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Service Manual E80 Excavator: S/N AETB11001 & Above S/N AET311001 & Above
Service Manual E80 Excavator: S/N AETB11001 & Above S/N AET311001 & Above
E80 Excavator
1 of 879
2 of 879
Dealer Copy -- Not for Resale
MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
1-1
3 of 879
4 of 879
1-2
Dealer Copy -- Not for Resale
CONTENTS
UNDERCARRIAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
7. Enclosure door latches must 15. Inspect the air cleaner for
open and close freely. damage or leaks. Check the
condition of the element.
FW EXC-0509 SM
18. Inspect for loose or broken 22. Inspect the X-Change™ for
parts or connections. wear or damage. Repair or
replace damaged parts.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
FW EXC-0509 SM
SI EXC-0308 SM
SI EXC-0308 SM
All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs. These starting aids can cause explosion and
onto hot surfaces or onto electrical components can injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.
SI EXC-0308 SM
Fire Extinguishers
SI EXC-0308 SM
Figure 10-141-1
P-86268
Module 2. - Production
Sequence (Series)
Figure 3
B-16315
OPERATOR SEAT
With SEAT BELT
BUCKET
CYLINDER
BOOM
CONTROL
ARM LEVERS
(JOYSTICKS)
AUXILIARY
QUICK
BOOM
COUPLERS
CYLINDER
BUCKET
BLADE
TIE DOWNS/ CYLINDER
[1] BUCKET LIFT POINTS
LIFT
POINTS
[2] CAB
RIGHT SIDE
COVER
REAR COVER
UPPERSTRUCTURE
BLADE
TIE
DOWN
B23930
TRACK B23931
[1] BUCKET - Several different buckets and other attachments are available for the Bobcat Excavator.
[2] Model E80 S/N AETB11235 & Above has a ROPS / TOPS as standard equipment. (ROPS / TOPS - Roll Over
Protective Structure per ISO 12117-2: 2008, and Tip Over Protective Structure per ISO 12117: 2000.)
Procedure
Figure 10-10-1
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903
WARNING
Put jackstands under the blade and rear corners of
the undercarriage before working under the machine.
Failure to block up the machine may allow it to move
P-86926 or fall and result in injury or death.
W-2218-1195
1
1
P-86416
Procedure
2 1
Figure 10-20-1 1
1 P-87278A
WARNING 45°
B-23947A
Figure 10-30-2
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200
P-86238A
From inside the cab, open the door using the handle
(Item 2) [Figure 10-30-2].
Front Window
Figure 10-30-3
P-86954
1
When the window is fully raised, push up on the window
slightly until the two latch pins (Item 1) (both sides)
engage into the bracket (Item 2) [Figure 10-30-5] to lock
P-86225 the window in the open position. Pull down slightly on the
window to make sure the latch pins are properly seated
to hold the window securely in the open position.
Figure 10-30-4 Support the window while rotating both window latch pins
(Item 1) [Figure 10-30-5] to the unlocked position.
P-86322
Figure 10-30-6
P-86908
P-86249
The window washer reservoir (Item 1) [Figure 10-30-8]
is located under the right side cover and to the front of
The front window is equipped with a wiper (Item 1) the radiator. (When the temperature is 0°C (32°F) or
[Figure 10-30-6] and washer. lower, fill the washer reservoir with washer fluid specified
1 2
2
1
P-86945A
Figure 10-30-9
P-86228
Figure 10-30-10
1
1
P-86951
P-86229
The excavator is equipped with seven air vents (Item 1)
[Figure 10-30-10], [Figure 10-30-11] and [Figure 10-30-
Figure 10-30-11 12] that can be adjusted to deflect air flow to the desired
area of the cab.
Figure 10-30-13
P-86230
P-86953
Use ramps that are the correct length and width and can P-87269
support the weight of the machine.
The rear of the trailer must be blocked or supported when Figure 10-40-3
loading or unloading the machine to prevent the front of
the transport vehicle from raising.
P-87267
Lower the boom, arm, bucket, and blade to the transport AVOID SERIOUS INJURY OR DEATH
vehicle. Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
Stop the engine and remove the key. loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
Put blocks at the front and rear of the tracks. W-2058-0807
Figure 10-50-1
P-86943
P-86256
The right side cover latch (Item 1) [Figure 10-50-2] can
be adjusted.
Pull the latch (Item 1) [Figure 10-50-1] and raise the right
side cover. Loosen the nut (Item 2) [Figure 10-50-2] and adjust the
Figure 10-60-1
P-86257
Figure 10-70-1
P-89349
See the service schedule for the correct service interval. Pull out on the three fasteners (Item 1) and remove the
(See SERVICE SCHEDULE on Page 10-80-1.) cover [Figure 10-90-2].
Daily Check
Clean the dust cup (Item 2) [Figure 10-90-2].
Figure 10-90-1
Figure 10-90-3
1
P-86955A
P-86262
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.
1
2
3
P-86260
Replace the inner filter every third time the outer filter is
replaced or as indicated.
Inner Filter
• Replace the inner filter every third time the outer filter
is replaced.
Figure 10-90-4
P-86261
Remove the air cleaner cover, the outer filter and the
inner filter (Item 1) [Figure 10-90-4].
Figure 10-100-1
P-87293
P-86942
Figure 10-100-2
P-87294
Use low air pressure to clean the filter. Replace the filter
when very dirty.
Check the cooling system every day to prevent over- Figure 10-110-2
heating, loss of performance or engine damage.
Cleaning
MIN 1
P-86273
WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot. P-86275
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using it in this machine:
Use only clean, high quality diesel fuel. Grade No. 2 or
Grade No. 1 with a cetane number of 45 or higher. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures:
• Biodiesel blend fuel is an excellent medium for
microbial growth and contamination which can cause
TEMPERATURE C° (F°) NO. 2 NO. 1
corrosion and plugging of fuel system components.
-9°(+15°) 100% 0%
Down to -29° (-20°) 50% 50% • Use of biodiesel blend fuel may result in premature
failure of fuel system components, such as plugged
Below -29° (-20°) 0% 100% fuel filters and deteriorated fuel lines.
At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel
• Shorter maintenance intervals may be required, such
must be used in this machine.
as cleaning the fuel system and replacing fuel filters
and fuel lines.
The following fuels may also be used in this machine:
• Using biodiesel blended fuels containing more than
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.
five percent biodiesel can affect engine life and cause
• Biodiesel Blend Fuel - Must contain no more than five deterioration of hoses, tubelines, injectors, injector
percent biodiesel mixed with low sulfur or ultra low pump and seals.
AVOID INJURY OR DEATH • Ensure that the fuel tank cap is securely tightened.
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an • Biodiesel blend fuel can damage painted surfaces.
explosion or fire. Remove all spilled fuel from painted surfaces
W-2063-0807 immediately.
Figure 10-120-1
P-86941
P-86263
Fuel Filters See the Chart for the service interval for when to replace
the fuel filter. (See Chart on Page 10-80-1.)
Removing Water
Primary Fuel Filter
See the Chart for the service interval for when to remove
water from the fuel filter. (See Chart on Page 10-80-1.) Turn the shut off valve (Item 2) [Figure 10-120-3]
clockwise to the closed position.
Open the right side cover. (See Opening And Closing on
Page 10-50-1.) Remove the filter (Item 3) [Figure 10-120-3].
Figure 10-120-3 Clean the area around the filter housing. Put clean oil on
the seal of the new filter. Install the fuel filter and tighten it
CLOSED 2 by hand.
Figure 10-120-4
P-87986
Clean the area around the filter housing. Put clean oil on
the seal of the new filter. Install the fuel filter and tighten it
by hand.
Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-120-4.)
After replacing the fuel filter or when the fuel tank has run
2 out of fuel, air must be removed from the fuel system
before starting the engine.
Figure 10-120-6
P-86318
P-86271
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
See the Chart for the service interval for when to replace
the engine oil and filter. (See SERVICE SCHEDULE on
Page 10-80-1.)
2 3 2
2 Remove the oil filter (Item 1) [Figure 10-130-5] and clean
the filter housing surface.
P-86925
1
From under the machine, loosen the two bolts (Item 1)
and remove four bolts / washers (Item 2) from the access
cover (Item 3) [Figure 10-130-3] from below the engine
area. Remove the access cover.
Figure 10-130-4
P-86268
Stop the engine. Check for leaks at the oil filter. Check
P-86924 the oil level.
Add oil as needed if it is not at the top mark on the
Remove the plug (Item 1) [Figure 10-130-4] from the dipstick.
engine oil pan. Drain the oil into a container.
Reinstall the access cover (Item 3) [Figure 10-130-3]
Recycle or dispose of used oil in an environmentally safe and tighten the bolts.
manner.
3 3
P-86906
2
P-86295
Clean the surface around the reservoir (breather) cap
(Item 1) and cover (Item 2) fully. Press down on the cover
Check the hydraulic fluid level. It must be visible in the (Item 2) and remove the six bolts (Item 3) from the cover
sight gauge (Item 1) between the two red lines (Item 2) (Item 2) [Figure 10-140-2]. Remove the cover.
[Figure 10-140-1].
Add the correct fluid to the reservoir until it is visible in the
sight gauge.
WARNING Check the O-ring under the cover (Item 2) [Figure 10-
140-2]. Replace the O-ring if damaged.
AVOID INJURY OR DEATH Reinstall the cover and align the bolt holes. Press down
Always clean up spilled fuel or oil. Keep heat, flames, on the cover (Item 2) and install the six bolts (Item 3)
sparks or lighted tobacco away from fuel and oil. [Figure 10-140-2]. Tighten the bolts.
Failure to use care around combustibles can cause
explosion or fire. Close the rear cover.
W-2103-0508
Figure 10-140-3
WARNING
AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
See the Chart for the correct service interval. (See Chart
on Page 10-80-1.)
TEMPERATURE RANGE ANTICIPATED Open the rear cover. (See Opening And Closing on Page
DURING MACHINE USE 10-60-1.)
