3.)
• Check the battery state of charge every 30 days on
machines that are not frequently used. (See Battery
Testing on Page 50-20-3.)

50-20-2 E08 Service Manual

BATTERY (CONT’D) Battery Charging

Battery Testing A battery charger designed for 12 volt charging systems

is recommended. Follow the battery charger
Figure 50-20-4 manufacturer’s instructions to charge the battery to 12.6
volts (100% charge). Batteries should be charged at
room temperature to avoid an undercharge or overcharge
condition. Never attempt to charge a frozen battery.

The following table can be used to identify the

approximate amount of time required to charge a
1
discharged battery. Allow at least 60 minutes after
operating the machine or charging the battery to get an
accurate reading.

STATE CHARGER MAXIMUM RATE

BATTERY
OF
VOLTAGE
CHARGE 30 Amps 20 Amps 10 Amps
P-30836 12.6 V 100% READY TO USE
12.4 V 75% 0.9 hr. 1.3 hr. 2.5 hr.
The simplest and most common check to determine 12.2 V 50% 1.9 hr. 2.7 hr. 5.1hr.
battery state of charge is to use a digital multimeter or
voltmeter (Item 1) [Figure 50-20-4]. 12.0 V 25% 2.9 hr. 4.3 hr. 7.8 hr.
11.8 V 0% 4.0 hr. 5.7 hr. 10.7 hr.
A battery found below 12.4 volts must be charged to
100% charge per the battery charger’s recommendation. NOTE: Use a good quality automatic charger to avoid
Allow at least 60 minutes after operating the machine battery damage from overcharging.
or charging the battery to get an accurate reading.

If the reading is less than 12.4 volts after the battery has
been charged for several hours, see your dealer to have
a more thorough battery test performed. WARNING
The freezing point of battery electrolyte is dependent on
BATTERY GAS CAN EXPLODE AND CAUSE
the battery state of charge. Keeping the battery voltage
SERIOUS INJURY OR DEATH
above 12.4 volts will help prevent batteries from freezing,
Keep arcs, sparks, flames and lighted tobacco away
even at extremely low temperatures.
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
If the battery freezes, the internal grid may be damaged
and the case will be distorted or cracked. If this happens,
Do not jump start or charge a frozen or damaged
dispose of the battery according to local regulations.
battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910

50-20-3 E08 Service Manual

BATTERY (CONT’D) Figure 50-20-7

Removal And Installation

Remove the upper left hand side cover.

Figure 50-20-5

1 1

S8286

Remove the two bolts (Item 1) [Figure 50-20-7] from the

hold down clamp and remove the clamp.

S8285 Remove the battery.

Always clean the terminals and the cable ends, even

Disconnect the negative (-) cable (Item 1) [Figure 50-20- when installing a new battery.
5] first.
Install the battery. Install the hold down clamp and tighten
Figure 50-20-6 the bolts.

Connect the battery cables. Connect the negative (-)

cable (Item 1) [Figure 50-20-5] last to prevent sparks.

1 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.
S6765
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention
Disconnect the positive (+) cable (Item1) [Figure 50-20- and wash eye with clean, cool water for at least 15
6]. minutes.

If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

50-20-4 E08 Service Manual

BATTERY (CONT’D) Figure 50-20-9

Using A Booster Battery (Jump Starting)

IMPORTANT
If jump starting the excavator from a second
machine: 1
When jump starting the excavator from a battery
installed in a second machine, make sure the engine
is NOT running while using the glow plugs. High
voltage spikes from a running machine can burn out
R0092
the glow plugs.
I-2060-0906
Connect one end of the second cable to the negative (-)
If it is necessary to use a booster battery to start the terminal of the booster battery. Connect the other end of
engine. BE CAREFUL! There must be one person for the same cable to the bolt at the front left corner of the
starting the excavator and one person to connect and excavator (Item 1) [Figure 50-20-9].
disconnect the battery cables.

Engage the upperstructure slew lock. Be sure the key

switch is OFF. The booster battery must be 12 volt.

Open the tailgate.

IMPORTANT
Figure 50-20-8 Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the excavator.
(Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2223-0903

1 Start the engine. After the engine has started, remove

the negative (-) cable first (Item 1) [Figure 50-20-9].

Disconnect the cable from the battery (Item 1) [Figure

50-20-8].
R0063

Remove the cover to the left of the operator’s seat to

access the battery.

Connect one end of the first cable to the positive (+)

terminal of the booster battery. Connect the other end of
the same cable to the positive (+) terminal (Item 1)
[Figure 50-20-8] on the excavator battery.

50-20-5 E08 Service Manual

50-20-6 E08 Service Manual
ALTERNATOR Tests

Description Perform the following alternator tests in this order:

Figure 50-30-1 Alternator Output Test: Tests the alternator and regulator
output.
3
4 2
Full Field Test: Tests the maximum amperage output of
1 the alternator.

Alternator Regulator Test: Tests the regulator voltage

output.

P-10018

Figure 50-30-2

1
3 2
4

5 P-10023

The output terminal (Item 1) [Figure 50-30-1] and

[Figure 50-30-2].

The battery or power sensing terminal (Item 2) [Figure

50-30-1] and [Figure 50-30-2].

The ignition terminal (Item 3) [Figure 50-30-1] and

[Figure 50-30-2].

Open terminal not used in the excavator harness (Item 4)

[Figure 50-30-1] and [Figure 50-30-2].

Access hole for full field test (Item 5) [Figure 50-30-1]

and [Figure 50-30-2].

50-30-1 E08 Service Manual

ALTERNATOR (CONT’D) Full Field Test

Alternator Output Test Start the engine and run at full rpm.

Check the battery and battery connections. (See Figure 50-30-4

Removal And Installation on Page 50-20-4.)

Figure 50-30-3

P-10021

S8288 Place a small screw driver in the test port (Item 1)

[Figure 50-30-4] to provide a ground to the alternator
case. This will give maximum amperage output from the
Use an induction meter and loop around the positive (+) alternator.
wire (Item 1) [Figure 50-30-3] at the alternator.
NOTE: The Full Field Test should only last long
Start the engine and run at full rpm. enough to get ammeter reading to prevent
damage to the alternator.
The ammeter reading should be between 35 and 40 amp.
The ammeter reading should be above 35 amp.
If the ammeter reading is less than 35 amp do the full
field test. If the ammeter reading is low, repair or replace the
alternator.

WARNING
WARNING
AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh AVOID INJURY OR DEATH
air must be added to avoid concentration of exhaust When an engine is running in an enclosed area, fresh
fumes. If the engine is stationary, vent the exhaust air must be added to avoid concentration of exhaust
outside. Exhaust fumes contain odorless, invisible fumes. If the engine is stationary, vent the exhaust
gases which can kill without warning. outside. Exhaust fumes contain odorless, invisible
W-2050-0807 gases which can kill without warning.
W-2050-0807

50-30-2 E08 Service Manual

ALTERNATOR (CONT’D) Alternator Regulator Test With Voltmeter

Alternator Regulator Test Figure 50-30-5

Disconnect the fuel stop solenoid connector.

Turn the lights on (if equipped) and crank the engine for 2
30 seconds to discharge the battery. 1

Connect the fuel stop solenoid connector.

Start the engine and run at full rpm.

The ammeter reading should be around 35 amp and

slowly decrease with alternator output.

If ammeter reading is low or does not decrease with time,

replace the alternator's regulator. S8289

Disconnect the negative (-) cable from the battery.

Connect the positive (+) voltmeter lead to the positive (+)
Reconnect the alternator wires. battery terminal (Item 1) [Figure 50-30-5].

Reconnect the negative (-) cable from the battery. Connect the negative (-) voltmeter lead to the negative (-)
battery terminal (Item 2) [Figure 50-30-5].
NOTE: The alternator regulator test can also be run
using a voltmeter. Start the engine and run at full rpm.

The voltmeter should read between 13,9 and 14,7 volt.

If the voltmeter reading is not within this range, replace

the alternator's regulator.

IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

50-30-3 E08 Service Manual

ALTERNATOR (CONT’D) Figure 50-30-8

Removal And Installation

Open the tailgate.

Figure 50-30-6

1
1

S8285

Disconnect the negative (-) cable (Item 1) [Figure 50-30-

8] from the battery.

S6774 Figure 50-30-9

Remove the fill cap (Item 1) [Figure 50-30-6] from the

1
hydraulic reservoir.

Figure 50-30-7

1
1

S8242

1
Disconnect the red wire (Item 1) [Figure 50-30-9].
1
Disconnect the wire harness connector (Item 2) [Figure
S7554 50-30-9].

Remove the four bolts (Item 1) [Figure 50-30-7].

Remove the cover.

NOTE: Allow the muffler to cool down before

removing the alternator.

50-30-4 E08 Service Manual

ALTERNATOR (CONT’D)

Removal And Installation (Cont’d)

Figure 50-30-10

S8243

Remove the alternator adjustment bolt (Item 1) and lower

mounting bolt (Item 2) [Figure 50-30-10].

NOTE: Alternator will fall if not supported while

removing bolts.

Figure 50-30-11

1 2 3 4
P-29995

NOTE: The lower alternator mounting bolt (Item 1) is

assembled with a washer (Item 2) spacer (Item
3) and retaining bracket with nut (Item 4)
[Figure 50-30-11] which will fall during
disassembly.

Remove belt from the alternator pulley.

Remove alternator.

50-30-5 E08 Service Manual

ALTERNATOR (CONT’D) If the charging system malfunctions check the following:

Charging System Inspection Check the condition and tension of the alternator belt.
(See Adjusting The Alternator Belt on Page 10-160-1.) If
belt is worn or deteriorated, replace.

WARNING Inspect the alternator wiring harness and connectors at

alternator. Harness and connectors must be clean and
tight.
AVOID INJURY OR DEATH Check the fuse for the alternator in the fuse panel. If fuse
Batteries contain acid which burns eyes and skin on is burned, find the cause and repair / replace. If fuse is in
contact. Wear goggles, protective clothing and doubt, remove it and check for continuity.
rubber gloves to keep acid off body.
Check the electrolyte level in the battery. Add distilled
In case of acid contact, wash immediately with water. water as needed. (Does not apply to maintenance free
In case of eye contact get prompt medical attention batteries.)
and wash eye with clean, cool water for at least 15 Verify the charge of the battery. Make sure battery is fully
minutes. charged.
If electrolyte is taken internally drink large quantities Disconnect the battery cables (negative first, then
of water or milk! DO NOT induce vomiting. Get positive). Inspect the cable clamps and battery posts for
prompt medical attention. corrosion. Remove acid or corrosion from the battery and
W-2065-0807 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.

WARNING
BATTERY GAS CAN EXPLODE AND CAUSE
SERIOUS INJURY OR DEATH
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.

Do not jump start or charge a frozen or damaged

battery. Warm battery to 16°C (60°F) before
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging.
W-2066-0910

IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

50-30-6 E08 Service Manual

ALTERNATOR (CONT’D)

Parts Identification

1. Alternator 15. Nut

2. Frame Assembly 16. Insulator
3. Plate 17. Bolt
4. Screw 18. Screw
5. Bearing 19. Nut
6. Stud 20. Nut
7. Frame End 21. Rotor Assembly
8. Holder 22. Bearing
9. Holder 23. Cover
10. Seal 24. Pulley
11. Brush 25. Spacer
12. Spring 26. Bolt
13. Regulator 27. Screw
14. Cover 28. Screw

4
6 3 23
2 5 22

21

28

24
14
26
27
25 10
20 9
15
16
19 28
12
7 11
18
1
13
17 8

C-3456

50-30-7 E08 Service Manual

50-30-8 E08 Service Manual
STARTER Figure 50-40-3

Removal And Installation

Stop the engine. 1

Remove the air cleaner. (See Removal And Installation

on Page 60-30-1.)

Figure 50-40-1

1 1

S8007

Remove the mounting bolts (Item 1) [Figure 50-40-3]

from the starter.

Installation: Tighten the bolts to 25 N•m (18 ft-lb) torque.

Remove the starter from the bell housing.

S8285

Disconnect the negative (-) cable (Item 1) [Figure 50-40-

1] from the battery.

Mark the starter wires for ease of assembly.

Figure 50-40-2

S8020

Disconnect the wires (Item 1) [Figure 50-40-2] from the

starter.

50-40-1 E08 Service Manual

STARTER (CONT’D) Cleaning And Inspection

Parts Identification

Figure 50-40-4
WARNING
AVOID INJURY OR DEATH
1 Wear safety glasses to prevent eye injury when any
2 of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
4 • Engine is running.
3 • Tools are being used.
W-2019-0907

5
Use a brush and air pressure to clean the drive, field
coils, armature and starter housing.
10
NOTE: Do not use solvent to clean the drive
assembly. The solvent will remove the
lubricant and the drive will slip.
7
Check the following items:
6
1. Starter Armature
2. Frame 8 Broken or burned insulation.
3. Brush Loose connections at commutator.
4. Armature 9 Open or grounded circuits.
5. Yoke Worn shaft or bearings.
6. Housing Rough commutator.
7. Pinion
8. Clutch Field Coils
9. Housing Broken or burned insulation.
10. Plunger B-19162 Electrical continuity.
Brush connections.

Drive Gear
Worn teeth.
Tooth engagement (drive gear must engage ring gear
by half the depth of the ring gear tooth).

Brush Holders
Broken springs.
Broken insulation.
Spring tension.

50-40-2 E08 Service Manual

LIGHTS Light Bulb Removal And Installation

Boom Light Removal And Installation Figure 50-50-3

Figure 50-50-1

3
1

1 S7547

S7547
Cut the tie-strap (Item 1) [Figure 50-50-3].

Cut the tie-strap (Item 1) [Figure 50-50-1]. Disconnect the wire harness (Item 2) [Figure 50-50-3].

Disconnect the wire harness (Item 2) [Figure 50-50-1]. Turn the light bulb assembly (Item 3) [Figure 50-50-3]
counterclockwise and remove from the housing.
Figure 50-50-2
Figure 50-50-4

S7548

S7549

Remove the nut and bolt (Item 1) [Figure 50-50-2] and

remove the boom light. Complete light bulb assembly [Figure 50-50-4].

NOTE: The light bulb can not be removed from the

light bulb assembly. If light bulb is broken, the
entire assembly must be replaced.

50-50-1 E08 Service Manual

LIGHTS (CONT’D) Figure 50-50-7

Light Switch Removal And Installation

Figure 50-50-5

1
1

S8292

Remove the three bolts (Item 1) [Figure 50-50-7] from

S8291 the right hand side of the instrument panel.

Figure 50-50-8
Remove the bolts (Item 1) [Figure 50-50-5] from the
throttle lever.

Installation: Tighten the bolts (Item 1) [Figure 50-50-5]

evenly until the throttle lever moves back and forth at a
comfortable tension. 1

Figure 50-50-6

1 3
2
1

S8293

Remove the three bolts (Item 1) [Figure 50-50-8] from

the left hand side of the instrument panel.

S7924

Remove the lever (Item 1), the two wave washers (Item
2) and the spacer (Item 3) [Figure 50-50-6].

50-50-2 E08 Service Manual

LIGHTS (CONT’D)

Light Switch Removal And Installation (Cont’d)

Figure 50-50-9

S7998

Pull back the instrument panel and disconnect the light

switch connector (Item 1) [Figure 50-50-9].

Figure 50-50-10

S8952

Remove the light switch (Item 1) [Figure 50-50-10] from

the instrument panel.

50-50-3 E08 Service Manual

50-50-4 E08 Service Manual
FUEL LEVEL SENDER Testing

Removal And Installation Use an ohmmeter to check the resistance of the fuel level
sender.
Remove the upper left hand side cover. (See Upper Left
Side Cover Removal And Installation on Page 40-210-1.) Figure 50-60-3

Figure 50-60-1
INSERT ONE
OHM TESTER
FUEL SENDER LEAD INTO
TOP VIEW EACH OF THE
FUEL SENDER
CONNECTIONS

FUEL SENDER
1 TOP VIEW

S8296

Disconnect the wire harness (Item 1) [Figure 50-60-1]

from the fuel level sender.

Figure 50-60-2

B-14140

Insert one of the ohm tester leads into each of the fuel
sender electrical connectors in the end of the fuel sender
[Figure 50-60-3].

With the fuel sender in the position shown [Figure 50-60-

S8297
3], read the ohms in the empty position. Slide the float
upward and the ohm reading will decrease. See
Remove the sender (Item 1) [Figure 50-60-2] from the resistance chart below.
fuel tank.
The approximate resistance should read as follows:

FULL: 15 - 35 Ohm.
HALF: 130 - 150 Ohm.
EMPTY: 230 - 250 Ohm.