[1] Synthetic Fluid; VG 46; Minimum VI 150
[2] BOBCAT Hydraulic / Hydrostatic Fluid Figure 10-140-4
Reinstall the cover and align the bolt holes. Press down 1
on the cover (Item 2) and install the four bolts (Item 3)
[Figure 10-140-2 on Page 10-140-1]. Tighten the bolts.
2 2
2
P-86906
Figure 10-140-5
1 1
P-86303
Inspect the O-ring (Item 2) [Figure 10-140-5] for Reinstall the cover and align the bolt holes. Press down
damage. Replace the O-ring if it is damaged. on the cover (Item 2) and install the six bolts (Item 2)
[Figure 10-140-4 on Page 10-140-2] and tighten the
Figure 10-140-6 bolts.
P-86302
See the Chart for the correct service interval. (See Chart
on Page 10-80-1.)
Figure 10-140-8
2 P-86300
2
3 1
Figure 10-140-10
P-86906
1
See the Chart for the correct service interval. (See Chart
on Page 10-80-1.)
Figure 10-140-11
Figure 10-140-12
P-86296
See the Chart for the correct service interval. (See Chart
on Page 10-80-1.)
1
WARNING
AVOID INJURY OR DEATH 2
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. P-86317
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 Rotate the cover plate (Item 1) [Figure 10-140-14] to
from a physician familiar with this injury. access the bottom of the hydraulic tank.
W-2072-0807
Remove the drain plug (Item 2) [Figure 10-140-14] from
the bottom of the hydraulic tank.
Retract the arm and bucket cylinders, and lower the
bucket to the ground. Lower the blade to the ground.
1
2
P-86316
Figure 10-140-15
1
1
P-86904
P-86927
Open the center cover to access the swing motor.
After the hydraulic fluid has been drained from the The swing motor gear box (Item 1) has a dipstick (Item 2)
excavator or after the hydraulic pump has been serviced, [Figure 10-140-16] for checking the swing motor gear
Figure 10-140-17
P-87254
Lubrication Locations
Figure 10-150-3
3 3
2
5
P-86313
6
Ref Description (# of Fittings)
Figure 10-150-4
7 9
P-86308
10
8 P-86307
Figure 10-150-8
15
11
16 15
P-86304
12
13
14
P-86905
Figure 10-150-12
21
25
S37512
22
23
25. Articulated Boom Pivot (1) [Figure 10-150-13].
24
S37506
Figure 10-160-1
1
1
P-86923
Check that the bolt and nut are securely tightened and
are not damaged.
Checking And Adding Oil For the correct service interval. (See Chart on Page 10-
80-1.)
Figure 10-170-1
Park the excavator on a level surface with plugs (Item 1,
2 and 3) in the position shown. Remove plugs (Item 2
and 3) [Figure 10-170-1] and drain the lubricant into a
container.
2
WARNING
3 AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
P-86327
explosion or fire.
W-2103-0508
Cleaning Procedure
WARNING
1
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
P-91994
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
Remove the plug (Item 1) [Figure 10-180-1] from the
bottom of the muffler.
Start the engine and let it run for about 10 seconds while
a second person, wearing safety glasses, holds a piece
WARNING of wood over the outlet of the muffler. The carbon
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
WARNING
When the engine is running during service, the
steering levers must be in neutral.
The door, the right side rear window and the front window
provide emergency exits.
Figure 10-190-1
P-86325
1
Front Window
P-86217
Figure 10-190-4
Figure 10-190-2
P-86322
WARNING
Failure to properly inspect and maintain the seat belt
can cause lack of operator restraint resulting in
serious injury or death.
W-2466-0703
B-22283
1 2
4 3
P-86920
Remove the nut (Item 1) [Figure 10-210-1] and washer Figure 10-210-4
from the right rear cab mount.
1
2
1
P-87893
Remove the nut (Item 1) [Figure 10-210-2] and washer NOTE: Do not use an impact wrench to raise / lower
from the left rear cab mount. the cab. Damage to the tilt assembly will
result.
For S/N AETB11235 & Above and AET311001 & Above
remove the bolt (Item 2) [Figure 10-210-2] and washer
from the left rear cab mount using a 36 mm socket.
Figure 10-210-5
P-87896
P-87895
WARNING
AVOID INJURY OR DEATH
Never work under the excavator cab without
installing an approved cab support device.
W-2435-0502
Figure 10-220-1
P-86321
Sit in the operator's seat, fasten the seat belt and start
the engine.
Procedure
LEGEND
1 HYDRAULIC RESERVOIR (PRESSURIZED) 17 PORT RELIEF / ANTI-CAVITATION VALVE – (2) 32 RELIEF VALVE – Slew Motor Brake 48 MINIMUM PUMP DISPLACEMENT
Reservoir Volume – (87 L) 23 Gal. (2nd Auxiliary – If Equipped) - (On Stroke Piston)
Oil Volume – (127 L) 35.5 Gal. (250 bar) 3626 PSI 33 SHUTTLE VALVE (Motion Alarm – If
Equipped)
2 18 3rd AUXILIARY QUICK COUPLERS – 49 TORQUE LIMITER (280 bar) 4061 PSI
MAIN FILTER - 10 MICRON
With (2,5 bar) 36 PSI By-Pass Valve Male / Female (If Equipped) 34 SHUTTLE VALVE (Slew Motor Brake Valve)
50 SHUTTLE VALVE – Auxiliary Hydraulic
3 19 MANUAL DIRECTIONAL CONTROL 35 SOLENOID ACTIVATED DIRECTIONAL
SUCTION FILTER - 150 MICRON
VALVE (Bucket Cylinder – 3rd Auxiliary CONTROL VALVE (2) (2nd Auxiliary) 51 BREATHER FILTER
Couplers) – (If Equipped)
4 CHECK VALVE - (2.5 bar) 36 PSI 36 ACCUMULATOR 52 PRESSURE SWITCH – Auto Idle
20 PILOT ACTIVATED DIRECTIONAL Nitrogen (10.2 bar) 148 PSI Precharged Activation – (24,8 bar) 360 PSI
CHECK VALVE - (3 bar) 44 PSI CONTROL VALVE (Load Holding valve) –
5
SOLENOID ACTIVATED DIRECTIONAL De-activation – (20 bar) 290 PSI
Boom 37
6 CONTROL VALVE (Two Speed) 53 PRESSURE REDUCING VALVE:
OIL COOLER 21 RELIEF VALVE - (Load Holding valve) –
Boom SOLENOID ACTIVATED DIRECTIONAL
38 Auto Idle Switch – (30 bar) 435 PSI
7 LOAD CHECK Dealer Copy -- NotCONTROL VALVE (Breaker)
for Resale PILOT ACTIVATED DIRECTIONAL
22 54
CHECK VALVE With Restriction - (Load 39
BACK-UP RELIEF VALVE: SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (Load Holding valve) –
8 Holding valve) – Boom
(340 bar) 4931 PSI CONTROL VALVE - (Console Lockout / Pilot Arm
23 LOCK VALVES – BLADE CYLINDER (2) Cut off)
9 FLUSHING VALVE: (25 bar) 362 PSI 55 RELIEF VALVE - (Load Holding valve) –
(If Equipped) 40 FILTER - Pilot Pressure Arm
10 LOAD SENSE BLEED VALVE 24 AUXILIARY QUICK COUPLERS – Male / Female
41 PRESSURE REDUCING VALVE - 56 CHECK VALVE With Restriction - (Load
11 LOAD SENSE RELIEF VALVE: 25 BRAKE RELEASE VALVE – Travel Motor (32 bar) 464 PSI Holding valve) – Arm
(280 bar) 4060 PSI (6,3 bar) 91 PSI 42 CHECK VALVE (0,5 bar) 7.25 PSI 57 2nd AUXILIARY QUICK COUPLERS –
12 PORT RELIEF / ANTI-CAVITATION VALVE 26 TWO SPEED SHIFT SPOOL – Travel Motor Male / Female (If Equipped)
(2) - (Boom Cylinder) - (310 bar) 4496 PSI 43 HYDRAULIC GEAR PUMP
27 CROSS PORT RELIEF VALVE (22 L/min.) 5.8 GPM at High Idle 58 HOSE - Accumulator (Used for vibration
13 PORT RELIEF / ANTI-CAVITATION VALVE and sound reduction)
(Travel Motor) (280 bar) 4061 PSI
(2) - (Bucket Cylinder) - (310 bar) 4496 PSI 44 HYDRAULIC PISTON PUMP
28 COUNTERBALANCE SPOOL (Travel Motor) (144 L/min.) 38 GPM at High Idle
14 PORT RELIEF / ANTI-CAVITATION VALVE
(2) - (Arm Cylinder) - (310 bar) 4496 PSI 45 TORQUE LIMITER SUPPLY SPOOL
29 BRAKE RELEASE VALVE - Slew Motor
(20 bar) 290 PSI
15 PORT RELIEF / ANTI-CAVITATION VALVE - (19 bar) 276 PSI
(Auxiliary – Two Way - Breaker) - 46 DESTROKE PISTON
30 CROSS PORT RELIEF VALVE - Slew Motor
(310 bar) 4496 PSI
(220 bar) 3190 PSI
47 PUMP MARGIN SPOOL (15 bar) 218 PSI
16 ANTI-CAVITATION VALVE- Boom Swing (2) 31 ANTI-CAVITATION VALVE – Slew Motor
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
27 27
SH S1
28 28 PG
23 P1 P2 P2 P1 30
Dr
23 REVERSE FORWARD REVERSE FORWARD 32
C2
18 M 55 30
C2
E
M
21
E 54
Mu
T V2
56 MALE FEMALE B A
T V2
20 22 Pa3 (LEFT)
31
(RIGHT)
Pb1
19
SWIVEL 24
58 57
JOINT A D A SWIVEL F T P B E
C
B P JOINT
LS M pb1 pb2 pb3 pb4 pb5 pb6 pb7 pb8 P2 pb9 pb10
BUCKET
7 7 7 7 7 7 7 7
7 7
B
2 UP P T DOWN 1
Pa4 Pb4
11
8 9 10
T B A T T B A T T B A T T B A T T B A T T B A T
T1 pa1 pa2 pa3 pa4 pa5 pa6 pa7 pa8 pa9 pa10
58
2 LEFT P T RIGHT 1
Pa8 Pb8
AUTO IDLE 52
SWITCH PW
5 53
T
P
PRESSURE Dealer Copy -- Not for Resale
REDUCING VALVE
2nd AUXILIARY
HYDRAULIC VALVE
Pb10
51 AUXILIARY pb5
HYDRAULICS R1 Pi1 R2 Pi2 R2 Pi2
Pa10
VALVE A B
45 T
2
50
1 P T 2
47
X Pa5 1 SWING 3 2 ARM 4 1 BUCKET 3 2 BOOM 4 1
LEFT
2 3
RIGHT
4 P1
TRAVEL TRAVEL
49 LEFT RIGHT OUT RETRACT UP REVERSE REVERSE
IN DOWN 35
B1 EXTEND FORWARD FORWARD
40
Pb2 Pa2
46 B2 37 38 39 C1
33
D1 A1
33
B1
1
P 33
A3 A2 A1
HYDRAULIC 43 MOTION ALARM
3 Dr1 8 7 6 5 VALVE
RESERVOIR 44
Dr2 (IF EQUIPPED)
C2 D2 E A2 B2
T1
Pb9 Pa9
Pb3 Pa3
41 42 34
HYDRAULIC S1 L1 L S2
48 Pa1 Pb1
PUMP B1 A1 MOTION ALARM
T PV PRESSURE SWITCH
SLEW MOTOR (IF EQUIPPED)
BRAKE VALVE
36
B2 S1 A2
86 of 879
Printed in U.S.A. ACCUMULATOR V-1315NA (7-29-10)
HYDRAULIC/HYDROSTATIC SCHEMATIC
E80 (S/N AET311001 AND ABOVE)
Printable Version Click Here
LEGEND
1 HYDRAULIC RESERVOIR (PRESSURIZED) 17 PORT RELIEF / ANTI-CAVITATION VALVE – (2) 32 RELIEF VALVE – Slew Motor Brake 48 MINIMUM PUMP DISPLACEMENT
Reservoir Volume – (87 L) 23 Gal. (2nd Auxiliary – If Equipped) - (On Stroke Piston)
Oil Volume – (127 L) 35.5 Gal. (250 bar) 3626 PSI 33 SHUTTLE VALVE (Motion Alarm – If
Equipped)
2 18 3rd AUXILIARY QUICK COUPLERS – 49 TORQUE LIMITER (280 bar) 4061 PSI
MAIN FILTER - 10 MICRON
With (2,5 bar) 36 PSI By-Pass Valve Male / Female (If Equipped) 34 SHUTTLE VALVE (Slew Motor Brake Valve)
50 SHUTTLE VALVE – Auxiliary Hydraulic
3 19 MANUAL DIRECTIONAL CONTROL 35 SOLENOID ACTIVATED DIRECTIONAL
SUCTION FILTER - 150 MICRON
VALVE (Bucket Cylinder – 3rd Auxiliary CONTROL VALVE (2) (2nd Auxiliary) 51 BREATHER FILTER
Couplers) – (If Equipped)
4 CHECK VALVE - (2.5 bar) 36 PSI 36 ACCUMULATOR 52 PRESSURE SWITCH – Auto Idle
20 PILOT ACTIVATED DIRECTIONAL Nitrogen (10.2 bar) 148 PSI Precharged Activation – (24,8 bar) 360 PSI
CHECK VALVE - (3 bar) 44 PSI CONTROL VALVE (Load Holding valve) –
5
SOLENOID ACTIVATED DIRECTIONAL De-activation – (20 bar) 290 PSI
Boom 37
6 CONTROL VALVE (Two Speed) 53 PRESSURE REDUCING VALVE:
OIL COOLER 21 RELIEF VALVE - (Load Holding valve) –
Boom SOLENOID ACTIVATED DIRECTIONAL
38 Auto Idle Switch – (30 bar) 435 PSI
7 LOAD CHECK Dealer Copy -- NotCONTROL VALVE (Breaker)
for Resale PILOT ACTIVATED DIRECTIONAL
22 54
CHECK VALVE With Restriction - (Load 39
BACK-UP RELIEF VALVE: SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE (Load Holding valve) –
8 Holding valve) – Boom
(340 bar) 4931 PSI CONTROL VALVE - (Console Lockout / Pilot Arm
23 LOCK VALVES – BLADE CYLINDER (2) Cut off)
9 FLUSHING VALVE: (25 bar) 362 PSI 55 RELIEF VALVE - (Load Holding valve) –
(If Equipped) 40 FILTER - Pilot Pressure Arm
10 LOAD SENSE BLEED VALVE 24 AUXILIARY QUICK COUPLERS – Male / Female
41 PRESSURE REDUCING VALVE - 56 CHECK VALVE With Restriction - (Load
11 LOAD SENSE RELIEF VALVE: 25 BRAKE RELEASE VALVE – Travel Motor (32 bar) 464 PSI Holding valve) – Arm
(280 bar) 4060 PSI (6,3 bar) 91 PSI 42 CHECK VALVE (0,5 bar) 7.25 PSI 57 2nd AUXILIARY QUICK COUPLERS –
12 PORT RELIEF / ANTI-CAVITATION VALVE 26 TWO SPEED SHIFT SPOOL – Travel Motor Male / Female (If Equipped)
(2) - (Boom Cylinder) - (310 bar) 4496 PSI 43 HYDRAULIC GEAR PUMP
27 CROSS PORT RELIEF VALVE (22 L/min.) 5.8 GPM at High Idle 58 HOSE - Accumulator (Used for vibration
13 PORT RELIEF / ANTI-CAVITATION VALVE and sound reduction)
(Travel Motor) (280 bar) 4061 PSI
(2) - (Bucket Cylinder) - (310 bar) 4496 PSI 44 HYDRAULIC PISTON PUMP
(144 L/min.) 38 GPM at High Idle 59 PORT RELIEF / ANTI-CAVITATION VALVE
28 COUNTERBALANCE SPOOL (Travel Motor) (2) - (Articulated Boom Cylinder - Option) -
14 PORT RELIEF / ANTI-CAVITATION VALVE
(2) - (Arm Cylinder) - (310 bar) 4496 PSI 45 TORQUE LIMITER SUPPLY SPOOL (310 bar) 4496 PSI
29 BRAKE RELEASE VALVE - Slew Motor
(20 bar) 290 PSI
15 PORT RELIEF / ANTI-CAVITATION VALVE - (19 bar) 276 PSI
(Auxiliary – Two Way - Breaker) - 46 DESTROKE PISTON
30 CROSS PORT RELIEF VALVE - Slew Motor
(310 bar) 4496 PSI
(220 bar) 3190 PSI
47 PUMP MARGIN SPOOL (15 bar) 218 PSI
16 ANTI-CAVITATION VALVE- Boom Swing (2) 31 ANTI-CAVITATION VALVE – Slew Motor
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
27 27
28 28
30
Dr 32
30
23 P1 P2 P2 P1
23 REVERSE FORWARD REVERSE FORWARD
C2
18 M Mu
C2 E 55
M A
21 31
(LEFT) (RIGHT)
E
C2 C2
54 T V2 M M
56 E E
MALE FEMALE
T V2 Pa3
20 22
V2 T V2 T
Pb1
19
SWIVEL 24 pb10
A SWIVEL
58
JOINT A D F C T P B E
2 UP P T DOWN 1
57
BUCKET
7 7 7 7 7 7 7 7 7 2 LEFT P T RIGHT 1
7 7
B Pa8 Pb8
11
8 9 10
ARTICULATED
T B A T T B A T T B A T T B A T T B A T T T B A T BOOM VALVE
T B A
(OPTION)
16
12 13 14 15 17
59
T1 pa1 pa2 pa3 pa4 pa5 pa6 pa7 pa8 pa9 pb10 pa11
58
2 UP P T DOWN 1
Pa10 Pb10
AUTO IDLE 52
SWITCH PW
5 53
T
P
PRESSURE
REDUCING VALVE
Dealer Copy -- Not for Resale
6
2nd AUXILIARY
HYDRAULIC VALVE
Pb11
51 AUXILIARY pb5
HYDRAULICS R1 Pi1 R2 Pi2 R2 Pi2
Pa11
VALVE A B
45 T
2
50
1 P T 2
47
X Pa5 1 SWING 3 2 ARM 4 1 BUCKET 3 2 BOOM 4 1
LEFT
2 3
RIGHT
4 P1
TRAVEL TRAVEL
49 LEFT RIGHT OUT RETRACT REVERSE REVERSE
IN UP DOWN 35
B1 EXTEND FORWARD FORWARD
40
Pa3 Pb2 Pa2 Pa1
46 B2 37 38 39 Pb3 Pb1
C1
33
D1 A1
33
B1
1
P 33
A3 A2 A1
HYDRAULIC 43 MOTION ALARM
3 Dr1 VALVE
RESERVOIR 44
Dr2 (IF EQUIPPED)
C2 D2 E A2 B2
T1
Pb9 Pa9
41 42 34
HYDRAULIC S1 L1 L S2
48
PUMP B1 A1 MOTION ALARM
T PV PRESSURE SWITCH
SLEW MOTOR (IF EQUIPPED)
BRAKE VALVE
36
B2 S1 A2
88 of 879
Printed in Europe ACCUMULATOR V-1315EMEA (7-29-10)
HYDRAULIC SYSTEM INFORMATION
MS-1892-1
MC 2340 (6-2-98)
MS-1892-2
MC 2340-2 (6-2-98)
MS-1892-3
MC 2340-3 (6-2-98)
Description
IMPORTANT 1
P-86566
The hydraulic system has two separate hydraulic circuits.
The piston pump circuit supplies fluid to the hydraulic Figure 20-10-2
control valve.
P-86558
Testing
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.
P-86898
Figure 20-20-4
1 Articulated Boom
1
Figure 20-20-2
Articulated Boom
1 S37540
S37539
Testing (Cont’d)
Figure 20-20-5
2 1
2
P-87000
Testing (Cont’d)
Figure 20-20-8
P-86896
Remove the hose from the base end of the cylinder. Cap
the hose (Item 1) [Figure 20-20-8].