50-60-1 E08 Service Manual

50-60-2 E08 Service Manual
ENGINE

ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Crankshaft Re-Grind Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-19
Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-20

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Thermostat Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4
Thermostat - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-4

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Oil Pump, Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Engine Oil Pressure, Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1

Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Fuel Shutoff Timer Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Fuel Injection Pump - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-3
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-5
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-7
Fuel Camshaft Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-7
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-8
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-9
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-10

60-01 E08 Service Manual

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-3
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-4
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-5
Cylinder Head, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-6
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-7
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-7
Valve And Valve Seat Reconditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-9
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-10
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-11
Rocker Arm And Shaft, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-12

CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-3
Cylinder Bore - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-5
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-5
Crankshaft And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-6
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-8

CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Timing Gearcase Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Timing Gears Checking Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Idler Gear And Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-3
Idler Gear And Shaft, Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-6

FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Hydraulic Pump Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Rear End Plate Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3

60-02 E08 Service Manual

ENGINE INFORMATION

Description

The E08 excavator has a Kubota® direct injected D722-

E2B diesel engine with a displacement of 0,719 L (43.88
in³).The engine is rated at 9,9 kWh (13.3 hp) and has an
open crankcase ventilation system.

The engine has three cylinders and the rotation is

counterclockwise (viewed from the flywheel side). Engine
block heaters are also available from Bobcat Parts.

The engine serial number is stamped on the engine and

is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.

The engine is liquid cooled with a propylene glycol / water

mixture. The cooling fan is belt driven. The speed of the
fan is determined by the engine speed.

60-10-1 E08 Service Manual

ENGINE INFORMATION (CONT'D)

Specifications

Fuel Injector Nozzles

Opening Pressure 13727 - 14713 kPa (137 - 147 bar) (1991 - 2134 psi)
Fuel Tightness Nozzle Seat 12748 kPa (127 bar) (1849 psi)

Fuel Injection Pump

Fuel Tightness of Pump Element 13727 kPa (137 bar) (1991 psi)
Fuel Tightness of Delivery Valve (factory spec) 10 Second Initial Pressure Drop From 13727 - 1 2748 kPa
(137 - 127 bar) (1991 - 1849 psi)
Fuel Tightness of Delivery Valve Limit Permitted 5 Second Initial Pressure Drop From 14713 - 13727 kPa
(137 - 127 bar) (2134 - 1991 psi)
Injection Timing @ 3600 rpm 19 - 21 degrees B.T.D.C.

Cylinder Head

Cylinder Head Distortion Limit 0,05 mm (0.002 in)

Thickness of Gasket Free 1,15 - 1,30 mm (0.0415 - 0.0512 in)
Thickness of Gasket Tightened 1,05 - 1,15 mm (0.0413 - 0.0453 in)
Top Clearance 0,50 - 0,70 mm (0.0197 - 0.0276 in)

Valves

Valve Seat Angle 45 degrees

Valve Seat Width 2,12 mm (0.084 in)
O.D. of Valve Stem 5,968 - 5,980 mm (0.2350 - 0.2354 in)
I.D. of Valve Guide 6,01 - 6,025 mm (0.2366 - 0.2372 in)
Clearance between Valve Stem and Guide 0,03 - 0,057 mm (0.0012 - 0.0022 in)
Limit Permitted 0,1 mm (0.004 in)
Depth of Valve -0,10 - 0,10 mm (-0.004 - 0.004 in)
Limit Permitted 0,30 mm (0.0118 in)
Valve Clearance (Cold) (Intake and Exhaust) 0,145 - 0,185 mm (0.006 - 0.007 in)

Valve Springs

Free Length 31,3 - 31,8 mm (1.232 - 1.252 in)

Limit Permitted 28,4 mm (1.118 in)
Fitted Length 27 mm (1.063 in)
Load to Compress to Fitted Length 6,6 kg (14.6 lb)
Limited Permitted 5,6 kg (12.3 lb)
Limited Permitted for Spring Tilt 1,2 mm (0.047 in)

60-10-2 E08 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont'd)

Rocker Arms

O.D. of Rocker Arm Shaft 10,47 - 10,48 mm (0.4123 - 0.4128 in)

I.D. of Rocker Arm Bushing 10,5 - 10,52 mm (0.4134 - 0.4141 in)
Clearance between Rocker Arm Shaft and Bushing 0,016 - 0,045 mm (0.0006 - 0.0018 in)
Limit Permitted 0,15 mm (0.006 in)

Camshaft

O.D. of Camshaft Bearing Journal 32,93 - 32,95 mm (1.2966 - 1.2972)

I.D. of Camshaft Bearing 33,00 - 33,025 mm (1.2992 - 1.3002 in)
Clearance between Camshaft Bearing and Journal 0,05 - 0,91 mm (0.002 - 0.004 in)
Limit Permitted 0,15 mm (0.006 in)
Alignment of the Camshaft Limit Permitted 0,01 mm (0.0004 in)
Cam Lobe Height 26,88 mm (1.0583 in)
Limit Permitted 26,83 mm (1.0563 in)
Idle Gear to Cam Gear Backlash 0,041 - 0,123 mm (0.002 - 0.005 in)
Limit Permitted 0,15 mm (0.006 in)

Cylinders

I.D. of Cylinder Liner 67,000 - 67,019 mm (2.6378 - 2.6385 in)

Limit Permitted 67,169 mm (2.6445 in)
Rebore Size for Oversize Piston 67,250 - 67,269 mm (2.6476 - 2.6484 in)

Piston Rings

Ring Gap, Top and Oil 0,15 - 0,30 mm (0.0059 - 0.0118 in)
Ring Gap, 2nd 0,30 - 0,45 mm (0.0118 - 0.0177) in
Limit Permitted 1,20 mm (0.0472 in)
Side Clearance of Ring in Groove;
Top Ring Because of top ring design, measurement does not apply
2nd Ring 0,085 - 0,12 mm (0.0033 - 0.0045 in)
Oil Ring 0,02 - 0,06 mm (0.0016 - 0.0031 in)
Limit Permitted 0,15 mm (0.006 in)

60-10-3 E08 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont'd)
Pistons

I.D. of Piston Pin Bore 20,00 - 20,013 mm (0.7874 - 0.7879 in)

Limit Permitted 20,05 mm (0.7894 in)
O.D. of Piston Pin 20,002 - 20,011 mm (0.7875 - 0.7878 in)

Connecting Rods

I.D. of Connecting Rod Bushing (Small End, Fitted) 20,03 - 20,04 mm (0.7884 - 0.7890 in)
Clearance between Piston Pin and Bushing 0,014 - 0,038 mm (0.0006 - 0.0015 in)
Clearance between Piston Pin and Bushing Limit 0,10 mm (0.004 in)
Permitted
Connecting Rod Alignment Limit Permitted 0,05 mm (0.002 in)

Crankshaft

Crankshaft Alignment Limit Permitted 0,02 mm (0.0008 in)

O.D. of Crankshaft Journal No. 1 (Water Pump Side) 39,93 - 39,95 mm (1.5722 - 1.5728 in)
I.D. of Crankshaft Bearing No. 1 39,98 - 40,04 mm (1.5715 - 1.5764 in)
Clearance between No. 1 Crankshaft Journal and Bearing 0,03 - 0,11 mm (0.0013 - 0.0042 in)
Limit Permitted 0,20 mm (0.008 in)
O.D. of Crankshaft Journal No. 2 (Flywheel Side) 43,93 - 43,95 mm (1.7297 - 1.7303 in)
I.D. of Crankshaft Bearing No. 2 43,98 - 44,03 mm (1.7317 - 1.7333 in)
Clearance between No. 2 Crankshaft Journal and Bearing 0,03 - 0,05 mm (0.0011 - 0.0020 in)
Limit Permitted 0,20 mm (0.008 in)
O.D. of Crankshaft Journal No. 3 (Intermediate) 39,93 - 39,95 mm (1.5722 - 1.5728 in)
I.D. of Crankshaft Bearing No. 3 39,98 - 40,03 mm (1.5742 - 1.5758 in)
Clearance between No. 3 Crankshaft Journal and Bearing 0,03 - 0,05 mm (0.0011 - 0.0020 in)
Limit Permitted 0,20 mm (0.008 in)
O.D. of Connecting Rod Journals 33,96 - 33,98 mm (1.3370 - 1.3376 in)
I.D. of Connecting Rod Bearings` 33,99 - 34,01 mm (1.3389 - 1.3390 in)
Clearance between Connecting Rod Journal and Bearing 0,02 - 0,051 mm (0.0008 - 0.0020 in)
Limit Permitted 0,15 mm (0.006 in)
Crankshaft End Play 0,15 - 0,31 mm (0.006 - 0.012 in)
Limit Permitted 0,50 mm (0.020 in)

Oil Pump

Oil Pressure At Rated rpm 193 - 441 kPa (2 - 4 bar) (28 - 64 psi)
Limit Permitted 145 kPa (1 bar) (21 psi)
Oil Pressure And Idle Speed 48 kPa (0,5 bar) (7 psi)
Clearance between Outer Rotor and Pump Body 0,07 - 0,15 mm (0.003 - 0.006 in)
End Clearance between Inner Rotor and Cover 0,08 - 0,14 mm (0.003 - 0.005 in)
Clearance between Inner Rotor and Outer Rotor 0,03 - 0,14 mm (0.0012 - 0.006 in)

60-10-4 E08 Service Manual

ENGINE INFORMATION (CONT’D)

Specifications (Cont'd)

Thermostat

Opening Temperature
Starting 70 - 73°C (157 - 163°F)
Full Open 85°C (185°F)

Engine Bolt Torque

N•m ft-lb
Camshaft Retainer Plate Bolts 18 - 21 14 - 15
* Connecting Rod Bolts 27 - 30 20 - 22
* Crankshaft Bolt 98 - 108 72 - 80
* Cylinder Head Bolts 38 - 42 28 - 31
* Flywheel Bolts 53,9 - 58,8 39.8 - 43.4
Fuel Camshaft Retainer Bolts 6,8 - 8,1 5-6
Fuel Injection Tubeline Fittings 25 - 34 18 - 25
Glow Plugs 8 - 15 6 - 11
* Idle Gear Shaft Bolt 10 - 11 7-8
Injection Nozzle 49 - 69 36 - 51
Injection Pump Mounting Nuts 24 - 27 18 - 20
* Main Bearing Bolts 27 - 30 20 - 22
* Main Bearing Case Bolts 13 - 16 9 - 12
Oil Switch 15 - 20 11 - 15
Rear Bearing Case Cover Bolts 10 - 11 7-8

* Lightly Oiled Threads

60-10-5 E08 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-1

Crankshaft Re-Grind Data B

6 1
3
If the standard size bearing cannot be used due to 1
excessive wear of the crank pin and crank journal use
undersize or oversize bearings.

For undersize or oversize bearing use, follow the

A
precautions noted below.

Grind the crankpin and journal with a wheel which has 4

C
specified round corner and width without shoulder 2
D
[Figure 60-10-1].
1 5
1. 1,8 - 2,2 mm (0.071 - 0.087 in) B-5928

2. 2,3 - 2,7 mm (0.091 - 0.106 in)

3. Be sure to chamfer the oil hole circumference to 1,0 -
1,5 mm (0.04 - 0.06”) radius with an oil stone.
4. The crankpin must be fine-finished to higher than
(0,4-S).
5. The crank journal must be fine-finished to higher than
(0,4-S).
6. The crank journal side surface must be fine-finished
to higher than (1,6-S)

SIZE CODE NO. NAME OF BEARING BEARING MARK CRANKSHAFT PROCESSING DIM
-0,2 mm 15861-23911 Crankshaft Bearing 1 020 US
(-0.008”) 0.008” minus (0,2 minus) 39,734 - 39,750 mm
-0,2 mm 15694-23931 Crankshaft Bearing 2 020 US (1.5643 - 1.5650”)
(-0.008”) 0.008” minus (0,2 minus)
-0,2 mm 15861-23861 Crankshaft Bearing 3 020 US 43,734 - 43,750 mm
(-0.008”) 0.008 minus (0,2 minus) (1.7218 - 1.7224 in)
-0,4 mm 15861-23921 Crankshaft Bearing 1 040 US A 39,534 - 39,550 mm
(-0.016”) 0.016” minus (0,4 minus) (1.5565 - 1.5571”)
-0,4 mm 15699-23941 Crankshaft Bearing 2 040 US
(-0.016”) 0.016” minus (0,4 minus)
-0,4 mm 15861-23871 Crankshaft Bearing 3 040 US 43,534 - 43,550 mm
(-0.0016”) 0.016 minus (0,4 minus) (1.7139 - 1.7146”)
-0,2 mm 15861-22971 Crank Pin Bearing 020 US 33,759 - 33,775 mm
(-0.008”) 0.008” minus (0,2 minus) (1.3291 - 1.3297”)
-0,4 mm 15861-22981 Crank Pin Bearing 040 US B 33,559 - 33,575 mm
(-0.016”) 0.016” minus (0,4 minus) 1.3212 - 1.3219”

+0.008” 15261-23951 Thrust Bearing 1 020 OS

(-0,2 mm) 0.008” plus (0,2 plus) 46,1 - 46,3 mm
15261-23971 Thrust Bearing 2 (1.815 - 1.823”)
0.008” plus (0,2 plus)
C
+0.016” 15261-23961 Thrust Bearing 1 040 OS
(+0,4 mm) 0.016 plus (0,4 plus) 46,3 - 46,5 mm
15261-23981 Thrust Bearing 2 (1.823 - 1.831”)
0.016” (0,4 plus)
0,2 mm Crankshaft over size 46,1 - 46,3 mm
(0.008”) Dimension D (1.815 - 1.823”)
0,4 mm 46,3 - 46,5 mm
(0.016”) (1.823 - 1.831”)

60-10-6 E08 Service Manual

ENGINE INFORMATION (CONT’D)

Torque Values

GRADE STANDARD SCREW AND BOLT SPECIAL SCREW AND BOLT

4 7

NOMINAL
UNIT N•m KFG M ft-lb N•m KFG M ft-lb
DIAMETER
M6 7,9 - 9,3 0.80 - 0.95 5.8 - 6.9 9,8 - 11,3 1.00 - 1.15 7.23 - 8.32
M8 18 - 20 1.8 - 2.1 13.0 - 15 24 - 27 2.4 - 2.8 18 - 20
M10 40 - 45 4.0 - 4.6 29 - 33 49 - 55 5.0 - 5.7 37 - 41
M12 63 - 72 6.4 - 7.4 47 - 53 78 - 90 7.9 - 9.2 58 - 66

60-10-7 E08 Service Manual

ENGINE INFORMATION (CONT’D)

Troubleshooting

The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.

PROBLEM CAUSE
Slow cranking speed 1, 2, 3, 4
Engine will not start 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28, 29
Engine is mis-firing 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue / white exhaust 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure 4, 33, 36
Overheating 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure 22, 27, 29, 30, 40, 49
Poor compression 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop 9, 10, 11

KEY TO CORRECT THE CAUSE

1. Battery capacity low 28. Worn valves and seat
2. Bad electrical connections 29. Broken or worn piston rings
3. Faulty starter motor 30. Worn valve stems or guides
4. Incorrect grade of oil 31. Worn or damaged bearings
5. Low cranking speed 32. Not enough oil in the oil pan
6. Fuel tank empty 33. Switch is defective
7. Faulty stop control operation 34. Oil pump worn
8. Plugged fuel line 35. Relief valve is stuck open
9. Plugged fuel filter 36. Relief valve is stuck closed
10. Restriction in the air cleaner 37. Broken relief valve spring
11. Air in the fuel system 38. Faulty suction pipe
12. Faulty fuel injection pump 39. Plugged oil filter
13. Faulty fuel injectors 40. Piston seizure
14. Broken injection pump drive 41. Incorrect piston height
15. Incorrect injection pump timing 42. Faulty engine mounting
16. Incorrect valve timing 43. Incorrect alignment of flywheel
17. Poor compression 44. Faulty thermostat
18. Plugged fuel tank vent 45. Restriction in water jacket
19. Incorrect grade of fuel 46. Loose alternator belt
20. Exhaust pipe restriction 47. Plugged radiator
21. Cylinder head gasket leaking 48. Plugged breather pipe
22. Over heating 49. Plugged breather pipe
23. Cold running 50. Damaged valve stem oil deflectors
24. Incorrect tappet adjustment 51. Coolant level too low
25. Sticking valves 52. Plugged oil pump pipe strainer
26. Incorrect high pressure fuel lines 53. Broken valve spring
27. Worn cylinder bores

60-10-8 E08 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-2

Removal And Installation

Open the tailgate. (See Opening And Closing The 1

Tailgate on Page 10-60-1.)