If there is any oil leakage from the base end fitting (Item
1) [Figure 20-20-8], remove the cylinder for repair or
replacement.
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.
P-86898
Figure 20-20-12
Articulated Boom
1
Figure 20-20-10 1
Articulated Boom
S37540
1
Install a sling (Item 1) [Figure 20-20-11] or [Figure 20-
20-12] and a lifting device to the rod end of the boom
cylinder.
S37539
1
P-86839
Figure 20-20-16
P-86896
Articulated Boom
Figure 20-20-14 2
3
S37541
Figure 20-20-17
2
1
1
P-87926
IMPORTANT 1
Figure 20-20-18
P-87008
P-87001
Parts Identification
1. Bolt 1
2. Washer 2
3. O-ring 4
4. Tubeline 5
5. Seal 3
6
6. U-bolt
8
7. Nut
8. Grease Fitting
9. Bushing 7 1 20
10. Set Screw 2
11. Piston 9
12. Back-up Ring 4 2
13. Wear Ring 5
14. Seal Assembly
15. Cushion Ring
16. Snap Ring 1 6 2
17. Head 7
18. Wiper Seal 2
19. Rod
10
15
7
3
12
1 5
14
5
12
16
9
17
5
5
18
16 8
19
5 MS-2790S
Disassembly
Figure 20-20-21
P-87090
Figure 20-20-22
P-87087
2
P-87086
Disassembly (Cont’d)
Figure 20-20-25
1 1
P-86848
Figure 20-20-28
Remove the four bolts (Item 1), lock washers and
tubeline (Item 2) [Figure 20-20-25].
1
1
P-86849
Disassembly (Cont’d)
Figure 20-20-29
P-86850
Figure 20-20-30
P-86851
Disassembly (Cont’d)
1
Figure 20-20-33
P-87032
Figure 20-20-36
Remove the piston (Item 1) [Figure 20-20-33].
1
P-87031
Disassembly (Cont’d)
Figure 20-20-37
P-87028
Figure 20-20-40
Remove O-ring (Item 1) [Figure 20-20-37] from the
piston.
P-86862
Disassembly (Cont’d)
1
Figure 20-20-41
P-86861
Figure 20-20-44
Remove the back-up ring (Item 1) [Figure 20-20-41]
from the piston.
1
1
P-86864
Disassembly (Cont’d)
Figure 20-20-45 1
P-86867
P-86868
P-86866
Disassembly (Cont’d)
2
Figure 20-20-49
1
P-887014
1
Remove the seal (Item 1) (both sides) and bushing (Item
P-87754 2) [Figure 20-20-51] from the rod end.
Figure 20-20-52
Remove the two seals (Item 1) [Figure 20-20-49].
1
2
P-87015
P-86870 Remove the seal (Item 1) (both sides) and bushing (Item
2) [Figure 20-20-52] from the base end.
Assembly
Lubricate all O-ring and seals with hydraulic oil during Install the bushing (Item 1) and snap ring (Item 2)
installation. [Figure 20-20-54] into the head.
Figure 20-20-53
P-87754
1
P-87010
Install the two seals (Item 1) [Figure 20-20-55] into the
head.
Support the end of the rod with a block (Item 1) [Figure
20-20-53].
Assembly (Cont’d)
Figure 20-20-56
P-86866
Figure 20-20-59
Install the wiper seal (Item 1) [Figure 20-20-56] into the
head.
P-86865
Assembly (Cont’d)
Figure 20-20-60 1
1
P86860
Figure 20-20-63
Install the O-ring (Item 1) [Figure 20-20-60].
P-87011
Assembly (Cont’d)
Figure 20-20-64
1 P-87029
Figure 20-20-67
Install the O-ring (Item 1) [Figure 20-20-64] into the
piston.
P-87030
Figure 20-20-68
P-87028
P-87031
Assembly (Cont’d)
Figure 20-20-69 2
1
P-86853
2
P-86851
P-87033 Tighten the nut until the bore (Item 2) [Figure 20-20-72]
of the set screw is aligned with the groove (Item 2)
[Figure 20-20-71] of the rod.
Install the seal (Item 1) [Figure 20-20-70] onto the
piston.
Assembly (Cont’d)
Figure 20-20-73
1
P-87077
Figure 20-20-76
Install the set screw (Item 1) [Figure 20-20-73] into the
nut. 1
Figure 20-20-74
1
1
P-86849
Assembly (Cont’d)
Figure 20-20-77
P-87087
Figure 20-20-80
Install the O-ring (Item 1) [Figure 20-20-77] into the
tubeline.
1
2
P-87090
2
Install the O-ring (Item 1) [Figure 20-20-80] into the
P-7088 tubeline.
Install the tubeline (Item 1), lock washers and bolts (Item
2) [Figure 20-20-78] onto the cylinder housing.
Assembly (Cont’d)
1
Figure 20-20-81 2
P-87014
Figure 20-20-84
Install the tubeline (Item 1) using the four bolts (Item 2)
[Figure 20-20-81] and lock washers.
P-36183
Testing 1
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.
Figure 20-21-1
P-87020
1
Figure 20-21-4
Figure 20-21-2
Articulated Boom
1 3
P-87076
S37544 Start the engine and fully retract the cylinder rod.
Testing (Cont’d)
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290 P-86831
Figure 20-21-6
Articulated Boom
S37542
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.
Figure 20-21-8
P-887020
Figure 20-21-11
Figure 20-21-9
Articulated Boom
1 2
1
3
P-87076
S37439
Support the boom with a chain hoist (Item 1) [Figure 20- IMPORTANT
21-8] or [Figure 20-21-9].
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-21-12
P-87078
1
1
Install a sling (Item 1) [Figure 20-21-14] on both ends of
P-87018 the cylinder.
P-87093
Figure 20-21-15
2 3 1
P-87095
S37543
Remove the nuts (Item 1), bolt (Item 2) and base end
pivot pin (Item 3) [Figure 20-21-15] or [Figure 20-21-
16].
Parts Identification
1
1. U-Bolt
2. Tubeline
7
3. Bolt 8
4. Washer
5. O-ring
6. Nut
2
7. Seal
8. Grease Fitting 4 9
9. Bushing 6
10. Check Valve 2 7
10
11. Spring 14
12. Spring Support 3 11
13. Plug 4 12
14. Housing 4 13
15. Cushion Plunger 5 3
16. Ring Stop
17
24
7
7
25
23 8
26
7 MS-2793S
Disassembly
Figure 20-21-18
P-87098
Figure 20-21-19
P-87096
1
1
P-87097
Disassembly (Cont’d)
Figure 20-21-22
1
P-86848
2
Figure 20-21-25
Remove the four bolts (Item 1), lock washers and hose
(Item 2) [Figure 20-21-22].
1
1
P-86849
Disassembly (Cont’d)
Figure 20-21-26
P-86850
Figure 20-21-27
P-86851
Disassembly (Cont’d)
Figure 20-21-30
1
P-87032
Figure 20-21-33
Remove the piston (Item 1) [Figure 20-21-30].
1
1
P-87031
Disassembly (Cont’d)
Figure 20-21-34
P-87028
Figure 20-21-37
Remove the O-ring (Item 1) [Figure 20-21-34] from the
piston.
P-86862
Disassembly (Cont’d)
Figure 20-21-38 1
P-86861
Figure 20-21-41
Remove the back-up ring (Item 1) [Figure 20-21-38].
1 1
P-86864
Disassembly (Cont’d)
Figure 20-21-42 1
P-86867
1
P-86868
P-86866
Disassembly (Cont’d) 2
Figure 20-21-46
1
P-887014
1
Remove the seal (Item 1) (both sides) and bushing (Item
P-87754 2) [Figure 20-21-48] from the rod end.
Figure 20-21-49
Remove the two seals (Item 1) [Figure 20-21-46].
1
2
P-87015
P-86870 Remove the seal (Item 1) (both sides) and bushing (Item
2) [Figure 20-21-49] from the base end.
Assembly
Lubricate all O-ring and seals with hydraulic oil during Install the bushing (Item 1) and snap ring (Item 2)
installation. [Figure 20-21-51] into the head.
Figure 20-21-50
P-87754
1
P-87010
Install the two seals (Item 1) [Figure 20-21-52] into the
head.
Support the end of the rod with a block (Item 1) [Figure
20-21-50].
Assembly (Cont’d)
Figure 20-21-53
P-86866
Figure 20-21-56
Install the wiper seal (Item 1) [Figure 20-21-53] into the
head.
P-86865
Assembly (Cont’d)
Figure 20-21-57 1
1
P86860
Figure 20-21-60
Install the O-ring (Item 1) [Figure 20-21-57].
P-87011
Assembly (Cont’d)
Figure 20-21-61
1 1
P-87029
Figure 20-21-64
Install the O-ring (Item 1) [Figure 20-21-61] into the
piston.
1
1
P-87030
Figure 20-21-65
P-87028
P-87031
Assembly (Cont’d)
Figure 20-21-66 2
1
1
P-86853
1
P-86851
P-87033 Tighten the nut until the bore (Item 2) [Figure 20-21-69]
of the set screw is aligned with the groove (Item 2)
[Figure 20-21-68] of the rod.
Install the seal (Item 1) [Figure 20-21-67] onto the
piston.
Assembly (Cont’d)
Figure 20-21-70
1 2
1
P-87077
Figure 20-21-73
Install the set screw (Item 1) [Figure 20-21-70] into the
nut. 2
2
P-86849
Tighten the bolts to 123 - 149 N•m (91 - 110 ft-lb) torque.
2
P-87013
Assembly (Cont’d)
Figure 20-21-74
1
1
P-87098
Figure 20-21-77
Install the O-ring (Item 1) [Figure 20-21-74] into the
hose.
2 1
2
2
P-87097
1
Install the tubeline (Item 1) using the four bolts (Item 2)
2
P-87099 [Figure 20-21-77] and lock washers.