Drain the fuel tank. (See Draining The Fuel Tank on Page
10-100-3.) 1

Drain and remove the hydraulic reservoir. (See Removal

And Installation on Page 20-90-1.)

Remove the air cleaner. (See Removal And Installation

on Page 60-30-1.) 1
S7621
Remove the hydraulic pump. (See Removal And
Installation on Page 20-50-3.)
Remove the two nuts and bolts (Item 1) [Figure 60-10-2]
Remove the muffler. (See MUFFLER on Page 60-20-1.) from the battery support.

Remove the battery. (See Removal And Installation on Figure 60-10-3

Page 50-20-4.)

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

S8419

Remove the nut and bolt (Item 1) [Figure 60-10-3].

IMPORTANT
Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an
environmentally safe manner. Some regulations
require that certain spills and leaks on the ground
must be cleaned in a specific manner. See local
regulations for the correct disposal.
I-2067-EN-0711

60-10-9 E08 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-6

Removal And Installation (Cont’d)

Figure 60-10-4

S8422

Mark and remove the tubeline (Item 1) [Figure 60-10-6].

S8420
Figure 60-10-7

Remove the nut and bolt (Item 1) [Figure 60-10-4].

Figure 60-10-5
3

S8423
1

Remove the hose clamp (Item 1) and hose (Item 2)

S8421 [Figure 60-10-7].

Remove the bolts (Item 3) [Figure 60-10-7] from the

Remove the nut and bolt (Item 1) [Figure 60-10-5]. hydraulic filter.

Remove the battery support. Remove the hydraulic filter.

60-10-10 E08 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-10

Removal And Installation (Cont’d)

Figure 60-10-8

2
3

1
1
S7576

2
Remove the hose clamp (Item 1) and hose (Item 2)
S7575 [Figure 60-10-10].

Mark and remove the hose (Item 3) [Figure 60-10-10].

Remove the hose clamp (Item 1) and hose (Item 2)
[Figure 60-10-8]. Figure 60-10-11

Figure 60-10-9

1
3
3

S7577

S7574
Remove the bolts and nuts (Item 1) [Figure 60-10-11].

Remove the hose clamp (Item 1) and hose (Item 2) Remove the overflow bottle and bracket.
[Figure 60-10-9].

Remove the bolts (Item 3) [Figure 60-10-9] from the fuel

filter bracket.

Remove the fuel filter and bracket

60-10-11 E08 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-14

Removal And Installation (Cont’d)

Figure 60-10-12

S7618

Remove bolts and nuts (Item 1) [Figure 60-10-14].

S7615
Installation: Tighten the bolts to 85 N•m (63 ft-lb) torque.

Remove the bolts and nuts (Item 1) [Figure 60-10-12]. Figure 60-10-15

Installation: Tighten the bolts to 50 N•m (37 ft-lb) torque.

Figure 60-10-13

1
2

1
1

S8430

Remove bolts and nuts (Item 1) [Figure 60-10-15].

S8424
Installation: Tighten the bolts to 85 N•m (63 ft-lb) torque.

Remove the bolts and nuts (Item 1) [Figure 60-10-13]. Remove bolt (Item 2) [Figure 60-10-15] from ground
cable.
Installation: Tighten the bolts to 50 N•m (37 ft-lb) torque.
Installation: Tighten the bolt to 50 N•m (37 ft-lb) torque.

Remove the floor panels. (See FLOOR PANELS on Page

40-120-1.)

60-10-12 E08 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-18

Removal And Installation (Cont’d)

Figure 60-10-16

S7579

Remove the hose clamp (Item 1) and lower radiator hose

S8425 (Item 2) [Figure 60-10-18].

Figure 60-10-19
Remove bolts and nuts (Item 1) [Figure 60-10-16].

Installation: Tighten the bolts to 50 N•m (37 ft-lb) torque.

2
Figure 60-10-17

S7580

Remove the hose clamp (Item 1) and upper radiator hose

(Item 2) [Figure 60-10-19].
S7620

Remove bolts and nuts (Item 1) [Figure 60-10-17].

Installation: Tighten the bolts to 50 N•m (37 ft-lb) torque.

Carefully lift frame upward and tilt forward to clear back

frame.

Remove the back frame from the excavator.

60-10-13 E08 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-22

Removal And Installation (Cont’d)

Figure 60-10-20
1

2
2

1
S7582

Disconnect the red wire (Item 1) [Figure 60-10-22] from

S8431 the alternator.

Disconnect the wire connector (Item 2) [Figure 60-10-22]

Remove the hose clamp (Item 1) and air intake hose from the alternator.
(Item 2) [Figure 60-10-20].
Figure 60-10-23
NOTE: Plug intake opening to prevent contamination
from getting into the engine.

Figure 60-10-21

1
2

S7583
1

Disconnect the wire connector (Item 1) [Figure 60-10-23]

S7581 from the oil pressure sending unit on the back side of the
engine.

Loosen the nuts (Item 1) [Figure 60-10-21] fastening the

throttle cable to the bracket.

Disconnect the throttle linkage (Item 2) [Figure 60-10-21]

from the throttle bracket.

Move the throttle cable out of the way of the engine.

60-10-14 E08 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-26

Removal And Installation (Cont’d)

Figure 60-10-24

1
S7586

Remove the grounding wires (Item 1) [Figure 60-10-26]

S7584 from the starter mounting bolt.

Figure 60-10-27
Remove the bolt and nut (Item 1) [Figure 60-10-24] from
the alternator bracket.

Move the wire harness out of the way of the engine and
alternator.

Figure 60-10-25

1
1

S7587

Remove nut and bolt (Item 1) [Figure 60-10-27] from

2 cable clamp.

Move the wire harness out of the way of the engine.

S8432

Mark the wires for ease of installation.

Remove the wires (Item 1) and (Item 2) [Figure 60-10-

25] from the starter.

60-10-15 E08 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-30

Removal And Installation (Cont’d)

Figure 60-10-28
1

1 S8427

Remove the bolt (Item 1) [Figure 60-10-30] from the fuse

S7588 block and reposition away from the engine lifting bracket.

Figure 60-10-31
Cut the tie-strap (Item 1) and disconnect wire connector
(Item 2) [Figure 60-10-28] from the fuel shutoff.

Figure 60-10-29
1

2
1

S7591

Remove and cap the return fuel line (Item 1) [Figure 60-
S7589 10-31].

Remove and cap the fuel lines (Item 2) [Figure 60-10-

Remove the wire (Item 1) [Figure 60-10-29] from the 31].
water temperature sending unit.

Remove the nut (Item 2) [Figure 60-10-29] from the glow

plugs.

Move the wire harness out of the way of the engine.

60-10-16 E08 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-34

Removal and Installation (Cont’d)

Figure 60-10-32

1 1

S7594

2 Remove the two engine mount bolts (Item 1) [Figure 60-

S7592 10-34].

Installation: Tighten the bolts to 5,5 N•m (48.68 in-lb)

Remove the bolt (Item 1) [Figure 60-10-32]. torque.

Installation: Tighten the bolt to 5,5 N•m (48.68 in-lb) Figure 60-10-35
torque.

Remove the exhaust extension (Item 2) [Figure 60-10-

32].

Figure 60-10-33

S7595
1

Remove the two engine mount bolts (Item 1) [Figure 60-

10-35]

S7593 Installation: Tighten the bolts to 5,5 N•m (48.68 in-lb)

torque.

Remove the two engine mount bolts (Item 1) [Figure 60- NOTE: The engine mounts are left assembled to the
10-33]. engine and will be removed with the engine.

Installation: Tighten the bolts to 5,5 N•m (48.68 in-lb)

torque.

60-10-17 E08 Service Manual

ENGINE INFORMATION (CONT’D)

Removal and Installation (Cont’d)

Figure 60-10-36

1
1

2
2

S7597

Connect a chain (Item 1) to the two engine lifting brackets

(Item 2) [Figure 60-10-36].

Figure 60-10-37

S8433

Lift and slide the engine out while turning the engine to
provide clearance during engine removal [Figure 60-10-
37].

NOTE: Protect the excavator from lifting chain

damage during engine removal.

60-10-18 E08 Service Manual

ENGINE INFORMATION (CONT’D) Figure 60-10-39

Engine Mount Replacement

Figure 60-10-38
8
7
7
6 6
5 5
4 4 3
3 2
2
1 1
P-68740

Use the following procedure to install new side engine

S8436 mounts:

Remove the existing side mount from the engine. Refer to

Use the following procedure to install new front and rear engine removal and installation for engine mount
engine mounts: locations.

Remove the existing mount from the engine. Refer to Use the parts shown to install the new engine mount for
engine removal and installation for engine mount the side engine mount [Figure 60-10-39].
locations.
Item 1 - Mounting Bolt
Replace the two front and rear engine mounts. Item 2 - Mount Washer
Item 3 - Flat Washer
Use the parts shown to install the new engine mounts for Item 4 - Nut
the front and rear engine mounts [Figure 60-10-38]. Item 5 - Spacer
Item 6 - Mount
Item 1 - Mounting Bolt Item 7 - Screw
Item 2 - Mount Washer Item 8 - Nut
Item 3 - Flat Washer
Item 4 - Spacer Tighten the mounting bolt to 43 - 47 N•m (32 - 35 ft-lb)
Item 5 - Mount torque.
Item 6 - Screw
Item 7 - Nut

Tighten the mounting bolts to 43 - 47 N•m (32 - 35 ft-lb)

torque.

60-10-19 E08 Service Manual

ENGINE INFORMATION (CONT’D) If the pressures are not within 10% of each other, apply a
small amount of oil in the cylinders and retest.
Compression Checking
If the pressures increase after applying oil, check cylinder
The tool listed will be needed to do the following walls and piston rings.
procedure:
If the pressures do not increase after applying oil, check
MEL10630 - Engine Compression Test Kit top clearance, valve clearance and cylinder head.

Warm the engine.

Remove the glow plugs from the engine. (If testing

through glow plug hole.)

Remove all injector nozzles. (If testing through injector

nozzle hole.)

Install the compression adapter in the cylinder head.

Figure 60-10-40

3
S7604

NOTE: Engine has been removed for photo clarity.

Connect the compression gauge (Item 1) to the adapter

(Item 2) [Figure 60-10-40].

Ensure the speed control lever is set at the low idle

setting.

Hold fuel shutoff lever (Item 3) [Figure 60-10-40] to no

fuel (shutoff). shutoff solenoid does not need to be
removed.

Turn the engine with the starter at 200 to 300 rpm. Run
the test for each cylinder more than twice for 5 to 10
seconds each time and take the average reading. Make
sure you are using a fully charged battery.

The correct compression for the engine is 2,8 - 3,2 MPa

(28 - 32 bar) (412 - 469 psi) with no more than 10%
difference between the cylinders.

60-10-20 E08 Service Manual

MUFFLER Figure 60-20-3

Removal And Installation

Figure 60-20-1

1
1

S6740
1

Remove the nuts and bolts (Item 1) [Figure 60-20-3]

S7554 from the exhaust mounting bracket.

Remove the bolts (Item 1) [Figure 60-20-1].

Remove the cover. WARNING

Figure 60-20-2
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
1 gases which can kill without warning.
W-2050-0807

WARNING
S6741
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
Loosen the exhaust extension clamp (Item 1) [Figure 60- W-2011-1285
20-2].

Installation: Tighten clamp to 8 - 10 N•m (70.80 - 88.50

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

60-20-1 E08 Service Manual

MUFFLER (CONT’D) Figure 60-20-6

Removal And Installation (Cont’d)

1 3
2
Figure 60-20-4

1
1

S7924

Remove the lever (Item 1), the two wave washers (Item
S8353 2) and the spacer (Item 3) [Figure 60-20-6].

Figure 60-20-7
Remove the four bolts (Item 1) [Figure 60-20-4] from the
muffler mount flange.

Figure 60-20-5
1

1 1

S8292

Remove the three bolts (Item 1) [Figure 60-20-7] from

S8291 the right hand side of the instrument panel.

Remove the bolts (Item 1) [Figure 60-20-5] from the

throttle lever.

Installation: Tighten the bolts (Item 1) [Figure 60-20-5]

evenly until the throttle lever moves back and forth at a
comfortable tension.

60-20-2 E08 Service Manual

MUFFLER (CONT’D)

Removal And Installation (Cont’d)

Figure 60-20-8

S8293

Remove the three bolts (Item 1) [Figure 60-20-8] from

the left hand side of the instrument panel.

Move the instrument panel to provide extra clearance for

muffler removal.

Slide muffler off exhaust extension and remove the

muffler from the excavator.

NOTE: Plug the exhaust manifold hole after muffler

removal so no contamination can get into the
engine.

60-20-3 E08 Service Manual

60-20-4 E08 Service Manual
AIR CLEANER Figure 60-30-3

Removal And Installation

Open the tailgate.

Remove the left hand side counterweight. (See Left Side

Counterweight Removal And Installation on Page 40-
200-2.) 1

Figure 60-30-1

2
S7552

1 Remove the two bolts (Item 1) [Figure 60-30-3] and

remove the air cleaner and hose assembly from the
excavator.

S7550

Remove the hose clamp (Item 1) and hose (Item 2)

[Figure 60-30-1].

NOTE: Plug intake hose to avoid contamination from

getting in.

Figure 60-30-2

S7551

Remove the hose (Item 1) [Figure 60-30-2] from the

back of the air cleaner.

60-30-1 E08 Service Manual

60-30-2 E08 Service Manual
ENGINE COOLING SYSTEM Figure 60-40-2

Radiator Removal And Installation

1 2

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

Drain the hydraulic reservoir. (See Replacing Hydraulic

S8409
Oil on Page 10-120-2.)

Drain the radiator coolant. (See Removing And Open the tailgate.
Replacing The Coolant on Page 10-90-2.)
Remove the bolts (Item 1) and the fan guard (Item 2)
Remove the right hand side counterweight. [Figure 60-40-2].
Remove the upper right hand side cover. (See Upper Figure 60-40-3
Right Side Cover Removal And Installation on Page 40-
210-1.)

Figure 60-40-1

1 2 1

S6777
2

Remove the hose clamp (Item 1) and filler neck hose

S8700 (Item 2) [Figure 60-40-3].

Remove the hose clamp (Item 1) and lower radiator hose

(Item 2) [Figure 60-40-1].

NOTE: There is still a small amount of coolant

present in the radiator and hose. Use a
container when removing lower radiator hose.

Recycle or dispose of the used coolant in an

environmentally safe manner.

60-40-1 E08 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Figure 60-40-6

Radiator Removal And Installation (Cont’d)

Figure 60-40-4

1
1
S6768

Remove the bolt (Item 1) [Figure 60-40-6] from the

S6775 radiator / oil cooler bracket.

Figure 60-40-7
Remove the nuts (Item 1) [Figure 60-40-4] from the
radiator / oil cooler bracket.

Figure 60-40-5

S8411

Gently pull the radiator / oil cooler bracket towards you

S8702 until you have access to the upper radiator hose.

Remove the hose clamp (Item 1) and upper radiator hose

Remove the bolts (Item 1) [Figure 60-40-5]. (Item 2) [Figure 60-40-7].

Remove the radiator / oil cooler bracket.

60-40-2 E08 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Radiator Removal And Installation (Cont’d)

Figure 60-40-8

S6778

Remove the bolts (Item 1) [Figure 60-40-8] from the

bottom of the bracket.

Figure 60-40-9

S6779

Remove the bolts (Item 1) [Figure 60-40-9] from the top

of the bracket.

Remove the radiator from the bracket.

60-40-3 E08 Service Manual

ENGINE COOLING SYSTEM (CONT’D) Thermostat Removal And Installation

Water Pump Removal And Installation Figure 60-40-11

Drain the cooling system.

1 2
Remove the radiator. (See Radiator Removal And
Installation on Page 60-40-1.) 2

Remove the alternator belt.

Remove the fan.

Figure 60-40-10

4
P-66480

Drain the engine coolant until it is below the thermostat

3 level.

5 Remove the hose (Item 1) [Figure 60-40-11].

Remove the bolts (Item 2) [Figure 60-40-11] and

thermostat housing.
2
1 B-14859A Installation: Make sure all gasket surfaces are clean.
Replace the gasket before installing the thermostat
housing. Install liquid gasket to thermostat housing.
Remove the water pump bolts (Item 1) [Figure 60-40-
10]. Figure 60-40-12

Remove the water pump.

1
Installation: Always use a new gasket (Item 2) [Figure
60-40-10] when installing the water pump and apply
Liquid-Type Gasket (Three Bond 1215 or equivalent) to
both sides of new gasket.

Water Pump Disassembly And Assembly

Put the water pump in a vise.

Remove the pulley. 2

Press the shaft (Item 3) [Figure 60-40-10] out of the B-3643

pulley side of the water pump. Press out the shaft with
the impeller on it.
Remove the housing and thermostat (Item 1) [Figure 60-
Remove the seal (Item 4) and impeller (Item 5) [Figure 40-12].
60-40-10].
Remove the four mounting bolts at the coolant housing
Install a new seal when assembling the water pump. (Item 2) [Figure 60-40-12].

Remove coolant housing from the engine block.

60-40-4 E08 Service Manual

ENGINE COOLING SYSTEM (CONT’D)

Thermostat - Checking

Hang the thermostats in a suitable container filled with

coolant.

Heat the coolant gradually. Use a thermometer to check

the temperature when it starts to open and when it's fully
open.

If the thermostats do not operate correctly they must be

replaced.

NOTE: See specifications on the thermostat. (See

TECHNICAL SERVICE GUIDE
SPECIFICATIONS on Page SPEC-20-1.)

60-40-5 E08 Service Manual

60-40-6 E08 Service Manual
LUBRICATION SYSTEM Figure 60-50-3

Oil Pan Removal And Installation

Remove the engine from the excavator. (See Removal

And Installation on Page 60-10-9.)
1
Figure 60-50-1

S7981

Remove the oil pump strainer (Item 1) [Figure 60-50-3].

1
Figure 60-50-4

2
S7983 1

Unscrew the oil pan mounting screws (Item 1) and

remove the oil pan (Item 2) [Figure 60-50-1].

Figure 60-50-2

P-62187
1
Installation: Check O-ring (Item 1) on strainer and use
hole 3 (Item 2) [Figure 60-50-4] when installing strainer.
Install the oil strainer, using care not to damage the O-
ring.

Apply liquid gasket to the oil pan (Item 1) [Figure 60-50-

1].
P-68745
Confirm that the liquid gasket coating surface is free of
water, dust and oil in order to maintain sealing effect.
Carefully apply the adhesive evenly.
NOTE: When mounting the adhesive-applied parts,
take care to install them to the mating parts.
Assemble the adhesive-applied parts within
10 minutes.
To avoid uneven tightening, tighten mounting
screws in diagonal order from the center.
After cleaning the oil strainer, install it.
Attach the oil pan with its central drain plug
facing toward the air suction side.

60-50-1 E08 Service Manual

LUBRICATION SYSTEM (CONT’D) Oil Pump, Service

Oil Pump Removal And Installation Figure 60-50-6

Remove the timing gearcase cover. (See Timing

Gearcase Cover Removal And Installation on Page 60-
90-1.)

Remove the crankshaft gear.

Figure 60-50-5

B-3616

Measure the clearance between the lobes of the inner

2 rotor and outer rotor with a feeler gauge [Figure 60-50-
6].

Figure 60-50-7
B-3658

Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 60-50-5].

Remove the oil pump mounting bolts. Remove the oil

pump (Item 2) [Figure 60-50-5].

Installation: Tighten the oil pump mounting bolts to 6,9 -

8,1 N•m (60 - 72 in-lb) torque.

A-2732

Measure the clearance between the outer rotor and

pump body with a feeler gauge [Figure 60-50-7].

If the clearance exceeds the factory limit, replace the oil

pump rotor assembly.

Clearance Between Inner and Outer Rotor

0,03 - 0,14 mm
(0.001 - 0.006 in)
Clearance Between Outer Rotor and Body
0,07 - 0,15 mm
(0.003 - 0.006 in)

60-50-2 E08 Service Manual

LUBRICATION SYSTEM (CONT’D) Engine Oil Pressure, Testing

Oil Pump, Service (Cont’d) Figure 60-50-9

Figure 60-50-8

B-14876

PI-10009
Remove the oil pressure sensor.

Put a piece of press gauge on the rotor face [Figure 60- Install a pressure gauge [Figure 60-50-9].
50-8].
Start the engine and run until it is at operating
Install the cover and tighten the bolts. temperature.

Remove the cover carefully. Measure the width of the Measure oil pressure at both idling and rated speeds.
press gauge [Figure 60-50-8].
If the oil pressure is less than the allowable limit, check
If the clearance exceeds the factory limit replace the oil the following item:
pump rotor assembly.
• Engine Oil Insufficient
End Clearance 0,08 - 0,14 mm • Oil Pump Defective
(0.003 - 0.005 in) • Oil Galley Plugged
• Oil Strainer Plugged
• Excessive Oil Clearance
• Foreign Matter in Relief Valve
• Oil Filer Cartridge plugged

At Idle Speed Allowable Limit 48,3 kPa

(0,48 bar) (7 psi)
At Rated Speed 193 - 441,3 kPa
(2 - 4 bar) (28 - 64 psi)
Allowable Limit 144,8 kPa
(1 bar) (21 psi)

Installation: After checking engine oil pressure, tighten

oil pressure sensor to 15 - 20 N•m (11 - 15 ft-lb) torque.

60-50-3 E08 Service Manual

LUBRICATION SYSTEM (CONT’D)

Relief Valve

The relief valve prevents damage of the lubricating

system due to high pressure. This relief valve is a ball
type.

Figure 60-50-10

3 2

4
C-3438

Remove the valve seat (Item 1) [Figure 60-50-10], ball

(Item 2) [Figure 60-50-10] and spring (Item 3) [Figure
60-50-10].

Check the parts for wear or damage and replace as

needed.

Spring Free Length

Factory Spec 32 mm (1.26 in)
Allowable Limit 28 mm (1.10 in)

Installation: Tighten the oil filter adapter (Item 4) [Figure

60-50-10] to 39 - 49 N•m (29 - 36 ft-lb) torque.

60-50-4 E08 Service Manual

FUEL SYSTEM Fuel Shutoff Timer Removal And Installation

Fuel Shutoff Solenoid Removal And Installation The fuel shutoff timers function is to provide pull in
current to the fuel solenoid for only a short duration.
Figure 60-60-1
Figure 60-60-2

3 3
1

1
S7605

S7609

Cut the tie-strap (Item 1) [Figure 60-60-1].

Disconnect the two wire harnesses (Item 1) [Figure 60-
Disconnect the wire connector from the solenoid (Item 2) 60-2] from the timer module.
[Figure 60-60-1].
Figure 60-60-3
Remove the solenoid mountings bolts (Item 3) [Figure
60-60-1].

Remove the solenoid.

1

S8427

Remove the nut and bolt (Item 1) [Figure 60-60-3] from

the timer module.

Remove the fuel shutoff timer.

60-60-1 E08 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-5

Fuel Injection Pump - Checking

NOTE: Never try to disassemble the injection pump

assembly. For repairs, you should contact a
Kubota-authorized pump service shop.

The tools listed will be needed to do the following

procedure: 2 3

MEL1237 - Adapter Fuel Line

MEL1173-1 - Pressure Gauge
1

B-8235

WARNING
Connect a pressure gauge (Item 1) to the long leg of the
AVOID INJURY OR DEATH test tubeline (Item 2) [Figure 60-60-5] and tighten.
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or Connect the short leg of the tubeline to the fitting at the
death. Fluid leaks under pressure may not be visible. fuel injection pump (Item 3) [Figure 60-60-5].
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid Set the speed control lever to the maximum engine
enters skin or eyes, get immediate medical attention speed position to allow full fuel delivery.
from a doctor familiar with this injury.
W-2072-EN-0909

Figure 60-60-4

S8428

To check the initial discharge pressure, remove a high

pressure tubeline (Item 1) [Figure 60-60-4] from the fuel
injection pump.

Loosen the other end of the tubeline at the injector, so

that the tubeline can be turned away from the fitting.

60-60-2 E08 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-6

Fuel Injection Pump Removal And Installation

IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment. 2
I-2028-0289

Clean the injection pump and area around it with a

cleaning solvent or steam cleaning.
S7605

Cut the tie-strap (Item 1) [Figure 60-60-6].

IMPORTANT Disconnect the wire connector from the solenoid (Item 2)

[Figure 60-60-6].
Never steam clean or put cold water on an injection
pump while the engine is running or while it is hot. If Figure 60-60-7
you do it will cause serious damage to the injection
pump.
I-2135-0997

IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289

Clean around the injection pump. S7606

Remove the fuel line clamps (Item 1) [Figure 60-60-7].

60-60-3 E08 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-9

Fuel Injection Pump Removal And Installation

(Cont’d)

Figure 60-60-8

2
4

S7610

4
3 Figure 60-60-10

S8428

Disconnect the high pressure lines (Item 1) [Figure 60-

60-8] from the fuel injectors and fuel injection pump.

Disconnect the fuel return hose (Item 2) and the fuel feed
hose (Item 3) [Figure 60-60-8].

Remove the four injection pump mounting bolts (Item 4)

[Figure 60-60-8]. 1

Remove the injection pump.

S7611
Installation: Tighten the pipe retaining nuts to 25 - 34
N•m (18 - 25 ft-lb) torque.
Installation: When installing the injection pump, align the
pin (Item 1) [Figure 60-60-10] on the control rack with
the slot (Item 1) [Figure 60-60-9] on the fork lever
correctly. If both are not aligned correctly, the engine will
run over maximum speed and serious damage can
result.

NOTE: Make sure the same number shims are

installed under the injection pump. The shims
are used for engine timing.

60-60-4 E08 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-13

Fuel Injection Pump - Timing

Timing the injection pump is done by changing the

number of shims between the injection pump and the 1
injection pump mounting surface.

Figure 60-60-11

S8428

Remove the number one cylinder high pressure line (Item

2
1) [Figure 60-60-13] from the fuel injection pump and
fuel injector.

S7605

Cut the tie-strap (Item 1) [Figure 60-60-11].

IMPORTANT
Disconnect the wire connector from the solenoid (Item 2) Do not bend the high pressure fuel injection tubes
[Figure 60-60-11]. when removing or installing them.
I-2029-0289

Figure 60-60-12

IMPORTANT
1
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289

S7606

Remove the fuel line clamp (Item 1) [Figure 60-60-12].

60-60-5 E08 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-15

Fuel Injection Pump - Timing (Cont’d)

Figure 60-60-14

1
1

S8466

At this point look at the timing mark (located on the

flywheel) for proper alignment (Item 1) [Figure 60-60-
S8429 15]. When the timing mark is aligned as shown the timing
is correct for the injection pump, which is 19 - 21°
B.T.D.C.
Install a short plastic tube (Item 1) [Figure 60-60-14] in
the number one cylinder port of the injection pump. The Figure 60-60-16
tube should fit tight in the port and point upward.

NOTE: The fuel must be in the tube before attempting

timing.

Move the fuel lever on the injection pump to full fuel

position (or full throttle).
1
Remove the muffler. (See Removal And Installation on
Page 60-20-1.) for easy access to flywheel.

NOTE: Engine has been removed for photo clarity.

Turn the flywheel counterclockwise (facing the flywheel)

slowly until the start of fuel rise in the plastic tube (Item 1) B-14422
[Figure 60-60-14].
The correct engine timing for all Kubota® D722-E2B
engines is 19 - 21° B.T.D.C. Add or subtract shims (Item
1) [Figure 60-60-16] to time the engine to 19 - 21°
B.T.D.C. The engine is correctly timed when the 19 - 21°
B.T.D.C. mark on the flywheel is aligned with the notch in
the timing hole.

NOTE: Adding or reducing the shim thickness by

0,05 mm (0.0020 in) retards or advances the
injection timing by approximately 0.5°.

Some problems caused by faulty injector nozzles:

• The engine is hard to start or will not start.

• Rough engine operation at idle.
• The engine will not have full power.
• The engine exhaust smoke is black, white or blue.

60-60-6 E08 Service Manual

FUEL SYSTEM (CONT’D) Fuel Camshaft Governor

Fuel Camshaft Removal And Installation The governor serves to keep the engine speed constant
by automatically adjusting the amount of fuel supplied to
Remove the timing gearcase cover. (See Timing the engine according to changes in the load.
Gearcase Cover Removal And Installation on Page 60-
90-1.) Figure 60-60-18

Remove the idler gear. (See Idler Gear And Camshaft

Removal And Installation on Page 60-90-3.)
2
Figure 60-60-17
1 4
2
5

3
11
10
6
9
1 8
7
1. Start Spring
B-14342 2. Governor Spring
3. Fork Lever
Remove the bolt (Item 1) from the retainer plate (Item 2) 4. Fork Lever
[Figure 60-60-17]. 5. Fork Lever Shaft
6. Governor Sleeve
Installation: Tighten the bolt to 6,8 - 8,1 N•m (60 - 72 in- 7. Retaining Plate
lb) torque. 8. Bearing
9. Fuel Camshaft
Remove the fuel camshaft retainer plate (Item 2) [Figure 10. Bearing
60-60-17]. 11. Snap Ring
B-14875

Remove the fuel camshaft and fork lever assembly at the

same time. Disassemble and assemble the governor and fuel
camshaft as shown [Figure 60-60-18].

Check all the parts for wear or damage and replace as

needed.

60-60-7 E08 Service Manual

FUEL SYSTEM (CONT’D) Figure 60-60-21

Fuel Injector Removal And Installation

IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them. 2
I-2029-0289

1
Figure 60-60-19
S8428

Disconnect the high pressure fuel lines (Item 1) [Figure

60-60-21] from the injection pump.
1
Disconnect the return fuel hose (Item 2) [Figure 60-60-
21] from the injection pump.
Figure 60-60-22

2
1

S7605

3
Cut the tie-strap (Item 1) [Figure 60-60-19].
4
Disconnect the wire connector from the solenoid (Item 1) 3 2
[Figure 60-60-19].
4
Figure 60-60-20 3 S7608

Disconnect the high pressure fuel lines (Item 1) [Figure

60-60-22] from the fuel injectors.
Disconnect the return fuel hose (Item 2) [Figure 60-60-
1
22].
Remove the high pressure fuel lines.
Remove the retainer nut (Item 3) [Figure 60-60-22] from
the top of the fuel injectors.
Remove the fuel return pipe (Item 4) [Figure 60-60-22].
Loosen the injector nozzle.

S7606
Remove the injector nozzle from the cylinder head.
Installation: Tighten the injector nozzle to 49 - 69 N•m
(36 - 51 ft-lb) torque.
Remove the high pressure fuel line clamps (Item 1)
[Figure 60-60-20]. NOTE: Be sure to replace the copper washer and
nozzle cap anytime new or reconditioned fuel
injectors are installed.

60-60-8 E08 Service Manual

FUEL SYSTEM (CONT’D) Each spacer will change the release pressure by about
234,4 kPa (2,3 bar) (34 psi).
Fuel Injector Nozzle Pressure - Checking
Fuel Injection Pressure. 13,7 - 14,7 MPa
(137 - 147 bar)
(1991 - 2134 psi)

IMPORTANT Figure 60-60-24

Do not disassemble or test the fuel injector nozzles

unless you have the correct service and testing
tools.
I-2027-0284

The tool listed will be needed to do the following

procedure:

MEL10018 - Injector Nozzle Tester

Figure 60-60-23

A-2513

Assemble the injector nozzle. Connect the nozzle to the

tester with the nozzle down [Figure 60-60-24].

Operate the hand lever at a slow rate and record the

opening pressure. If the pressure is not correct,
disassemble the nozzle and add or remove the spacer
1 (Item 2) [Figure 60-60-23] as needed.

NOTE: When assembling the injector nozzle, tighten

the retainer nut (Item 1) [Figure 60-60-23] to
2 25,3 - 28,9 N•m (23.5 - 28.9 ft-lb) torque. Any
higher torque will cause slow action of the
3 valve.

4 (1) Nozzle Holder When the injector nozzle is assembled, tighten the nozzle
5 (2) Adjusting Washer body to 49 - 69 N•m (36 - 51 ft-lb) torque.
(3) Nozzle Spring
6 (4) Push Rod Check for inside leakage. Operate the hand lever until the
(5) Distance Piece pressure 12,7 MPa (127 bar) (1849 psi). Keep the nozzle
(6) Nozzle Piece under this pressure for 10 seconds, check to see if fuel
(7) Nozzle Retaining Nut leaks from the nozzle. If fuel leaks, replace the nozzle.
7

PI-9981

The nozzle release pressure can be adjusted by adding

or removing washer(s) (Item 2) from the top of the nozzle
spring (Item 3) [Figure 60-60-23].