Install the hose (Item 1), lock washers and bolts (Item 2)
[Figure 20-21-75] onto the cylinder housing.
Assembly (Cont’d)
Figure 20-21-78
1
2
P-36183
P-87014
Testing
Figure 20-22-4
Figure 20-22-2
P-87412
P-87411
1
Place a board (Item 1) [Figure 20-22-7] between the
2
cylinder and the excavator frame.
Figure 20-22-8
Figure 20-22-6 1
P-87417
P-87410
1
1
1
P-87413
Figure 20-22-12
Remove the hoses (Item 1) [Figure 20-22-9].
1
1
P-87415
Figure 20-22-13
1 1
P-89345
Figure 20-22-16
Slide the cylinder out of the front of the excavator until the
cable tie (Item 1) [Figure 20-22-13] can be removed.
Figure 20-22-14
P-89347
Continue sliding the cylinder out until the second cable tie
(Item 1) [Figure 20-22-14] can be removed.
Parts Identification
1. Seal 1
2. Bushing
3. Rod
4. Grease Fitting
2
5. Snap Ring
6. Wiper
7. Head
3
8. Lock Ring
9. O-ring
4
10. Back-up Ring
11. Piston
12. Wear Ring
13. Set Screw
14. Nut
15. Housing
16. Fitting 5 1
6
1
7
1
12
13
14
15 1
16
1
MS-2795S
Disassembly
Hold the cylinder over a drain pan and slowly move the
rod in and out to remove the oil from the cylinder.
1
Figure 20-22-17
1 P-87421
Figure 20-22-20
Figure 20-22-18
1 P-87422
P-87420
Disassembly (Cont’d)
Figure 20-22-21
2
1
1
P-87425
Figure 20-22-24
Remove the rod assembly (Item 1) [Figure 20-22-21]
from the housing.
Figure 20-22-22
P-87390
1 Clamp the rod end in a vise. Support the rod with a block
(Item 1) [Figure 20-22-24].
P-87424
Disassembly (Cont’d)
Figure 20-22-25
1 P-87429
1
1
P-87430
Disassembly (Cont’d)
Figure 20-22-29
P-87433
P-87446
Disassembly (Cont’d)
Figure 20-22-33
1
P-87436
P-87437
Disassembly (Cont’d)
Figure 20-22-37
1
P-87440
P-87444
Disassembly (Cont’d)
Figure 20-22-41 1
P-87445
P-87443
Lubricate all O-ring and seals with hydraulic oil during P-87442
installation.
P-87445
Figure 20-22-45
P-87443
Assembly (Cont’d)
Figure 20-22-47
1
P-87439
2
P-87438
P-87437
Assembly (Cont’d)
Figure 20-22-52
1
P-87434
P-87446
1
P-87435
Assembly (Cont’d)
Figure 20-22-56
P-87431
Figure 20-22-57
P-87430
P-87439
Install the seal (Item 1) [Figure 20-22-59].
Assembly (Cont’d)
Figure 20-22-60
P-87428
1
Install the set screw (Item 1) [Figure 20-22-61].
P-87429
Use a center punch to deform the threads of the set
screw bore.
Install the piston (Item 1) [Figure 20-22-60].
Figure 20-22-63
1
P-87426
P-87427
Assembly (Cont’d)
Figure 20-22-64
2 1
P-87423
Figure 20-22-67
Install the bushing (Item 1) and seal (Item 2) [Figure 20-
22-64] (both sides) into the rod end.
P-87422
1
Assembly (Cont’d)
Figure 20-22-68
P-87421
Bend the lock ring tab (Item 1) [Figure 20-22-68] into the
groove on the head.
P-87420
Fully retract the bucket and arm cylinders. Lower the boom until the bucket is on the ground.
With the engine off and the key in the run position, move
the joysticks to relieve hydraulic pressure.
Figure 20-23-1 1
1
P-87021
Figure 20-23-2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
1 clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-86829
If there is any oil leakage from the base end fitting (Item
2) [Figure 20-23-2] on the bucket cylinder, remove the
cylinder for repair or replacement.
2 1
P-86832
Figure 20-23-7
Remove the hose (Item 1) [Figure 20-23-4] from the
base end.
Figure 20-23-5
P-86833
P-86834
Figure 20-23-8
1
1 P-86835
Figure 20-23-11
Remove the rod end pivot pin (Item 1) [Figure 20-23-8].
P-86838
1
Parts Identification
1. Bolt
2. Lockwasher 1
3. O-ring
4. Tubeline 2
5. Seal 4
6. Grease Fitting 3
8 3
7. Bushing
6
8. U-Bolt
9 1
9. Nut
10. Housing 2 2
11. Set Screw
7
12. Piston 4
13. Wear Ring
14. Seal Assembly 10
1
15. Back-up Ring 2 8
16. Cushion Ring 2 5
17 Snap Ring
18. Head
21
19. Wiper Seal
20. Rod
11
3
15
7
18
5
5
19
17
6
20
7
5
MS-2794S
Disassembly
Figure 20-23-12
P-86843
Figure 20-23-15
1
Figure 20-23-13
P-86842
1 1
P-86840
Disassembly (Cont’d)
Figure 20-23-16
1 1
P86847
2
Remove the O-ring (Item 1) [Figure 20-23-18] from the
P-86844 tubeline.
1
2
1
P-86845
1
P-86848
Remove the four bolts (Item 1), lock washers and Support the cylinder with a block (Item 1) [Figure 20-23-
tubeline (Item 2) [Figure 20-23-17]. 19].
Disassembly (Cont’d)
1
Figure 20-23-20
P-86852
Figure 20-23-23
Remove the eight bolts (Item 1) [Figure 20-23-20].
P-86850
1
Disassembly (Cont’d)
Figure 20-23-24
1
P-86542
Figure 20-23-27
Apply moderate heat to the nut (Item 1) [Figure 20-23-
24].
Figure 20-23-25
P-87032
P-86853
Disassembly (Cont’d)
Figure 20-23-28
P-87029
Figure 20-23-31
Remove the seal (Item 1) [Figure 20-23-28].
P-87028
Disassembly (Cont’d)
Figure 20-23-32
1
P-86860
Figure 20-23-35
Remove the O-ring (Item 1) [Figure 20-23-32] from the
piston.
P-86861
Disassembly (Cont’d)
Figure 20-23-36
P-86866
P-86867
P-86865
Disassembly (Cont’d)
Figure 20-23-40
1 1
2
P-86870
Remove the wiper seal (Item 1) [Figure 20-23-40]. Remove the rod from the vise.
2
1
P-87754 P-887014
Remove the two seals (Item 1) [Figure 20-23-41]. Remove the seal (Item 1) (both sides) and bushing (Item
2) [Figure 20-23-43] from the rod end.
Disassembly (Cont’d)
Figure 20-23-44
2
1
P-87015
Assembly
Lubricate all O-rings and seals with hydraulic oil during Install the bushing (Item 1) and snap ring (Item 2)
installation. [Figure 20-23-46] into the head.
Figure 20-23-45
P-87754
1
P-87010
Install the two seals (Item 1) [Figure 20-23-47] into the
head.
Support the end of the rod with a block (Item 1) [Figure
20-23-45].
Assembly (Cont’d)
Figure 20-23-48
P-86866
Figure 20-23-51
Install the wiper seal (Item 1) [Figure 20-23-48] into the
head.
P-86865
Assembly (Cont’d)
Figure 20-23-52 1
1
P86860
Figure 20-23-55
Install the O-ring (Item 1) [Figure 20-23-52].
P-87011
Assembly (Cont’d)
Figure 20-23-56
1
1
P-87029
Figure 20-23-59
Install the O-ring (Item 1) [Figure 20-23-56] into the
piston.
P-87030
Figure 20-23-60
P-87028
P-87031
Assembly (Cont’d)
2
Figure 20-23-61
1
P-86853
1 1
P-86851
P-87033 Tighten the nut until the bore (Item 2) [Figure 20-23-64]
of the set screw is aligned with the groove (Item 2)
[Figure 20-23-64] of the rod.
Install the seal (Item 1) [Figure 20-23-62] onto the
piston.
Assembly (Cont’d)
Figure 20-23-65
1
P-87077
Figure 20-23-68
Install the set screw (Item 1) [Figure 20-23-65] into the
nut. 2
Figure 20-23-66
2
P-86849
1
P-87013
Assembly (Cont’d)
Figure 20-23-69
2
1
P-86844
1
Install the U-bolt (Item 1), lock washers and nuts (Item 2)
P-86847 [Figure 20-23-71].
Figure 20-23-72
Install the O-ring (Item 1) [Figure 20-23-69] into the
tubeline.
P-86842
2
Install the O-ring (Item 1) [Figure 20-23-72] into the
P-86845 tubeline.
Install the tubeline (Item 1), lock washers and bolts (Item
2) [Figure 20-23-70] onto the cylinder housing.
Assembly (Cont’d)
Figure 20-23-73
1
2
1
P-86839
Figure 20-23-76
Install the O-ring (Item 1) into the spacer (Item 2) [Figure
20-23-73].
1
3 3
P-87014
Assembly (Cont’d)
Figure 20-23-77
1
2
P-36183
Testing
With the engine off and the key in the run position, move
the blade lever to relieve hydraulic pressure.
Figure 20-24-1
Figure 20-24-2
P-86490
If there is any oil leakage from the base end fitting (Item
2) [Figure 20-24-2] of the blade cylinders, remove the
cylinder for repair or replacement.
IMPORTANT P-86491
When repairing hydrostatic and hydraulic systems, Remove the nuts (Item 1) and bolt (Item 2) [Figure 20-
clean the work area before disassembly and keep all 24-4] from the base end retaining pin.
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-24-5
damage the system.
I-2003-0888
2
1
1
P-86492
Figure 20-24-6
P-86496
Figure 20-24-9
P-86493
Figure 20-24-7
P-86495
Figure 20-24-10
P-86498
Figure 20-24-11
P-86497
Parts Identification
1. Grease Fitting
2. Bushing
3. Rod 1
4. Snap Ring
5. Wiper Seal 3
6. Seal
7. Head
8. O-ring 4 2
9. Back-up Ring 5
7
10. Snap Ring
6
11. Piston
12. Seal 8
13. Slipper Seal Assy 9
14. Wear Ring
15. Set Screw 2
10
16. Nut
8
17. Housing
9
11
12
16
17
MS-2796S
Disassembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all 1
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-86501
Hold the cylinder over a drain pan and slowly move the
rod in and out to remove the oil from the cylinder.
Straighten the head lock ring (Item 1) [Figure 20-24-13].
Figure 20-24-12
Figure 20-24-14
2 P-86500
P103657
Disassembly (Cont’d)
Figure 20-24-15
P-86504
P-86506
1
Apply moderate heat to the nut (Item 1) [Figure 20-24-
18].
P-86505
Remove the nut.
Clamp the rod end in a vise. Support the end of the rod
with a block (Item 1) [Figure 20-24-16].
Disassembly (Cont’d)
Figure 20-24-19
P-86541
P-86548
Disassembly (Cont’d)
Figure 20-24-23
P-86532
P-86531
Disassembly (Cont’d)
Figure 20-24-27 1
P-86517
P-86518
1
Disassembly (Cont’d)
Figure 20-24-31
P-86524
1
P-86525
Disassembly (Cont’d)
Figure 20-24-35
P-86529
1 P-86531
Disassembly (Cont’d)
Figure 20-24-39
P-86544
P-86533
Assembly
Lubricate all O-rings and seals with hydraulic oil during Install the bushing (Item 1) [Figure 20-24-42] into the
assembly. rod.
P-86543 P-86530
Install the bushing (Item 1) [Figure 20-24-41] into the Install the bushing (Item 1) and snap ring (Item 2)
base end of the housing. [Figure 20-24-43] into the head.
Assembly (Cont’d)
Figure 20-24-44
1 1
P-86526
1
1
P-86525
Assembly (Cont’d)
Figure 20-24-48
P-86519
P-86518
P-86523
Install the head (Item 1) [Figure 20-24-51] onto the
cylinder rod.
Install the back-up ring (Item 1) [Figure 20-24-49].
Assembly (Cont’d)
Figure 20-24-52
1
P-86515
1
1
P-86531
Assembly (Cont’d)
Figure 20-24-56
1
P-86540
P-86548
Assembly (Cont’d)
Figure 20-24-60
1
2
P-86507
Figure 20-24-63
Install the wear ring (Item 1) [Figure 20-24-60].
P-86506
Tighten the nut until the bore of the set screw is aligned
Install the seal (Item 1) [Figure 20-24-61]. with the groove (Item 2) [Figure 20-24-62] of the rod.
Assembly (Cont’d)
Figure 20-24-64
P103657
Figure 20-24-67
Install the set screw (Item 1) [Figure 20-24-64].
Figure 20-24-65
1
P-86501
1
Bend the lock ring tab (Item 1) [Figure 20-24-67] into the
groove on the head.
P-86503
Assembly (Cont’d)
Figure 20-24-68
P-86500
Testing
2
Lower the boom / bucket and blade to the ground.
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure.
Figure 20-25-1
1
S37546
Figure 20-25-4
S37547
1
Start the engine and fully retract the cylinder rods (Item 2)
2 [Figure 20-25-4].
Testing (Cont’d)
WARNING
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Figure 20-25-5
S37548
If there is any oil leakage from the base end fittings (Item
1) [Figure 20-25-5], remove the cylinder for repair or
replacement.
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic
pressure. 3
Figure 20-25-6
S37650
Figure 20-25-9
S37544
2
Support the boom with a chain hoist (Item 1) [Figure 20-
25-6].
Figure 20-25-7
1
3
S37651
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-25-10
1
S37653
Parts Identification
1. Bushing
2. Housing
3. Band
4. Bolt
5. Washer 4
6. Set Screw 3
7. Nut
8. Piston
9. Wear Ring 5
10. Seal
1
11. O-ring
12. Back-up Ring
13. Bushing 4
5
14. Head
15. Inner Seal 6
16. Wiper
17. Snap Ring 3
18. Rod
8
9
10
10
11
11
12
17
13
11
14
11
15
16
17
18
NA5527S
Disassembly
Figure 20-25-11
S37656
1
Figure 20-25-14
Figure 20-25-12
S37657
S37655
Disassembly (Cont’d)
Figure 20-25-15
P-87390
1
Clamp the rod end in a vise. Support the rod with a block
(Item 1) [Figure 20-25-17].
P-87424
Figure 20-25-18
1
1
S37688
Disassembly (Cont’d)
Figure 20-25-19
S37690
S37689
S37687
Disassembly (Cont’d)
Figure 20-25-23
1
P-87435
P-87436
1
P-87434
Disassembly (Cont’d)
Figure 20-25-27
1
P-87439
P-87440
P-87438
Disassembly (Cont’d)
Figure 20-25-31
1
P-87443
1
Remove the bushing (Item 1) [Figure 20-25-33].
1 2
P-87445
P-87442
Assembly
1
P-87442
P-87445
Assembly (Cont’d)
Figure 20-25-38
1
P-87439
1 2
Install the lock ring (Item 1) [Figure 20-25-40].
P-87438
Figure 20-25-42
P-87440
P-87437
Assembly (Cont’d)
Figure 20-25-43 1
P-87434
S37691
1
P-87435
Assembly (Cont’d)
2
Figure 20-25-47
S37687
1
S37692
S37690 Tighten the nut until the bore of the set screw is aligned
with the groove (Item 2) [Figure 20-25-49] of the rod.
Assembly (Cont’d)
Figure 20-25-51 1
1
P-87425
Figure 20-25-52
P-87424
Assembly (Cont’d)
Figure 20-25-55
S37655
S37656
S37657
Bend the lock ring tab (Item 1) [Figure 20-25-56] into the
groove on the head.
Description
Figure 20-30-1
P-86566
Figure 20-30-2
P-86558
The piston pump circuit has one load sense relief valve
(Item 1) [Figure 20-30-1] and one back-up relief valve
(Item 1) [Figure 20-30-2] located on the hydraulic control
valve. The load sense relief valve (Item 1) [Figure 20-30-
1] is factory set at 28000 kPa (280 bar) (4060 psi).
The back-up relief valve and load sense relief valve are
tested and adjusted during the piston pump testing and
adjusting. (See Pump Testing on Page 20-50-6.)
Figure 20-31-2
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
3
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. 2
I-2003-0888
A portable hydraulic hand pump will be used to test the Install the hand pump (Item 1), hose (Item 2) and a
work port relief valves. The hand pump must have clean pressure gauge (Item 3) [Figure 20-31-2] (minimum of
Bobcat hydraulic fluid. 34500 kPa (345 bar) (5000 psi) into the valve section
work port in which the port relief valve is located.
Figure 20-31-1 Pressurize this section with the hand pump until the port
relief valve opens. Record the pressure reading.
5
1 P-86413
Bucket Port Relief set at: Remove the protective cap (Item 1) [Figure 20-31-3].
Rod End (Item 3) [Figure 20-31-1] 31000 kPa (310 bar)
(4495 psi)
Figure 20-31-4
2
P-86412
With the engine off, and the key in the run position, lower 1
the left console and move both joysticks to relieve
hydraulic pressure.
WARNING P-86423
AVOID INJURY OR DEATH Install the test fittings and 6900 kPa (69 bar) (1000 psi)
Never work under the excavator cab without gauge (Item 1) [Figure 20-32-1] in between the A-1 port
installing an approved cab support device. fitting and existing hose. Route the gauge to the outside
W-2435-0502 of the excavator.
With the engine off, and the key in the run position, lower
P-86422 the left console and move both joysticks to relieve
hydraulic pressure.
The pressure reducing valve (Item 1) [Figure 10-141-1]
is located on the end of the manifold. If adjustment is needed, remove the center cover. (See
Removal And Installation on Page 40-70-1.)
Remove the hose (Item 2) [Figure 10-141-1] from the A-
1 port.
P-86425
Figure 20-32-3
Description
Remove the left upperstructure cover. (See Removal And Figure 20-40-3
Installation on Page 40-20-1.)
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-87118
Figure 20-40-1
Remove the pilot lines from the outboard side of the
valve [Figure 20-40-3].
P-87116
Mark and remove the hoses from the top of the valve
[Figure 20-40-1].
Figure 20-40-4
1
1
P-87121
Figure 20-40-7
Remove the bolt (Item 1) [Figure 20-40-4] and washer.
1
1
1
P-87122
Parts Identification
15
16
17
MS2831S
Figure 20-40-8
1
1
P-87128
Figure 20-40-11
Remove the bolts (Item 1) [Figure 20-40-8], washers
and mounts.
1 1
P-87129
Figure 20-40-12
Articulated Boom 1
P-87130
Figure 20-40-15
Remove the articulated boom valve section (Item 1)
[Figure 20-40-12]. (If equipped.)
1 1
P-87131
1 1
Remove the four O-rings (Item 1) [Figure 20-40-15].
P-87131
Figure 20-40-16
1
1
1
1
2
P-87134
Remove the four O-rings (Item 1). Remove the right hand
P-87132 travel valve section (Item 2) [Figure 20-40-18].
Figure 20-40-19
Remove the mid inlet (Item 1) [Figure 20-40-16] valve
section.
2
1 P-87135
Remove the four O-rings (Item 1). Remove the left hand
2 travel valve section (Item 2) [Figure 20-40-19].
P-87133
Figure 20-40-20 1
2 1
P-87138
1
Remove the four O-rings (Item 1). Remove the arm valve
P-87136 section (Item 2) [Figure 20-40-22].
Figure 20-40-23
Remove the four O-rings (Item 1). Remove the auxiliary
valve section (Item 2) [Figure 20-40-20].
1
2
1
P-87139
Figure 20-40-24
P-87140
2 1
P-87141
Remove the four O-rings (Item 1). Remove the tie rods
(Item 2) [Figure 20-40-25] from the inlet valve section.