60-60-9 E08 Service Manual

ENGINE COMPONENTS AND TESTING (CONT’D) Valve Seat Tightness

Fuel Injector Nozzle Pressure - Checking (Cont’d) Figure 60-60-26

WARNING
AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a doctor familiar with this injury.
W-2072-EN-0909 3EEABAC1P014A

Figure 60-60-25 Set the injection nozzle to a nozzle tester (Code No.
07909-31361) [Figure 60-60-26].

Raise the fuel pressure, and keep at 12,75 MPa (127,5

bar) (1849 psi) for 10 seconds.
CORRECT WRONG
If any fuel leak is found, replace the injection nozzle
assembly or repair.

Valve seat Factory No fuel leak at 

tightness spec. 12,75 MPa
(127,5 bar)
(1849 psi)

A-2621

Check that the spray pattern is correct [Figure 60-60-25]:

1. Fuel does not come out the side of the nozzle.

2. Drops of fuel are not present at the nozzle.
3. The injector has an even flow coming from the
nozzle.

60-60-10 E08 Service Manual

CYLINDER HEAD

Glow Plug Removal And Installation

IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289

Figure 60-70-1

1 2 1
1

S7613

Remove the nuts (Item 1) [Figure 60-70-1].

Remove the glow plug lead (Item 2) [Figure 60-70-1] and

nut.

Figure 60-70-2

S7614

Remove the glow plugs (Item 1) [Figure 60-70-2] from

the cylinder head.

Installation: Tighten the glow plugs to 8 - 15 N•m (6 - 11

ft-lb) torque.

60-70-1 E08 Service Manual

CYLINDER HEAD (CONT’D) Valve Clearance Adjustment

Glow Plug Removal And Installation (Cont’d) NOTE: The valve clearance must be checked and
adjusted when the engine is cold.
Figure 60-70-3
Remove the cylinder head cover and the glow plugs.

Adjust the valve clearance as follows:

Figure 60-70-4

2
1
3
B-15856

Connect an ohmmeter to the terminal end of the glow

plug, touch the other lead from the ohmmeter to the
heating end of the glow plug [Figure 60-70-3].
P-62022

The reading will be approximately 0.9 ohm. If the

resistance is zero ohm, the glow plug has a short circuit. Loosen the locknut (Item 1) [Figure 60-70-4].
If the resistance is infinite, the coil of the glow plug is
broken. Turn the adjustment screw (Item 2) [Figure 60-70-4] until
the correct clearance is obtained.

NOTE: The clearance is measured between the

rocker arm and valve stem tip (Item 3) [Figure
60-70-4].

If adjustments are necessary, tighten locknut before

moving on to the next rocker arm.

60-70-2 E08 Service Manual

CYLINDER HEAD (CONT’D) Valve Timing - Checking

Valve Clearance Adjustment (Cont’d) Stop the engine and open the rear door.

Figure 60-70-5 Remove the engine. (See Removal And Installation on

Page 60-10-9.)

Remove the timing gearcase cover. (See Timing

Gearcase Cover Removal And Installation on Page 60-
90-1.)

Figure 60-70-7

4
6 3

5
P-62023 6

1
With No. 1 piston at TDC (compression) both the intake 2
and exhaust valves are up. Set both No. 1 valves, No. 2 (1) Idle Gear
exhaust valve and No. 3 intake valve. [Figure 60-70-5]. (2) Idle Collar
(3) External Snap Ring
Rotate the flywheel 360°, No. 1 (overlap position). Set (4) Cam Gear
(5) Camshaft B-14341
No. 2 intake valve and No. 3 exhaust valve. [Figure 60-
70-5].
Make sure the timing marks (Item 6) [Figure 60-70-7] are
Figure 60-70-6 in correct alignment.

0,145 - 0,185 mm
(0.0057 - 0.0073”)

A-2730

Make sure the piston is at TDC when adjusting the

clearance at the valves. The correct clearance is 0,145 -
0,185 mm (0.0057 - 0.0073 in) cold clearance [Figure
60-70-6].

60-70-3 E08 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-9

Cylinder Head Removal And Installation 2 1

Figure 60-70-8

3 2
2

2
2 1
3 S8000

Remove the rocker arm bracket screws (Item 1) and shaft

S7995 assembly (Item 2) [Figure 60-70-9].

Installation: Tighten the nuts to 9,8 - 11,3 Nm (7 - 8.3 ft-

Remove the breather hose (Item 1) [Figure 60-70-8]. lb) torque.

Remove the four bolts (Item 2) from the valve cover and Remove the push rods (Item 3) [Figure 60-70-9].
remove the valve cover and gasket (Item 3) [Figure 60-
70-8]. Remove the intake and exhaust manifolds.

Installation: Tighten the bolts to 7 - 11 N•m (62 - 97.3 in- Figure 60-70-10
lb) torque. Gradually tighten center bolts before the end
bolts to avoid cracking valve cover.

Remove the fuel injector nozzles. (See Fuel Injector

Removal And Installation on Page 60-60-8.)
1
Remove the glow plugs. (See Glow Plug Removal And 2
Installation on Page 60-70-1.)

Remove the alternator. (See Removal And Installation on

Page 50-30-4.)

P-62174

Remove the water return hose [Figure 60-70-10].

60-70-4 E08 Service Manual

CYLINDER HEAD (CONT’D) Cylinder Head Disassembly And Assembly

Cylinder Head Removal And Installation (Cont’d) Figure 60-70-13

Figure 60-70-11

4 B-14418

B-14490
Use a valve spring compressor to compress the valve
spring [Figure 60-70-13].
Remove the cylinder head bolts in order of #14 to #1
[Figure 60-70-11]. Figure 60-70-14

Installation: Put oil on the bolt threads. Tighten the bolts

in the correct sequence of #1 to #14 to 38 - 42 N•m (28 -
31 ft-lb) torque.
2
NOTE: Re-tighten the cylinder head bolts in the
correct sequence after the engine has been
run for 30 minutes.

Remove the cylinder head from the engine block.

Figure 60-70-12
1 2 3 4 5 6

B-4122

Remove the valve cap (Item 1) [Figure 60-70-14] and

valve spring collet (Item 2) [Figure 60-70-13] and
[Figure 60-70-14].

Remove the valve spring retainer (Item 3) [Figure 60-70-

13] and [Figure 60-70-14] and the spring (Item 4)
1 [Figure 60-70-13] and [Figure 60-70-14].

Remove the valve (Item 5) [Figure 60-70-13] and

P-62175 [Figure 60-70-14].

Installation: Always use a new head gasket and new O- Remove the seal (Item 6) [Figure 60-70-14].
ring. Make sure the O-ring (Item 1) [Figure 60-70-12] is
seated over the dowel.

60-70-5 E08 Service Manual

CYLINDER HEAD (CONT’D) Cylinder Head, Servicing

Cylinder Head Disassembly And Assembly (Cont’d) Figure 60-70-16

Figure 60-70-15
1

1 A-2735

B-3643
Clean the surface of the cylinder head.

Remove the thermostat cover and thermostat from the Put a straight edge (Item 1) [Figure 60-70-16] on the
cylinder head. Remove the thermostat housing (Item 1) cylinder head.
[Figure 60-70-15].
NOTE: Do not put the straight edge across
Installation: Apply Liquid-Type Gasket (Three Bond combustion chambers.
1215 or equivalent) to both sides of the new thermostat
cover gasket and new thermostat housing gasket. Put a feeler gauge (Item 2) [Figure 60-70-16] between
the straight edge and the surface of the cylinder head.

Figure 60-70-17

PI-9988

Put the straight edge on the cylinder head's four sides

and two diagonal as shown in figure [Figure 60-70-17].

The maximum distortion of the head surface ± 0,05 mm

(± 0.002 in). If the measurement is more than the
specification, remove the combustion chambers, then
grind the cylinder head. Grind the same amount of
material from the bottom of the combustion chambers as
was removed from the head.

60-70-6 E08 Service Manual

CYLINDER HEAD (CONT’D) Valve Guide - Checking

Cylinder Head Top Clearance Remove the valve and spring from the cylinder head.
(See Cylinder Head Removal And Installation on Page
Figure 60-70-18 60-70-4.)

Clean the valve seat and combustion chamber.

2
Figure 60-70-19

1
3

PI-9989

Install the cylinder head gasket. Put the piston (Item 1)

[Figure 60-70-18] being checked at T.D.C.
B-3634

Put three pieces of 1,5 mm (0.06 in) diameter solder

(Item 2) [Figure 60-70-18] on the top piston. Use grease Install the valve into the guide. Measure the valve
to hold them in position. recessing with a depth gauge [Figure 60-70-19].

NOTE: Put the solder in position so they do not touch Figure 60-70-20
the valves.
2
Turn the piston to bottom dead center.

Install the cylinder head and tighten to the correct torque

in the correct sequence. (See Cylinder Head Removal
1
And Installation on Page 60-70-4.)

Turn the crankshaft until the piston exceeds T.D.C.

Remove the cylinder head.
1. Cylinder Head
Remove the solder wire (Item 3) [Figure 60-70-18] and
Surface
measure it.
2. Recessing
If the measurement exceeds the specifications, check the PI-9990
oil clearance of the crank pin journal or the piston pin.

Top clearance 0,50 - 0,70 mm (0.0197 - 0.0276 in) If the measurement exceeds the allowable limit, replace
the valve or cylinder head [Figure 60-70-20].

Recessing 0,10 mm (0.004 in)

Allowable Limit (Recessing) 0,30 mm (0.012 in)

Remove the carbon from the valve guide.

60-70-7 E08 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-22

Valve Guide - Checking (Cont’d) 200 mm (7.87 in)

40 mm
80 mm (3.15 in) (1.57 in)
20 mm
Figure 60-70-21 (0.79 in)

9,96 - 9,98 mm 5,5 - 5,7 mm

(0.3921 - 0.3929 in) (0.2165 - 0.2244 in)

5,0 mm 7,0 mm 18,0 mm

(0.2 in) (0.276 in) (0.71 in)

6,0 - 6,1 mm 15,0 mm 10,6 - 10,7 mm

(0.236 - 0.240 in) (0.59 in) (0.417 - 0.421 in)
MC-1364

To remove and replace the valve guide, make the driver

B-14335 tools as shown in figure [Figure 60-70-22].

Figure 60-70-23
Measure the valve stem O.D. [Figure 60-70-21].

Measure the valve guide I.D. [Figure 60-70-21].

Calculate the clearance. If the clearance exceeds the

allowable limit, replace the valve and / or valve guide.

Valve Guide I.D 6,01 - 6,025 mm (0.2366 - 0.2372 in) 1

Valve Stem O.D 5,968 - 5,980 mm (0.2350 - 0.2354 in)

Clearance Between Valve Stem and Guide
0,03 - 0,057 mm (0.0012 - 0.0022 in) 2
Allowable Limit 0,10 mm (0.0039 in)

PI-9992

Press the used valve guide out of the cylinder head using
the special driver tool [Figure 60-70-23]. (See previous
page for tool dimensions.)

Put oil on the outside diameter of the new valve guide.

Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 and 2)
[Figure 60-70-23], press the new guide until the tools
contact the cylinder head.

Ream the valve guide to the correct specifications.

NOTE: Valve guide I.D. (Intake and Exhaust) factory

spec. is 6,01 - 6,025 mm (0.2366 - 0.2372 in).

60-70-8 E08 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-26

Valve And Valve Seat Reconditioning 1 2

Figure 60-70-24
15°

2,12 mm (0.0835 in)

PI-9995

Check the seat surface and valve face (Item 1) [Figure

PI-9993 60-70-26].

If the seat surface is too wide, use a 15 degree cutter

Grind the valve face to the correct angle using a valve (Item 2) to get the correct width (Item 3) [Figure 60-70-
refacer [Figure 60-70-24] and [Figure 60-70-26]. 26].

Figure 60-70-25 Valve Seat Width

Intake 2,12 mm (0.0835 in)

Exhaust 2,12 mm (0.0835 in)

Valve Seat and Face Angle

Intake 45°
Exhaust 45°
15° 45° (30°)

PI-9994

Grind the valve surface in the cylinder head to the correct

angle [Figure 60-70-25].

60-70-9 E08 Service Manual

CYLINDER HEAD (CONT’D) Figure 60-70-28

Valve Spring

Figure 60-70-27

A-2759

Put the spring on a tester and compress to specified

B-3680 length [Figure 60-70-28].

Read the compressed load on the gauge. If the

Measure the length of the valve spring. If the measurement exceeds allowable limit, replace the spring.
measurement is less than the allowable limit, replace the
spring [Figure 60-70-27]. Setting Length 27 mm (1.063 in)
Setting Load 64,7 N (14.6 lbf)
Free Length 31,3 - 31,8 mm (1.232 - 1.252 in)
Allowable Limit (setting load)
Allowable Limit 28,4 mm (1.118 in)
54,9 N (12.3 lbf)
Put the spring on a flat surface, place a square on the
side of the spring [Figure 60-70-27].

Rotate the spring and measure the maximum tilt. If the

measurement is in excess of the allowable limit, replace
the spring.

Tilt 1,2 mm (0.047 in)

60-70-10 E08 Service Manual

CYLINDER HEAD (CONT’D) If the oil clearance exceeds the allowable limit or the
tappet is damaged, replace the tappet.
Valve Tappets
Oil clearance Factory 0,016 - 0,052 mm
Figure 60-70-29 between tappet spec. (0.00063 - 0.00205 in)
and guide Allowable 0,10 mm
1
limit (0.0039 in)

Tappet O.D. Factory 17,966 - 17,984 mm

spec. (0.70732 - 0.70803 in)
Tappet guide Factory 18,000 - 18,018 mm
I.D. spec. (0.70866 - 0.70937 in)

P-37202

Remove the tappets (Item 1) [Figure 60-70-29] from the

crankcase.

When reassembling replace the head gasket with a new

one.

Before installing the tappets (Item 1) [Figure 60-70-29],

apply engine oil thinly around them.

NOTE: Mark the cylinder number to the tappets to

prevent interchanging.

Figure 60-70-30

P-37174

Measure the tappet O.D. with an outside micrometer

[Figure 60-70-30].

Measure the I.D. of the tappet guide bore with a cylinder

gauge, and calculate the oil clearance [Figure 60-70-30].

60-70-11 E08 Service Manual

CYLINDER HEAD (CONT’D)

Rocker Arm And Shaft, Checking

Figure 60-70-31

2 1

B-3697

Measure the rocker arm I.D. (Item 1) [Figure 60-70-31]

with an inside micrometer.

Measure the rocker shaft O.D. (Item 2) [Figure 60-70-31]

with an outside micrometer.

If the clearance exceeds the allowable limit, replace the

rocker arm and measure the clearance again.

If the clearance still exceeds the allowable limit after the

rocker arm is replaced, replace the rocker arm shaft.

Oil Clearance Between Rocker Arm and Shaft

0,016 - 0,045 mm
(0.0006 - 0.0018 in)
Allowable Limit 0,15 mm (0.0059 in)
Rocker Arm Shaft 10,47 - 10,48 mm
(0.4123 - 0.4128 in)
Rocker Arm I.D. 10,5 - 10,52 mm
(0.4134-0.4141 in)

60-70-12 E08 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 60-70-4.)

Remove the top edge from the cylinder bore with a ridge

828
reamer.
1
Figure 60-80-1

828
A-2903

Installation: Make sure the marks (Item 1) on the

connecting rod and bearing are aligned when installing
the bearing cap [Figure 60-80-2].

Repeat the procedure to remove the other piston /

connecting rod assemblies from the engine block.

PI-10013

Remove the rod cap and bearing [Figure 60-80-1].

Use a hammer handle and push the piston connecting

rod assembly out of the cylinder bore [Figure 60-80-1].

NOTE: Make sure the pistons are marked so they will

be returned to the same cylinder bore.

60-80-1 E08 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-4

Piston And Connecting Rod Removal And

Installation (Cont’d) 2

Figure 60-80-3

6 1
4 180°

1
5 2
3
4

3 PI-10015A PI-10015

7
Installation: When installing new rings, assemble the
ring so the mark (Item 1) near the gap faces the top of the
B-3621
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
3) [Figure 60-80-4].
Remove the first compression ring (Item 1) [Figure 60-
80-3]. Figure 60-80-5

Remove the second compression ring (Item 2) [Figure 3 4

60-80-3].

Remove the oil ring (Item 3) [Figure 60-80-3]. 1

2
Remove the snap ring (Item 4) and piston pin (Item 5)
[Figure 60-80-3].

Separate the piston (Item 6) from the connecting rod

(Item 7) [Figure 60-80-3].

NOTE: Make sure the piston and rod assembly is

marked so as not to change the piston rod
assembly with another piston or connecting PI-10014B 5 PI-10014A
rod.

Installation: When reassembling, align the marks (Item

1) on the connecting rod and piston (Item 2). Heat the
piston in oil to 80°C (176°F) for 10 - 15 minutes and tap
the piston pin into position. Place the piston rings so that
there are gaps every 120° (Item 3, 4 and 5) [Figure 60-
80-5] with no gap facing the piston pin in the cylinder.

60-80-2 E08 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the bushing. If it still exceeds the
Piston And Connecting Rod - Servicing specifications, replace the piston pin.

Figure 60-80-6 Piston Pin O.D. 20,002 - 20,011 mm

(0.7875 - 0.7878 in)
Bushing I.D. 20,025 - 20,04 mm
(0.7884 - 0.7890 in)
Oil Clearance between Piston Pin and Bushing
0,014 - 0,038 mm
(0.0006 - 0.0015 in)
Allowable Limit 0,10 mm (0.004 in)

Figure 60-80-8

20 mm (0.79”)
A-2733
145 mm (5.7”)
25 mm
Measure the I.D. of the piston pin bore in both horizontal (0.98”) 25 mm
and vertical direction [Figure 60-80-6]. (0.98”)

If the measurement exceeds the allowable limit, replace

the piston.
21,9 - 21,96 mm
(0.8622 - 0.8642”) 19,9 - 19,95 mm
Piston Pin Bore I.D. 20,00 - 20,013 mm (0.7835 - 0.7854”)
0.7874 - 0.7879 in
MC-1366A
Allowable Limit 20,05 mm (0.789 in)

Figure 60-80-7 To replace the connecting rod small end bushing, make a
driver tool as shown in figure [Figure 60-80-8].

1
B-3633

Measure the O.D. of the piston pin (Item 1) [Figure 60-

80-7].

Measure the I.D. of the connecting rod small end (Item 2)

[Figure 60-80-7].

60-80-3 E08 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) If the gap exceeds the allowable limit, replace the piston
ring.
Piston And Connecting Rod - Servicing (Cont’d)
Top Compression Ring and Oil Ring
Figure 60-80-9
0,15 - 0,30 mm (0.006 - 0.012 in)
Second Compression Ring
Removing Installing
0,30 - 0,45 mm (0.012 - 0.018 in)
Allowable Limit 1,2 mm (0.047 in)

Figure 60-80-11

PI-10016

Use a press and special driver tool to remove the small

end bushing [Figure 60-80-9].

Installation: Clean the small end bushing and bore. Put

oil on the bushing and press into the connecting rod until B-14475
it is flush [Figure 60-80-9].

Figure 60-80-10 Remove the carbon from the ring grooves. Measure the
clearance between the ring and groove with a feeler
gauge [Figure 60-80-11].

Second ring 0,09 - 0,12 mm (0.0033 - 0.0045 in)

Oil ring 0,04 - 0,08 mm (0.0016 - 0.0031 in)
Allowable limit second ring
0,15 mm (0.0059 in)
Allowable limit oil ring
0,15 mm (0.0059 in)

If the clearance exceeds the allowable limit, replace the

piston.
B-3622

Install a new piston ring into the lower part of the cylinder
bore. Measure the ring gap with a feeler gauge [Figure
60-80-10].

60-80-4 E08 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Connecting Rod Alignment

Cylinder Bore - Checking NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
Figure 60-80-12 doing this check.

Install the piston pin into the connecting rod.

Install the connecting rod on an alignment tool.

Put the gauge over the piston pin and move it against the
face plate.

Figure 60-80-14

B-10073

Check the inside diameter of the cylinder line [Figure 60-

80-12].

Figure 60-80-13

B-4067

If the gauge does not fit squarely against the face place,
measure the space between the gauge and face plate
[Figure 60-80-14].

If the measurement exceeds the allowable limit, replace

the connecting rod.

Rod Alignment Allowable Limit

0,05 mm (0.002 in)
A-2717A

To find the maximum wear check the inside diameter in

six different locations [Figure 60-80-13].

When the cylinder bore is not within specifications, bore

and hone the cylinder for an oversize piston.

Cylinder Bore I.D. 67,0 - 67,02 mm (2.638 - 2.639 in)

Allowable Limit 67,17 mm (2.644 in)

NOTE: Make sure you use the correct oversize

pistons and rings.

60-80-5 E08 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-17

Crankshaft And Bearings Removal And Installation

3
Remove the piston and connecting rod assemblies. (See
Piston And Connecting Rod Removal And Installation on
Page 60-80-1.)

Remove the engine flywheel. (See Cylinder Head

Removal And Installation on Page 60-70-4.)

Remove the bolts which fasten the bearing case cover to

the block.

Installation: Tighten the bearing case cover bolts to 10 - 2 1

11 N•m (7 - 8 ft-lb) torque. Tighten bolts with even force
on the diagonal line. P-62181

Figure 60-80-15
Installation: When installing the bearing case gasket
(Item 1) [Figure 60-80-16] and [Figure 60-80-17], and
the bearing case cover gasket (Item 2) [Figure 60-80-16]
and [Figure 60-80-17] make sure the mark (Item 3)
[Figure 60-80-17] is in the up position.

Figure 60-80-18

B-3648

Install two bolts into the bearing case cover and pull the
cover out [Figure 60-80-15].

Figure 60-80-16
B-9565

3
Before removing the crankshaft / main bearings, check
2 the end play. Install a dial indicator. Measure the end play
1 by moving the crankshaft back and forth [Figure 60-80-
18].

If the measurement exceeds the allowable limit, replace

the thrust washers.

End Play 0,15 - 0,31 mm (0.006 - 0.012 in)

4 Allowable Limit 0,5 mm (0.020 in)
P-62185

Installation: When installing the cover (Item 4), make

sure the casting mark (Item 3) is in the up position.
Lightly oil inside lip of oil seal (Item 3) [Figure 60-80-16].

60-80-6 E08 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-21

Crankshaft And Bearings Removal And Installation

(Cont’d)

Figure 60-80-19

B-4092

Remove the two bearing case bolts [Figure 60-80-21].

1
B-14346 Remove the bearing case and bearing.

Installation: Tighten the bearing case bolts (Item 1)

Remove the main bearing case bolt (Item 1) [Figure 60- [Figure 60-80-22] to 13 - 16 N•m (9 - 12 ft-lb) torque.
80-19].
Figure 60-80-22
Installation: Align the bearing case hole (Item 2) [Figure
60-80-19] with the hole in the block. Put oil on the bolt
1
threads and tighten to 27 - 30 N•m (20 - 22 ft-lb) torque.

Figure 60-80-20

3
P-62182

Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to the flywheel
B-14878 side of the engine block [Figure 60-80-22]. Be sure the
thrust washer with its oil grooves face outward.

Remove the crankshaft / main bearing assembly from the Identification marks on the main bearing case
engine block [Figure 60-80-20]. assemblies are the alignment number (Item 2) and the
marking “1” or “2” (Item 3) [Figure 60-80-22] can be
Mark the bearing case halves for correct installation. found on the main bearing case assemblies to ensure
proper assembly.

60-80-7 E08 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-25

Crankshaft And Bearings - Servicing

Figure 60-80-23

A-2716

Measure the crankpin O.D. [Figure 60-80-25].

A-2763
Calculate the oil clearance.

Put the crankshaft on V-blocks. Install a dial indicator on Crankpin Bearing I.D.
the center journal [Figure 60-80-23].
33,99 - 34,01 mm (1.3389 - 1.3390 in)
Turn the crankshaft at a slow rate. Crankpin O.D. 33,96 - 33,98 mm (1.3370 - 1.3376 in)
Oil Clearance 0,020 - 0,051 mm (0.0008 - 0.0020 in)
If the misalignment exceeds the allowable limit, replace
the crankshaft. Allowable limit 0,15 mm (0.0059 in)

Alignment 0,02 mm (0.0008 in) Figure 60-80-26

Tighten the connecting rod cap bolts 27 - 30 N•m (20 - 22

ft-lb) torque.

Figure 60-80-24

1
120° PI-10024B

A-2727

Measure the crankpin bearing I.D. [Figure 60-80-24].

60-80-8 E08 Service Manual

CRANKSHAFT AND PISTONS (CONT’D) Figure 60-80-28

Crankshaft And Bearings, Servicing (Cont’d)

Figure 60-80-27

130 mm
(5.12”)

R 40 mm
(R 1.57”)

20 mm 39,90 - 39,95 mm
(0.79”)
(1.5709-1.5728”)

72 mm
(2.83”)
PI-10025
68 mm 24 mm
(62.68”) (0.95”)
Measure the flattened press gauge [Figure 60-80-28].
9 mm
(0.35”) B-14879
If the clearance exceeds the allowable limit, replace the
crankshaft bearing.
Remove the bearing (Item 1) [Figure 60-80-26] from the
front of the engine block with the removal tool shown in Crankshaft Journal O.D. (Flywheel side)
[Figure 60-80-27].
43,93 - 43,95 mm
Installation: Clean the new bearing and bore and apply (1.7297 - 1.7303 in)
oil to them. Install the new bearing with the installation Bearing I.D. 43,98 - 44,03 mm
driver tool [Figure 60-80-26]. (1.7317 - 1.7333 in)
Crankshaft Journal O.D. (Middle)
Clean the crankshaft journal and bearing. Put a strip of
press gauge on the center journal. 39,93 - 39,95 mm
(1.5722 - 1.5728 in)
Install the main bearing case halves and tighten the bolts Bearing I.D. 39,98 - 40,03 mm
to 12,7 - 15,7 N•m (9 - 12 ft-lb) torque. Remove the (1.5742 - 1.5758 in)
bearing case halves. Crankshaft journal O.D. (Front)
39,93 - 39,95 mm
(1.5722 - 1.5728 in)
Bearing I.D. 39,98 - 40,04 mm
(1.5714 - 1.5764 in)
Oil Clearance 0,034 - 0,106 mm
(0.0013 - 0.0042 in)
Allowable Limit 0,2 mm (0.008 in)

60-80-9 E08 Service Manual

60-80-10 E08 Service Manual
CAMSHAFT AND TIMING GEARS Figure 60-90-3

Timing Gearcase Cover Removal And Installation

Remove the fuel injection pump. (See Fuel Injection

Pump Removal And Installation on Page 60-60-3.)

Figure 60-90-1 1

2
2
B-14870

Remove the bolt (Item 1) and disconnect the shaft spring

(Item 2) [Figure 60-90-3].
1
Figure 60-90-4
B-14868

Remove the cylinder head, rocker arms and push rods.

(See Cylinder Head Removal And Installation on Page
60-70-4.)

Remove the screws (Item 1) from the speed control plate

(Item 2) [Figure 60-90-1].

NOTE: Take care not to damage the spring.

Figure 60-90-2

B-14871

Remove the crankshaft pulley bolt.

1
Installation: Tighten the bolt to 98 - 108 N•m (72 - 80 ft-
lb) torque.

Use a puller and remove the crankshaft pulley [Figure

60-90-4].

B-14869

Separate the speed control plate from the engine and

remove the spring (Item 1) [Figure 60-90-2].

Remove the speed control plate.

60-90-1 E08 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-90-7

Timing Gearcase Cover Removal And Installation

(Cont’d)

Figure 60-90-5

Oil Seal O-rings

B-3617

Installation: Install three new O-rings and the oil seal

into the timing gearcase cover [Figure 60-90-7].
B-14872

When installing the crank shaft pulley, make sure the

alignment marks are aligned [Figure 60-90-5].

Remove the timing gearcase cover bolts.

Installation: Tighten the bolts to 10 - 11 N•m (7 - 8 ft-lb)

torque.

Figure 60-90-6

B-14873

Remove the timing gearcase [Figure 60-90-6].

60-90-2 E08 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Idler Gear And Camshaft Removal And Installation

Timing Gears Checking Backlash Figure 60-90-9

Figure 60-90-8

1
2
3

B-14341

PI-10005
Remove the snap ring (Item 1) and collar (Item 2) from
the idler gear shaft (Item 3) [Figure 60-90-9].
When the gears are installed, check the backlash of the
gears. Figure 60-90-10

Install a dial indicator with its tip on a gear tooth [Figure

60-90-8]. 1

Hold one gear while turning the other gear [Figure 60-
90-8].

If the backlash exceeds the allowable limit, check the oil

clearance of the shaft and gear. If the oil clearance is
correct, replace the gears.

Crank Gear and Idler Gear. 2

0,043 - 0,124 mm
(0.002 - 0.005 in)
B-3699
Allowable Limit 0,15 mm (0.006 in)
Cam Gear and Idler Gear
Remove the idler gear (Item 1) [Figure 60-90-10].
0,047 - 0,12 mm
(0.002 - 0.005 in)
Remove idler gear mounting screws (Item 2) [Figure 60-
Allowable Limit 0,15 mm (0.006 in) 90-10].
Injection Pump Gear and Idler Gear
Installation: Tighten screws to 10 - 11 N•m (7 - 8 ft-lb)
0,046 - 0,124 mm
torque.
(0.002 - 0.005 in)
Allowable Limit 0,15 mm (0.006 in)
Oil Pump Gear and Crankshaft Cover
0,041 - 0,123 mm
(0.002 - 0.005 in)
Allowable Limit 0,15 mm (0.006 in)

60-90-3 E08 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-90-13

Idler Gear And Camshaft Removal And Installation

(Cont’d)

Figure 60-90-11

B-3620

Measure the camshaft bearing in the engine block

[Figure 60-90-13].
B-14874
Figure 60-90-14

Installation: Make sure the timing marks are in correct

alignment when installing the timing gears [Figure 60-90-
11].

Align the holes on the camshaft gear with the camshaft

retainer plate bolts.

Remove the bolts.

Figure 60-90-12

A-2761

Measure the camshaft journal [Figure 60-90-14].

Calculate the oil clearance. If the clearance exceeds the

allowable limit, replace the camshaft.

Bearing I.D. 33,00 - 33,03 mm

(1.299 - 1.300 in)
Journal O.D. 32,93 - 32,95 mm
B-3655
(1.2966 - 1.2972 in)
Clearance of Camshaft Journal
Remove the camshaft from the engine block [Figure 60- 0,05 - 0,09 mm
90-12]. (0.002 - 0.004 in)

Installation: Tighten the camshaft retainer bolts to 18 - Allowable Limit 0,15 mm (0.006 in)
21 N•m (14 - 15 ft-lb) torque.

60-90-4 E08 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-90-16

Idler Gear And Camshaft Removal And Installation

(Cont’d)

Figure 60-90-15

A-2760

Put the camshaft in V-blocks. Install a dial indicator

[Figure 60-90-16].
B-5001
Turn the camshaft at a slow rate. If the misalignment
exceeds the allowable limit, replace the camshaft.
Measure the cam lobes at their highest point [Figure 60-
90-15]. Camshaft Alignment Allowable Limit

If the measurement is less than the allowable limit, 0,01 mm (0.0004 in)
replace the camshaft.

Cam Lob Height 26,88 mm (1.058 in)

Allowable Limit 26,83 mm (1.056 in)

60-90-5 E08 Service Manual

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 60-90-18

Idler Gear And Shaft, Servicing

20 mm (0.79 in)
Figure 60-90-17
150 mm (5.91 in)
25 mm
(0.98 in) 30 mm
(1.18 in)

21,9 - 21,95 mm
(0.862 - 0.864”) 19,9 - 19,95 mm
(0.784 - 0.785 in)

MC-1366A

To replace the idler gear bushing, make a driver tool as

PI-10003 shown in figure [Figure 60-90-18].

Figure 60-90-19
Measure the O.D. of the idler gear shaft [Figure 60-90-
17].

Measure the I.D. of the idler gear bushing [Figure 60-90-

17].

If the clearance exceeds the allowable limit, replace the

bushing.

Idler Gear Shaft O.D. 19,97 - 19,98 mm

(0.786 - 0.787 in)
Idler Gear Shaft I.D. 20,00 - 20,05 mm
(0.787 - 0.789 in) 0 - 0,2 mm
(0 - 0.008 in)
Oil Clearance between Idler Shaft and Gear Bushing
PI-10004
0,020 - 0,084 mm
(0.0008 - 0.0033 in)
Use a press and special driver tool, to remove the old
Allowable Limit 0,10 mm (0.004 in)
bushing and install the new bushing [Figure 60-90-19].

60-90-6 E08 Service Manual

FLYWHEEL AND HOUSING Figure 60-100-3

Removal And Installation

Remove the air cleaner. (See Removal And Installation 1

on Page 60-30-1.)

Remove the hydraulic pump. (See Removal And

Installation on Page 20-50-3.)