Figure 20-40-26 1
1
1 2
P-87144
2
Figure 20-40-29
Remove the load sense relief valve (Item 1) and back-up
relief valve (Item 2) [Figure 20-40-26].
Figure 20-40-27
1
1 1
P-87145
Figure 20-40-30
P-35277
1
Remove the O-ring (Item 1) [Figure 20-40-32].
Figure 20-40-31
P-87147
P-87146
Figure 20-40-34
P-87148
P-87149
Figure 20-40-36
1
1
P-87156
1
1
P-35253
P-35260
Figure 20-40-40
1
1
P-35279
1
1
1
2 2
2
P-35266
1
Remove the centering spring (Item 1) [Figure 20-40-43]
P-87158 from both ends.
P-87151
P-35267
Record the orientation of the spool (Item 1) [Figure 20- Apply moderate heat to the plug (Item 1) [Figure 20-40-
40-44]. 46] to melt the thread adhesive. Remove the plug from
Figure 20-40-45
Cut
0.5625 Dia
2.0 in
P-87152
0.750 in B-14674
Figure 20-40-48
2 3
1
P-35269
3 1
Remove the poppet (Item 1) and spring (Item 2) from the
plug. Remove the O-ring (Item 3) [Figure 20-40-50] from
P-87154 the plug.
Figure 20-40-49
1
P-35268
Figure 20-40-51
1 1
P-87165
P-35253
1
2
Remove the O-ring (Item 1) [Figure 20-40-54].
P-87160
Figure 20-40-55
P-35279
1
2
2
1 P-35266
Figure 20-40-59
1 2
1 3
P-35269
Figure 20-40-62
Remove the spool (Item 1) [Figure 20-40-59].
P-87167
Figure 20-40-63
P-87168
Figure 20-40-64
P-87161
Figure 20-40-65 1
2 1
1 P-35253
Figure 20-40-68 2
1
P-35281
1 1
P-35283
Figure 20-40-72
P-35279
Figure 20-40-73 1
2
2
P-35266
1
P-35269
1
P-35268
Figure 20-40-79 1 2
4 3
1
1 1
P-87171
Figure 20-40-82
Remove the valves (Item 1) [Figure 20-40-79].
Figure 20-40-80
P-87156
Figure 20-40-83
1
1
1
2 P-87166
P-87157
P-35279
Figure 20-40-87
1
2 P-35268
Figure 20-40-88
1 2
1 3
P-35269
Figure 20-40-91
P-87161
1
1
P-35253
P-35260
Figure 20-40-95 2
1
P-35281
1 1
P-35283
Figure 20-40-99
P-35279
Figure 20-40-100 1
2
2
P-35266
1
P-35269
1
P-35268
If any of the following adjustments are not obtainable, pump repair is required.
The outline listed below, gives the five adjustments for setting the hydraulic pump. The adjustments are listed in the order
in which they MUST be performed. Below each adjustment is a list of the steps. Behind each adjustment is the page
location within the Service Manual for the complete adjustment procedure.
2. Remove the plug and install fitting and hose from the torque limit supply spool to a drain pan.
3. Install a 5000 kPa (50 bar) (725 psi) pressure gauge on the test port on the hydraulic control valve.
7. Record pressure
8. Remove the hose and fitting from the torque limiter supply spool and plug the port
11. Adjust as necessary to get 1800 ± 138 kPa (18 ± 1,38 bar) (260 ± 20 psi).
__________ PM PRESSURE
13. Remove 5000 kPa (50 bar) (725 psi) pressure gauge.
14. Install 69000 kPa (690 bar) (10000 psi) gauge on the test port on the hydraulic control valve.
16. Run engine at high idle and raise the blade until the blade cylinders are fully retracted and the relief valve opens.
17. Adjust back-up relief valve as necessary to get 34000 ± 345 kPa (340 ± 3,45 bar) (4931 ± 50 psi).
__________ PRESSURE
20. Install 69000 kPa (690 bar) (10000 psi) gauge on the test port on the hydraulic control valve.
21. Run engine at high idle and raise the blade until the blade cylinders are fully retracted and the relief valve opens.
22. Adjust load sense relief valve as necessary to get 28000 ± 345 kPa (280 ± 3,45 bar) (4060 ± 50 psi).
__________ PRESSURE
24. Remove the 69000 kPa (690 bar) (10000 psi) gauge, from the diagnostic coupler at the hydraulic control valve.
25. Remove the outlet hose from the pump, install a cap on the hose and install the inlet hose from the hydraulic tester,
to the outlet of the pump.
26. Route the outlet hose of the hydraulic tester to the tee fitting installed on the hydraulic reservoir adapter.
27. Bottom out the pump margin spool (approximately six turns in)
29. Free flow on the hydraulic tester is 144 L/min (38 U.S. gpm)
30. Adjust the hydraulic tester to 10300 kPa (103 bar) (1500 psi)
__________ FLOW
33. Adjust the hydraulic tester to 24100 kPa (241 bar) (3500 psi).
34. Adjust the torque limiter to obtain 64 L/min (17 U.S. gpm)
__________ FLOW
37. Install the pump outlet hose on the hydraulic control valve.
38. Reset pump margin spool to 1800 ± 138 kPa (18 ± 1,38 bar) (260 ± 20 psi).
Testing Information
Use the gauge and hose assembly from test kit MEL Item 3 [Figure 20-50-1]: MEL 1713-3 Male-12 BSPP to
1173A. Male-8 NPTF.
Figure 20-50-2
1 P-86559
P-86558
Pump Testing
Figure 20-50-4 1
3
2
1
P-86562
Figure 20-50-5 Turn the pump margin spool (bottom spool) (Item 3)
[Figure 20-50-6] all the way in (approximately six turns).
P-86561
Tighten the nut (Item 4) [Figure 20-50-6].
Pump Testing (Cont’d) Tilt the cab. (See Tilting The Cab on Page 10-210-1.)
Figure 20-50-7
P-86566
1
Remove the plastic cap (Item 1) [Figure 20-50-8].
P-86561
Loosen the locknut and turn the load sense relief valve
WARNING adjustment screw (Item 1) [Figure 20-50-9] in 1.5 turn,
increasing the relief pressure approximately 8274 kPa
(83 bar) (1200 psi) to 36266 kPa (363 bar) (5260 psi).
AVOID INJURY OR DEATH The load sense relief is now set to a higher pressure.
Never work under the excavator cab without
installing an approved cab support device. Lower the cab.
W-2435-0502
Figure 20-50-10
1
2
P-86564
Figure 20-50-12
P-86560
The pressure at the gauge (Item 2) [Figure 20-50-10] Loosen the lock nut (Item 1) [Figure 20-50-12].
should be 34000 kPa (340 bar) (4931 psi).
Turn the adjustment screw (Item 2) [Figure 20-50-12]
Stop the engine. inwards to increase pressure and outwards to decrease
pressure.
Tilt the cab and turn the load sense relief valve
adjustment screw (Item 1) [Figure 20-50-9 on Page 7]
one turn outwards to the original setting.
Figure 20-50-13
P-86567
Move the engine speed control to the high idle position. Tighten the lock nut and lower the cab.
Figure 20-50-15
1
P-86571
Figure 20-50-16 1
P-86572
2
P-86570
Figure 20-50-19
1 P-86575
Figure 20-50-20
1 P-86576
Figure 20-50-23
P-22253
The flow should be 144 L/m (38 U.S. gpm) on the flow
1
tester (Item 1) [Figure 20-50-25].
1
P-86577
P-86578
Figure 20-50-27 Remove the hydraulic tester, fittings and adapter hose.
Figure 20-50-28
1
2
P-86579
1
Figure 20-50-29
P-87478
1
1
Remove the top inlet flange bolts (Item 1) [Figure 20-50-
31].
1 Figure 20-50-32
1
3
P-87476
Figure 20-50-30
2
P-87479
Remove the load sense line (Item 1), high pressure lines
(Item 2) and case drain line (Item 3) [Figure 20-50-32].
P-87477
Figure 20-50-33
P-87482
Slide the pump away from the engine and remove the
P-87480 pump [Figure 20-50-35].
P-87481
1. Plug
2. O-ring
3. Spring 7
4. Spring Seat
5. Spool Assembly
6. Spool
7. Bolt
8. O-ring 19
9. Spring Seat
10. Spring
11. Spring
12. O-ring
6
13. Body
14. Locknut
5
15. Washer
16. Screw 3 4
17. Nut 1 2
18. Cap
19. Housing
18
17
16
14 15
13
12
11
10
9
MS-2790S
Clean the outside of the pump with clean solvent and dry
it with compressed air before removing any components
from the pump.
Figure 20-50-36
P-87516
Figure 20-50-37
P-35330
Figure 20-50-38
1 1
2
N-23329
Figure 20-50-41
Remove the O-ring (Item 1) [Figure 20-50-38] from the
torque limiter valve.
Figure 20-50-39 1
P-35320
N-23328
Figure 20-50-42
2
N-23333
1
2
Remove the two springs (Items 1 and 2) [Figure 20-50-
P-35321 44].
Figure 20-50-45
Remove the metering spool (Item 1) from the control
spool (Item 2) [Figure 20-50-42].
P-35322
Figure 20-50-46
2
P-35325
1
Loosen the large nut (Item 1) [Figure 20-50-48].
P-35323
Turn the small nut (Item 2) [Figure 20-50-48] to remove
the adjustment body.
Remove the O-ring (Item 1) [Figure 20-50-46].
Figure 20-50-49
Figure 20-50-47
P-35326
P-35324
Figure 20-50-50
1
4
P-35327
Figure 20-50-51
P-35328
Figure 20-50-52
P-35327
1
Install the O-ring washer (Item 1) on the adjustment
screw (Item 2) [Figure 20-50-53].
Figure 20-50-54
P-35328
P-35325
Figure 20-50-55
N-23332
1
Install the spring seat (Item 1) [Figure 20-50-57] in the
P-35324 valve body with the ball side facing the control spool.
Figure 20-50-58
Install the dust cap (Item 1) [Figure 20-50-55].
Figure 20-50-56
2 1
2
1
P-35321
Figure 20-50-59
N-23328
1
Figure 20-50-62
Install the control spool assembly (Item 1) [Figure 20-50-
59] in the valve body.