Remove the spark arrester muffler. (See MUFFLER on

1
Page 60-20-1.)
1
Figure 60-100-1

S8469

Remove the four flywheel housing bolts (Item 1) [Figure

60-100-3].
1
Installation: Tighten the bolts to 24 - 26 N•m (18 - 19 ft-
lb) torque.

Remove the flywheel housing.

S8467

Install a chain hoist to the engine lifting eye to support the

engine (Item 1) [Figure 60-100-1].

Figure 60-100-2

S8466

Remove the mount bolts and nuts (Item 1) [Figure 60-

100-2].

Installation: Tighten the bolts and nuts to 24 - 26 N•m 

(18 - 19 ft-lb) torque.

60-100-1 E08 Service Manual

FLYWHEEL AND HOUSING (CONT’D) Flywheel Removal And Installation

Hydraulic Pump Coupler Removal And Installation Remove the flywheel housing. (See Removal And
Installation on Page 60-70-1)
Remove the flywheel housing. (See Removal And
Installation on Page 60-100-1.) Remove the hydraulic pump coupler. (See Hydraulic
Pump Coupler Removal And Installation on Page 60-70-
Figure 60-100-4 2)

1 Figure 60-100-5

1
2

S8578

1
S8577
Remove the three bolts (Item 1) [Figure 60-100-4] from
the hydraulic pump coupler.
Remove the five bolts (Item 1) [Figure 60-100-5] from
Installation: Apply Loctite® 242 (Blue) to bolts and the flywheel.
tighten the bolts to 71 - 79 N•m (53 - 58 ft-lb) torque. Also
lubricate the bolt heads prior to installation. Remove the flywheel (Item 2) [Figure 60-100-5].

NOTE: Apply anti-seize compound on spline teeth

prior to pump installation.

Remove the hydraulic pump coupler (Item 2) [Figure 60-

100-4].

60-100-2 E08 Service Manual

FLYWHEEL AND HOUSING (CONT’D)

Rear End Plate Removal And Installation

Remove the flywheel housing. (See Removal And

Installation on Page 60-70-1)

Remove the hydraulic pump coupler. (See Hydraulic

Pump Coupler Removal And Installation on Page 60-70-
2)

Remove the flywheel. (See Flywheel Removal And

Installation on Page 60-70-2)

Figure 60-100-6

S8472

Figure 60-100-7

2
1

P-68765

Remove the bolts (Item 1) from the rear end plate (Item
2) [Figure 60-100-6] and [Figure 60-100-7]. Remove
end plate from the side of the engine.

60-100-3 E08 Service Manual

60-100-4 E08 Service Manual
SPECIFICATIONS

EXCAVATOR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Working Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Rated Lift Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Function Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-5
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-6
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-7
Temperature Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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-20-2
Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-3
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-4

TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2

HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-4

HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
Decimal And Millimeter Equivalents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1

SPEC-01 E08 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
General Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-7
HVAC Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-8

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.

SPEC-02 E08 Service Manual

EXCAVATOR SPECIFICATIONS

Machine Dimensions
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.

2793
550 mm
mm
(110.0
21.6 inin)
2153 mm
(84.8 in)

992 mm 2209 mm
(39.0 in) (87.0 in)

363 mm
(14.3 in)

987 mm 180 mm
(38.9 in) 220 mm (7.1 in)
16 mm 968 mm (8.6 in)
(0.6 in) (38.1 in)
1280 mm 1000 mm
(50.4 in) (39.4 in)

413 mm
(16.2 in)
1162 mm
1220 mm
(45.8 in)
(48.1 in)
471 mm
(18.5 in)

550 mm
21.6 in 1121 mm
(44.1 in)

SPEC-10-1 E08 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Working Range

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

3145 mm
(123.8 in)
3093 mm
(121.8 in)

1374 mm
(54.1 in)

196°

2685 mm
(105.7 in)
1899 mm
(74.8 in) 1818 mm
(71.6 in)
196 mm
(7.7 in)

230 mm
(9.1 in)

1383 mm
(54.4 in)

1820 mm
(71.7 in)

SPEC-10-2 E08 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Rated Lift Capacity

7135258

SPEC-10-3 E08 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Performance

Digging force, arm (ISO 6015) 5550 N (1248 lbf)

Digging force, bucket (ISO 6015) 8294 N (1865 lbf)
Drawbar pull (theoretical at 90% efficiency) 9905 N (2227 lbf)
Ground pressure 28,8 kPa (0,288 bar) (4.18 psi)

Function Time

Boom raise time 4,0 s

Boom lower time 3,5 s
Bucket curl time 3,3 s
Bucket dump time 2,3 s
Arm retract time 4,8 s
Arm extend time 3,4 s
Boom swing left time 4,0 s
Boom swing right time 3,1 s
Blade raise time 1,6 s
Blade lower time 1,1 s
Slew rate 9 rpm
Undercarriage expand time 3,8 s
Undercarriage retract time 2,8 s

Weights

Operating weight with TOPS canopy, rubber tracks, 1138 kg (2509 lb)
400 mm bucket

Controls

Engine Hand levers on right hand side

Starting Key-type starter switch and shutdown
Blade Right hand lever
Boom swing Right foot pedal
Hydraulics Two levers control boom, bucket, arm and upperstructure slew
Auxiliary hydraulics Left-hand foot pedal
upperstructure slew brake Hydraulic lock on motor
Holding brake for upperstructure slew Pin lock
Steering Direction and speed controlled by two hand levers

SPEC-10-4 E08 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Engine
Serial Number A4BP11001 & Above B4PC11001 & Above
Make / Model Kubota / D722-E2B-BCZ-6 (Tier 2) Kubota / D722-E4B-BCZ-6 (Stage 5)
Fuel Diesel Diesel
Cooling Liquid Liquid
Horsepower: 
– Gross power (ISO 14396) 7,5 kW (10.0 hp) @ 2000 rpm 7,5 kW (10.0 hp) @ 2000 rpm
– Gross power (SAE J1995) 7,6 kW (10.2 hp) @ 2000 rpm 7,6 kW (10.2 hp) @ 2000 rpm
– Net power (SAE J1349 / ISO 9249) 7,4 kW (9.9 hp) @ 2000 rpm 7,4 kW (9.9 hp) @ 2000 rpm
Maximum governed speed 2000 rpm 2000 rpm
High idle speed 2370 rpm 2370 rpm
Low idle speed 1300 - 1400 rpm 1300 – 1400 rpm
Torque: 
– Gross torque (SAE J1995) 40,1 N•m (39.6 lb-ft) @ 1600 rpm 40,1 N•m (39.6 lb-ft) @ 1600 rpm
– Net torque (SAE J1349 / ISO 9249) 39,1 N•m (28.8 lb-ft) @ 1600 rpm 39,1 N•m (28.8 lb-ft) @ 1600 rpm
Number of cylinders 3 3
Displacement 0,72 L (43.9 in³) 0,72 L (43.9 in3)
Bore 67 mm (5.64 in) 67 mm (2.6 in)
Stroke 68 mm (5.68 in) 68 mm (2.7 in)
Lubrication Forced lubrication with cartridge type Forced lubrication with cartridge type
filter filter
Crankcase ventilation Closed breathing Closed breathing
Air filter Dual dry replaceable paper cartridge Dual dry replaceable paper cartridge
Ignition Compression ignited (diesel) Compression ignited (diesel)
Starting aid Intake air heater Intake air heater

Electrical
Alternator 12 V - 40 A - open frame with internal regulator
Battery 12 V - 530 A cold cranking current - 75 min reserve capacity
Starter 12 V - reduction drive - 1,4 kW

Hydraulic System
Pump Type Double gear pump
Pump capacity 21,0 L/min @ 2000 RPM (2.6 U.S. gpm)
System relief pressure 18500 kPa (185 bar) (2683 psi)
Joystick control pressure 3000 kPa (30 bar) (435 psi)
System relief pressure for slew circuits 8400 kPa (84 bar) (1218 psi)
Main hydraulic filter bypass 172 kPa (1.72 bar) (25 psi)
Boom base and arm rod port relief 23200 kPa (232 bar) (3365 psi)
Arm base port relief 22500 kPa (225 bar) (3263 psi)
Control valve Nine-spool parallel type, open centre
Hydraulic filter Full-flow replaceable
Fluid lines SAE standard tubelines, hoses, and fittings
Auxiliary flow 20,0 L/min (5.3 U.S. gpm)
Pump Type Double gear pump

SPEC-10-5 E08 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Hydraulic Cylinders

Boom cylinder Cushion up

Boom cylinder bore 63,5 mm (2.5 in)
Boom cylinder rod 31,8 mm (1.3 in)
Boom cylinder stroke 312,4 mm (12.3 in)
Arm cylinder Cushion
Arm cylinder bore 50,8 mm (2.0 in)
Arm cylinder rod 31,8 mm (1.3 in)
Arm cylinder stroke 325,6 mm (12.8 in)
Bucket cylinder No cushion
Bucket cylinder bore 44,5 mm (1.8 in)
Bucket cylinder rod 25,4 mm (1.0 in)
Bucket cylinder stroke 385,1 mm (15.2 in)
Boom swing cylinder No cushion
Boom swing cylinder bore 57,1 mm (2.3 in)
Boom swing cylinder rod 31,8 mm (1.3 in)
Boom swing cylinder stroke 274,6 mm (10.8 in)
Blade cylinder No cushion
Blade cylinder bore 50,8 mm (2.0 in)
Blade cylinder rod 31,8 mm (1.3 in)
Blade cylinder stroke 96,8 mm (3.8 in)
Undercarriage cylinder No cushion
Undercarriage cylinder bore 44,5 mm (1.8 in)
Undercarriage cylinder rod 25,4 mm (1.0 in)
Undercarriage cylinder stroke 299,9 mm (11.8 in)

Drive System

Travel motor Each track is driven by a hydrostatic axial piston motor

Drive reduction Two-stage planetary gear reduction 23,0:1

Traction

Track width, rubber, standard 180 mm (7.1 in)

Track adjusters Grease type adjusters, rubber
Track type, standard Half-pitch, rubber
Travel speed 2,1 km/h (1.3 mph)
Undercarriage Sealed track rollers with box section track roller frame
Number of track rollers per side 3
Gradeability travelling down or backing up slopes 25°
Gradeability travelling on side slopes 15°
Gradeability travelling up side slopes 15°
Track width, rubber, standard 180 mm (7.1 in)

SPEC-10-6 E08 Service Manual

EXCAVATOR SPECIFICATIONS (CONT’D)

Capacities

Serial Number A4BP11001 & Above B4PC11001 & Above

Cooling system 5,7 l (6.02 qt) 3,0 L (3.2 qt)
Engine lubrication plus oil filter 3,5 l (3.7 qt) 2,8 L (3.0 qt)
Fuel reservoir 23,8 l (25.15 qt) 16,0 L (16.9 qt)
Hydraulic reservoir 11,2 l (11.83 qt) 2,6 L (2.8 qt)
Hydraulic system with bucket and dipper cylinder 18,8 l (19.88 qt) 9,4 L (9.9 qt)
retracted, bucket on the ground, and blade down
Travel motor (each) 0,5 l (.5 qt) 0,5 L (0.5 qt)

Environmental

DECLARED SINGLE-NUMBER NOISE EMISSION VALUES

In accordance with ISO 4871
Noise level per Directive 2000/14/EC - LwA 93 dB

DECLARED VIBRATION EMISSION VALUES

Ina accordance with EN 12096
Value Uncertainty
Whole-body vibration per ISO 2631-1 0,72 m/s2 0,36 m/s2
Hand-arm vibration per ISO 5349-1 1,19 m/s2 ---

Temperature Range

Operation and storage -17° - +43°C (-1.3° - +109.4°F)

SPEC-10-7 E08 Service Manual

SPEC-10-8 E08 Service Manual
TECHNICAL SERVICE GUIDE SPECIFICATIONS

Engine

Engine Oil Pressure at Low Idle 48 kPa (0,48 bar) (7 psi)

Engine Oil Pressure at High Idle 193 - 441 kPa (1,9 - 4,4 bar) (28 - 64 psi)
Firing Order 1-2-3
Location of Number 1 Cylinder Closest to water pump
Injection Timing 19° - 21° BTDC
Crankshaft Rotation (Facing
Clockwise
Crankshaft Pulley)
Compression at Cranking Speed 10% variance between pistons. 2800 -3200 kPa (28 - 32 bar) (412 - 469 psi)
Valve Clearance (Cold) Intake 0,145 - 0,185 mm (0.0057 - 0.0072 in)
Valve Clearance (Cold) Exhaust 0,145 - 0,185 mm (0.0057 - 0.0072 in)

NOTE: For additional engine specifications, (See Specifications on Page 60-10-2.)

Engine Torques

Engine Oil Drain Cap 33 - 37 N•m (24 - 27 ft-lb)

Fuel Injection Tubeline Nuts 25 - 34 N•m (18 - 25 ft-lb)
Glow Plugs 8 - 15 N•m (6 - 11 ft-lb)
Injection Pump Mounting Bolts/Nuts 22 - 27 N•m (16 - 20 ft-lb)
Valve Cover Bolts 7 - 11 N•m (5 - 8 ft-lb)
Head Bolts 38 - 42 N•m (28 - 31 ft-lb)

NOTE: For additional engine torques, (See Removal And Installation on Page 60-10-9.)

Cooling System

Coolant Type and Mix 47% Water and 53% Propylene Glycol
Radiator Cap Pressure 90 kPa (0,90 bar) (13 psi)
Thermostat Fully Open at 85°C (185°F)

NOTE: For additional cooling system information, (See ENGINE COOLING SYSTEM on Page 60-40-1.)

SPEC-20-1 E08 Service Manual

TECHNICAL SERVICE GUIDE SPECIFICATIONS (CONT’D)

Excavator Torques

Drive Motor To Frame Bolt 40 - 50 N•m (29 - 37 ft-lb)

Sprocket To Drive Motor 66 - 75 N•m (48 - 55 ft-lb)
Swing Bearing To Frame Bolt 105 - 115 N•m (78 - 85 ft-lb)
Swing Bearing To Upperstructure Bolt 57 - 63 N•m (42 - 47 ft-lb)
Swing Motor Drive Carrier 105 - 115N•m (78 - 85 ft-lb)
Swing Motor Mounting Bolts 71 - 79 N•m (52.5 - 58.5 ft-lb)
Swivel Joint Mounting Bolts 75 - 85 N•m (55 - 60 ft-lb)

NOTE: Additional excavator torques can be found in the relevant section of this manual.

SPEC-20-2 E08 Service Manual

TECHNICAL SERVICE GUIDE SPECIFICATIONS (CONT’D)

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
SAE Grade 5 SAE Grade 8
Size
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)
(in-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
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

SPEC-20-3 E08 Service Manual

TECHNICAL SERVICE GUIDE SPECIFICATIONS (CONT’D)

Torque For General Metric Bolts

THREAD SIZE MATERIAL

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

SPEC-20-4 E08 Service Manual

TORQUE SPECIFICATIONS FOR BOLTS

Torque For General SAE Bolts

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

THREAD SIZE SAE GRADE 5 SAE GRADE 8

N•m 0.250 9,0 - 10,2 12,4 - 13,6
(in-lb) (80 - 90) (110 - 120)
0.3125 20,3 - 22,6 24,2 - 27,1
(180 - 200) (215 - 240)
N•m 0.375 34 - 38 47 - 54
(ft-lb) (25 - 28) (35 - 40)
0.4375 54 - 61 81 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 122 - 136
(65 - 70) (90 - 100)
0.5625 122 - 136 170 - 190
(90 - 100) (125 - 140)
0.625 170 - 190 240 - 260
(125 - 140) (175 - 190)
0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 1475 - 1625
(900 - 1000) (2000 - 2200)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2200 - 2400)
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 E08 Service Manual

TORQUE SPECIFICATIONS FOR BOLTS (CONT’D)

Torque For General Metric Bolts

Thread Size Material

(Dia.) 8.8 10.9 12.9
M4 2,5 - 3,5 N•m 3,8 - 4,2 N•m 4,7 - 5,3 N•m
(22.12 - 31 in-lb) (33.6 - 37.2 in-lb) (41.6 - 47 in-lb)
M5 5,5 - 6,5 N•m 8,4 - 7,6 N•m 8,5 - 9,5 N•m
(48.7 - 57.5 in-lb) (74.3 - 67.3 in-lb) (75.2 - 84 in-lb)
M6 9,5 - 10,5 N•m 12,2 - 13,7 N•m 14,2 - 15,8 N•m
(7.0 - 7.5 ft-lb) (9.1 - 10.1 ft-lb) (10.4 - 11.6 ft-lb)
M7 15 - 17 N•m 20 - 22 N•m 23,7 - 26,3 N•m
(11.0 - 12.5 ft-lb) (16.2 - 14.7 ft-lb) (17.5 - 19.5 ft-lb)
M8 24 - 26 N•m 29,4 - 32,6 N•m 35 - 39 N•m
(18 - 19 ft-lb) (21.7 - 24.0 ft-lb) (25.5 - 28.5 ft-lb)
M10 43 - 47 N•m 57 - 63 N•m 71 - 79 N•m
(32 - 35 ft-lb) (42.0 - 46.5 ft-lb) (52.5 - 58.5 ft-lb)
M12 75 - 85 N•m 105 - 115 N•m 91 - 110 N•m
(55 - 60 ft-lb) (78 - 85 ft-lb) (91 - 110 ft-lb)
M14 125 - 140 N•m 118 - 133 N•m 140 - 155 N•m
(100 - 90 ft-lb) (118 - 133 ft-lb) (140 - 155 ft-lb)
M16 190 - 210 N•m 255 - 285 N•m 300 - 330 N•m
(140 - 155 ft-lb) (188 - 210 ft-lb) (225 - 245 ft-lb)
M18 260 - 290 N•m 345 - 385 N•m 420 - 460 N•m
(190 - 215 ft-lb) (255 - 285 ft-lb) (210 - 340 ft-lb)
M20 370 - 410 N•m 490 - 550 N•m 590 - 650 N•m
(275 - 300 ft-lb) (360 - 405 ft-lb) (440 - 490 ft-lb)
M22 500 - 550 N•m 740 - 760 N•m 800 - 880 N•m
(370 - 400 ft-lb) (554 - 560 ft-lb) (590 - 650 ft-lb)
M24 640 - 700 N•m 850 - 950 N•m 1000 - 1120 N•m
(470 - 520 ft-lb) (625 - 700 ft-lb) (730 - 830 ft-lb)
M27 930 - 1030 N•m 1230 - 1370 N•m 1470 - 1630 N•m
(680 - 760 ft-lb) (900 - 1000 ft-lb) (1100 - 1200 ft-lb)
M30 1260 - 1400 N•m 1700 - 1900 N•m 2000 - 2200 N•m
(930 - 1030 ft-lb) (1250 - 1400 ft-lb) (1500 - 1600 ft-lb)
M33 1720 - 1900 N•m 2300 - 2500 N•m 2700 - 3100 N•m
(1270 - 1400 ft-lb) (2300 - 2500 ft-lb) (2000 - 2300 ft-lb)
M36 2200 - 2450 N•m 2900 - 3200 N•m 3500 - 3900 N•m
(1620 - 1800 ft-lb) (2200 - 2400 ft-lb) (2600 - 2900 ft-lb)

SPEC-30-2 E08 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-2

O-ring Face Seal Connection O-ring Face Seal Tightening Torque

Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)
1/4” 9/16” - 18 18 (13)
IMPORTANT 3/8” 11/16” - 16 30 (22)
1/2” 13/16” - 16 54 (40)
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 5/8” 1” - 14 81 (60)
parts clean. Always use caps and plugs on hoses, 3/4” 1 - 3/16” - 12 114 (84)
tubelines and ports to keep dirt out. Dirt can quickly
7/8” 1 - 3/16” - 12 133 (98)
damage the system.
I-2003-0888 1” 1 - 7/16” - 12 160 (118)
1 - 1/4” 1 - 11/16” - 12 209 (154)
Figure SPEC-40-1
1 - 1/2” 2” - 12 221 (163)

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 E08 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Tubelines And Hoses
(CONT’D)
Replace any tubelines that are bent or flattened. They will
Straight Thread O-ring Fitting restrict flow, which will slow hydraulic action and cause
heat.
Figure SPEC-40-3
Replace hoses which show signs of wear, damage or
weather cracked rubber.

Always use two wrenches when loosening and tightening

Nut Nut hose or tubeline fittings.

Washer
Washer
O-ring

O-ring

A-1852

Lubricate the O-ring before installing the fitting. Loosen

the locknut and install the fitting. Tighten the locknut until
the washer is tight against the surface [Figure SPEC-40-
3].

SPEC-40-2 E08 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS
(CONT’D)

Flare Fitting

Figure SPEC-40-4

TS-1619A

Use the following procedure to tighten the flare fitting:

Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-40-4]

Use the chart [Figure SPEC-40-5] to find the correct

tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.

Figure SPEC-40-5
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft-lb)
1/4” 7/16” - 20 18 (13)
5/16” 1/2” - 20 23 (17)
3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
5/8” 7/8” - 14 81 (60)
3/4” 1 - 1/16” - 12 114 (84)
7/8” 1 - 3/16” - 12 133 98)
1” 1 - 5/16” - 12 160 (118)
1 - 1/4” 1 - 5/8” - 12 209 (154)
1 - 1/2” 1 - 7/8” - 12 221 (163)
2” 2 - 1/2” - 12 342 (252)

SPEC-40-3 E08 Service Manual

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-7
(CONT'D)
Port Seal and O-ring Boss
Port Seal Fitting
Tightening Torque
Figure SPEC-40-6 x TORQUE
x N•m
Thread Size (ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” -16 54 (40)
7/8” - 14 81 (60)
1 - 1/16” - 12 114 (84)
Nut Seals
To Fitting 1 - 3/16” - 12 133 (98)
1 - 5/16” - 12 160 (118)
1 - 7/16” - 12 209 (154)
Nut Seals
1 - 5/8” - 12 221 (163)
To Port

Use the following procedure to tighten the port seal

fitting:
Secondary O-ring Seal P-13008
Port seal and nut, washer and O-ring (O-ring Boss)
fittings use the same tightening torque valve chart.
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-6].

The hex portion of the nut does not contact the surface of
the component when the nut is tight.

SPEC-40-4 E08 Service Manual

HYDRAULIC FLUID SPECIFICATIONS

Specifications
WARNING
Use Bobcat hydraulic fluid (P/N 6904842 - 5, 25, 209,
1000 L), (P/N 6904843 - 5, 25, 209, 1000 L).
During cold weather (0°C [32°F] and below), do not
operate machine until the engine has run for at least
5 minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.

When temperatures are below -30°C (-20°F), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above -18°C (0°F) if possible.
W-2027-0311

DO NOT use automatic transmission fluids in the

excavator or permanent damage to the hydraulic system
will result.

WARNING
AVOID INJURY OR DEATH

Diesel fuel or hydraulic fluid under pressure can

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

When temperatures below -18°C (0°F) are common, the

excavator must be kept in a warm building. Extra warm-
up time must be used each time the excavator is started
during cold temperature conditions. Cold fluid will not
flow easily and it makes action of the hydraulic function
slower. Loss of fluid flow to the hydraulic system can
cause damage in less than 60 seconds.

SPEC-50-1 E08 Service Manual

SPEC-50-2 E08 Service Manual
CONVERSIONS

Decimal And Millimeter Equivalents

U.S. To Metric Conversion Chart

SPEC-60-1 E08 Service Manual

SPEC-60-2 E08 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
7217666, 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 Service PC

7217666 Remote Start Tool Kit This tool replaced the original
 remote start tool kit MEL1563,
(Was 7003031) 7003031 and 6689779. Kit
 7217666 includes: 7022042,
(Was 6689779) 6689747, 6689746 and
6689745.
7022042 Remote Start Tool This tool replaces remote start
 tool 6689778 and 7003030.
(Was 7003030)

(Was 6689778)
6689747 Remote Start Tool Used with 7022042 to connect
Harness remote start tool to machine.

6689746 Remote Start Tool Used with 7022042 to connect

Harness Service PC to remote start tool.

6689745 BOSS Service Tool

Harness

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-0919

SPEC-70-1 E08 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

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-0919

SPEC-70-2 E08 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

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-0919

SPEC-70-3 E08 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
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-0919

SPEC-70-4 E08 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 1.8L & 2.4L Used for installing rear main seal
Installer Bobcat
Engine
Models

7031369 Front Seal Installer T4 Bobcat Used for installing front seal
Engine
Applications

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-0919

SPEC-70-5 E08 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
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 7332314 includes: 7332313 - Oil
Block Adapter Kit Sensor Block Adapter and 7332298 -
Turbo Oil Adapter.
MEL1653-1 Engine Removal Tool

MEL1653-3 Engine Removal Tool E50 1.8L Bobcat Engine Tier 4.

MEL1653-8 Engine Removal Tool Used with MEL1653-1

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-0919

SPEC-70-6 E08 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

Engine Tools (Cont’d)

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
MEL1653-9 Engine Removal Tool E50 2.4L Bobcat Engine Tier 4.

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

General Tools

TOOL PART MODELS

DESCRIPTION COMMENT IMAGE
NUMBER USED ON
7340184 Counterweight Lift M-Series E26 Used to remove Excavator
Tool - E55 and All Counterweight.
R-Series
Bobcat
Compact
Excavators

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-0919

SPEC-70-7 E08 Service Manual

SERVICE TOOLS REQUIRED (CONT’D)

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,
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-0919

SPEC-70-8 E08 Service Manual

ALPHABETICAL INDEX

AIR CLEANER . . . . . . . . . . . . . . . . . . . 10-80-1 FOLD-DOWN TOPS . . . . . . . . . . . . . . .10-50-1

AIR CLEANER . . . . . . . . . . . . . . . . . . . 60-30-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
ALTERNATOR BELT . . . . . . . . . . . . . 10-160-1 FUEL LEVEL SENDER . . . . . . . . . . . .50-60-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . 50-30-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . .10-100-1
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . .60-60-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 50-20-1 FUEL TANK . . . . . . . . . . . . . . . . . . . .40-130-1
BLADE / TRACK EXPAND VALVE . . . 20-110-1 HORN . . . . . . . . . . . . . . . . . . . . . . . . .40-140-1
BLADE CONTROL . . . . . . . . . . . . . . . . 40-70-1 HYDRAULIC CONNECTION
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-40-1
BOOM . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1 HYDRAULIC CONTROL VALVE . . . . . .20-40-1
BUCKET . . . . . . . . . . . . . . . . . . . . . . . 40-180-1 HYDRAULIC FLUID SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
CAMSHAFT AND TIMING 
GEARS . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1 HYDRAULIC PUMP . . . . . . . . . . . . . . .20-50-1
CONTROL CONSOLE  HYDRAULIC RESERVOIR . . . . . . . . . .20-90-1
LOCKOUTS . . . . . . . . . . . . . . . . . . . . 10-180-1 HYDRAULIC SYSTEM 
CONVERSIONS . . . . . . . . . . . . . . . SPEC-60-1 INFORMATION . . . . . . . . . . . . . . . . . . .20-10-1
COUNTERWEIGHTS . . . . . . . . . . . . . 40-200-1 INSTRUMENT PANEL . . . . . . . . . . . .40-220-1
CRANKSHAFT AND PISTONS . . . . . . 60-80-1 LEFT CONTROL HANDLE . . . . . . . . . .40-50-1
CYLINDER (ARM) . . . . . . . . . . . . . . . . 20-21-1 LEFT PEDAL AND LINKAGE . . . . . . .40-110-1
CYLINDER (BLADE) . . . . . . . . . . . . . . 20-24-1 LIFTING AND BLOCKING THE 
EXCAVATOR . . . . . . . . . . . . . . . . . . . . .10-10-1
CYLINDER (BOOM SWING) . . . . . . . . 20-22-1
LIFTING THE EXCAVATOR . . . . . . . . .10-30-1
CYLINDER (BOOM) . . . . . . . . . . . . . . . 20-20-1
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . .50-50-1
CYLINDER (BUCKET) . . . . . . . . . . . . . 20-23-1
LUBRICATION OF THE 
CYLINDER (TRACK FRAME EXPANSION) EXCAVATOR . . . . . . . . . . . . . . . . . . . .10-130-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1
LUBRICATION SYSTEM . . . . . . . . . . .60-50-1
CYLINDER HEAD . . . . . . . . . . . . . . . . 60-70-1
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1
DELIVERY REPORT . . . . . . . . . . . . . . . . 1-14
MOTION ALARM . . . . . . . . . . . . . . . .10-210-1
ELECTRIC BLADE / TRACK EXPAND 
VALVE . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1 MUFFLER . . . . . . . . . . . . . . . . . . . . . . .60-20-1
ELECTRICAL SYSTEM  OIL COOLER . . . . . . . . . . . . . . . . . . .20-100-1
INFORMATION . . . . . . . . . . . . . . . . . . . 50-10-1 RIGHT CONTROL HANDLE . . . . . . . .40-40-1
ENGINE COOLING SYSTEM . . . . . . . 10-90-1 RIGHT PEDAL AND LINKAGE . . . . . . .40-90-1
ENGINE COOLING SYSTEM . . . . . . . 60-40-1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . 1-9
ENGINE INFORMATION . . . . . . . . . . . 60-10-1 SEAT BELT . . . . . . . . . . . . . . . . . . . . .10-170-1
ENGINE LUBRICATION SYSTEM . . . 10-110-1 SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . .40-30-1
ENGINE SPEED CONTROL . . . . . . . . 40-60-1 SERIAL NUMBER LOCATIONS . . . . . . . . 1-13
EXCAVATOR IDENTIFICATION . . . . . . . . 1-15 SERVICE SCHEDULE SYMBOLS . . . . . . . 1-4
EXCAVATOR SPECIFICATIONS . . SPEC-10-1 SERVICE SCHEDULE . . . . . . . . . . . . .10-70-1
EXCAVATOR STORAGE AND RETURN TO SERVICE TOOLS REQUIRED . . . .SPEC-70-1
SERVICE . . . . . . . . . . . . . . . . . . . . . . 10-190-1 SIDE COVERS . . . . . . . . . . . . . . . . . .40-210-1
FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-11 SLEW MOTOR . . . . . . . . . . . . . . . . . . .20-80-1
FLOOR PANELS . . . . . . . . . . . . . . . . 40-120-1 SPARK ARRESTER MUFFLER . . . . .10-150-1
FLYWHEEL AND HOUSING . . . . . . . 60-100-1 STARTER . . . . . . . . . . . . . . . . . . . . . . .50-40-1

INDEX-01 E08 Service Manual

STOPPING AND LEAVING THE 
EXCAVATOR . . . . . . . . . . . . . . . . . . .10-200-1
SWING CIRCLE GEAR . . . . . . . . . . . .30-40-1
SWING FRAME . . . . . . . . . . . . . . . . .40-150-1
SWIVEL JOINT (S/N A4BP11001 -
A4BP11117) . . . . . . . . . . . . . . . . . . . . .20-73-1
SWIVEL JOINT (S/N A4BP11117 -
A4BP11467) . . . . . . . . . . . . . . . . . . . . .20-72-1
SWIVEL JOINT (S/N A4BP11468 -
A4BP11672) . . . . . . . . . . . . . . . . . . . . .20-71-1
SWIVEL JOINT (S/N A4BP11673 & ABOVE
AND S/N B4PC11001 & ABOVE) . . . . .20-70-1
TAILGATE . . . . . . . . . . . . . . . . . . . . . . .10-60-1
TAILGATE . . . . . . . . . . . . . . . . . . . . . .40-190-1
TECHNICAL SERVICE GUIDE
SPECIFICATIONS . . . . . . . . . . . . . SPEC-20-1
TOPS . . . . . . . . . . . . . . . . . . . . . . . . . .40-20-1
TORQUE SPECIFICATIONS FOR 
BOLTS . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
TRACK MAINTENANCE . . . . . . . . . . .30-30-1
TRACK UNDERCARRIAGE 
COMPONENTS . . . . . . . . . . . . . . . . . .30-20-1
TRANSPORTING THE 
EXCAVATOR . . . . . . . . . . . . . . . . . . . .10-40-1
TRAVEL CONTROLS . . . . . . . . . . . . .40-100-1
TRAVEL MOTOR . . . . . . . . . . . . . . . .10-140-1
TRAVEL MOTOR . . . . . . . . . . . . . . . . .20-60-1
UPPERSTRUCTURE SLEW LOCK . . .10-20-1
UPPERSTRUCTURE SLEW LOCK . . .40-80-1
UPPERSTRUCTURE . . . . . . . . . . . . . .40-10-1
VALVE (MAIN RELIEF) . . . . . . . . . . . . .20-30-1
VALVE (PORT RELIEF) . . . . . . . . . . . .20-31-1

INDEX-02 E08 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

Needed

Check Engine Air Filter, Change As Lubricate Grease Fittings

Necessary

Drain Contaminants From Fuel Filter Seat Belt

Drain Contaminants From Fuel Tank Cab / Canopy

Change Fuel Filter Spark Arrestor Muffler

Check Hydraulic Fluid

Change Hydraulic Fluid and Filter(s)

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.