Figure 20-50-60
N-23327
2
1
N-23329
Figure 20-50-63
1
P-35323
P-35322
Figure 20-50-65
107 mm
(4.21 in)
P-40592
1
Measure from the plug to the top of the small adjusting
screw [Figure 20-50-67]. Set the small adjustment screw
to 106 mm (4.15 in).
Figure 20-50-66
2 1
P-35330
96 mm
(3.78 in)
Align the linkage pin (Item 1) on the hydraulic piston
pump into the hole (Item 1) [Figure 20-50-68] in the
P-40592 torque limiter valve.
Figure 20-50-69
P-87516
6
2
7 6
8
7
9 8
10 9
10
2 11
11
2
2 2
2
12
2
14
13
15 2
14 2
2
11 11
MS1540
Clean the outside of the pump with clean solvent and dry
it with compressed air before removing any components
from the pump.
Figure 20-50-70
P-87516
Figure 20-50-71
1 1
P-87517
Figure 20-50-72
4
3
1 2
1
P-35335
Remove the adjustment screw (Item 1), nut (Item 2), and
P-35332 O-ring washer (Item 3) from the adjustment assembly
(Item 4) [Figure 20-50-74].
Remove the three O-rings (Item 1) [Figure 20-50-72] Remove the adjustment assembly (Item 4) [Figure 20-
from the valve. 50-74].
Figure 20-50-73
3
2 3 1 4
1
P-35344
P-35333
Remove the adjustment seat (Item 1), large spring (Item
2), and the small spring (Item 3) [Figure 20-50-75] from
Before disassembling the pump margin control, remove the adjustment assembly.
the cap (Item 1) and O-ring washer (Item 2) [Figure 20-
50-73] from the adjustment assembly (If equipped.) Remove the O-ring (Item 4) [Figure 20-50-75].
Figure 20-50-76
N-23380
Check the spool for scratches and make sure the orifice
1 (Item 1) [Figure 20-50-78] is not plugged.
Figure 20-50-77
P-35338
P-35337
Figure 20-50-80
1
3
2
P-35341
Figure 20-50-82
P-35342
Figure 20-50-83 1
3
1
P-35345
4
Remove the spring seat (Item 1) [Figure 20-50-85].
2
Figure 20-50-86
P-35343
Figure 20-50-84
P-35346
4
3
Remove the spool (Item 1) [Figure 20-50-86].
1
2
P-35344
Figure 20-50-87
P-35348
N-23379
Figure 20-50-88
P-35347
Parts Identification
1. Snap Ring
2. Seal
3. Housing
4. Plug
5. O-ring 7
6. Bearing
5 6
7. Shaft
8. Shim 3
9. Swash Plate
10. Rotating Group
11. Piston Assembly
12. Retaining Plate
13. Ball Guide
14. Cylinder Block 2
15. Pin 1
16. Thrust Washer 19
17. Spring
18. Snap Ring 18
19. Valve Plate 17
14 16
20. Piston
25 5
27
21
17
20
8 6
29
22
5
24 26
23
B-23974
Disassembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
1
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
N-23355
Clean the outside of the hydraulic piston pump with
solvent and dry with compressed air.
Remove the pin assembly (Item 1) [Figure 20-50-91].
Remove the torque limiter valve. (See Torque Limiter
Valve Removal And Installation on Page 20-50-17.) Figure 20-50-92
1
P-61054
Disassembly (Cont’d)
1
3
Figure 20-50-93
P-61070
2
1
1 1
N-23387
P-61055
Disassembly (Cont‘d)
Figure 20-50-97
2
1
P-61072
Figure 20-50-100
Remove the spring (Item 1) from the stroking piston (Item
2) [Figure 20-50-97].
1
1
P-61073
Lay the pump assembly on its side and remove the rotary
P61071 group, swash plate, and shaft (Item 1) [Figure 20-50-
100] from the housing.
Disassembly (Cont’d)
1
Figure 20-50-101
3
P-35354
Figure 20-50-102
1 P-35355
P-35361
Disassembly (Cont’d)
1
Figure 20-50-105
2
4 4
3 2 3
1 2 3
4
N-15289
To remove the spring from inside the cylinder block, use NOTE: The modified washer (Item 1) must fit between
a threaded rod (or bolt) (Item 1), two trimmed washers the three pins (Item 4) [Figure 20-50-107].
4
1
2
1
2
3
N-15290
N-15288
Disassembly (Cont’d)
Figure 20-50-109
1
2 3
1 3
3 2
N-23395
N-15284
P-61075
Disassembly (Cont’d)
Figure 20-50-113
1
N-15277
Figure 20-50-116
Remove the snap ring (Item 1 [Figure 20-50-113] from
the housing.
1
1
N-15280
Disassembly (Cont’d)
Figure 20-50-117
1 1
1
1
P-61078
1
Remove the bearing race from the port block assembly
P-61076 with a bearing puller (Item 1) [Figure 20-50-119].
Figure 20-50-120
Remove the O-rings (Item 1) [Figure 20-50-117].
N-23418
Remove the valve plate (Item 1) [Figure 20-50-118]. Remove the destroking piston (Item 2) [Figure 20-50-
120].
Assembly
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-61080
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and damage. Install the bearing race (Item 1) [Figure 20-50-122] in the
port block assembly.
Replace any worn or damaged parts.
Figure 20-50-121
P-61079
Assembly (Cont’d)
Figure 20-50-123
P-35356
1
1
N-15285
Assembly (Cont’d)
1
Figure 20-50-127 2
P-61083
Figure 20-50-128
P-35360
Assembly (Cont’d)
Figure 20-50-131
N-15277
Figure 20-50-133
Install a dial indicator on the housing as shown [Figure
20-50-131] and set it to zero.
Assembly (Cont’d)
Figure 20-50-134
3 2
1 2 3
1
2
N-15299
Install the swash plate (Item 1) on the shaft (Item 2) Figure 20-50-137
[Figure 20-50-134].
3 3
2 1
N-15289
N-15291 Install the threaded rod and nut (Item 1) through the
modified washer (Item 2) and the block assembly (Item 3)
[Figure 20-50-137].
Apply clean grease to the three pins (Item 1) [Figure 20-
50-135] and install them in the appropriate groove.
Assembly (Cont’d)
1
Figure 20-50-138
2
1
3
P-35354
Figure 20-50-141
NOTE: The modified washer (Item 1) must fit over the
spring (Item 2), but must also fit inside the
1
Figure 20-50-139
2
1 P-35361
Figure 20-50-142
2
1
1
P-61072
P-61074
Install the shim (Item 1) [Figure 20-50-144].
Slide the rotary group assembly (Item 1) on the shaft Figure 20-50-145
(Item 2) [Figure 20-50-142].
2
1
P-61086
Lay the pump housing on its side and install the rotary Install the O-ring (Item 2) [Figure 20-50-145].
group assembly, swash plate and shaft in the housing
[Figure 20-50-143].
Assembly (Cont’d)
1
Figure 20-50-146
P-61089
1
3
Install the stroking piston assembly (Item 1) [Figure 20-
N-23399 50-148].
Figure 20-50-149
Install the valve plate (Item 1) on the port block assembly.
The valve plate can only be installed by aligning the
Figure 20-50-147
3
1 2
2
3
1
1 P-61090
1
Install the end cap (Item 1) [Figure 20-50-149].
Assembly (Cont’d)
Figure 20-50-150
1
1 N-23354
Install the four bolts (Item 1) [Figure 20-50-150] and Install the torque limiter valve. (See Torque Limiter Valve
tighten to 119 N•m (88 ft-lb) torque. Removal And Installation on Page 20-50-17.)
2
N-23355
Figure 20-51-1
1
P-86580
To test the gear pump, use the following fittings from MEL
1713 Hydraulic Test Kit: 1
If the high pressure flow is less than 80% of the free flow,
remove the hydraulic pump for repair or replacement.
P-22253
Start and run the engine at a low rpm. Make sure the
tester is connected correctly. If no flow is indicated at the
tester, the hoses are connected wrong.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
P-87372
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Installation: Install the O-ring (Item 1) [Figure 20-51-6]
I-2003-0888 in the O-ring groove of the flange.
P-87371 P-87373
Remove the four bolts (Item 1) [Figure 20-51-5], flange Remove the four bolts, flange (Item 1) [Figure 20-51-7]
and hose from the high pressure side of the pump. and hose from the suction side of the pump.
Figure 20-51-8
2
1
P-87376
P-87375
Figure 20-51-11
1
P-87379
1 1
1
1 P-87380
P-87378
Figure 20-51-15
P-87383
P-87384
P-87387
Figure 20-51-22
Remove the drive gear (Item 1). Remove the idler gear
(Item 2) [Figure 20-51-19].
P-87384
Figure 20-51-23
1
1
P-87390
P-87138
Description
With the engine off and the key in the run position, move
the control levers to relieve hydraulic pressure.
Figure 20-60-3
1
1 P-87104
1
P-87106
IMPORTANT
Remove the bolts (Item 1) [Figure 20-60-3] and remove
When repairing hydrostatic and hydraulic systems, the manifold.
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 20-60-4 1
2 2 2
P-87109
Figure 20-60-7
Remove the nuts (Item 1) [Figure 20-60-4] and remove
the coils.
P-87110
2 2
1 1
P-87113
1 1
Figure 20-60-11
Remove the back-up rings (Item 1) and O-rings (Item 2)
[Figure 20-60-8].
1
P-87114
Figure 20-60-12
P-87115
Figure 20-70-1 1
P-87914
Figure 20-70-2
1 2
2
1 2
2
2
P-87910
Parts Identification
1 Spring
2 Piston Assembly
3 Shoe 2 1
3
4 Pin
5 4
5 Pivot 6
6 Seal
7
7 Bearing
8 Shaft 8
9 Swash Plate 9
10 Piston
11 Retainer Plate 10
12 Thrust Ball
13 Washer 11
14 Pin
15 Cylinder 12
16 Snap Ring
17 Mating Plate
18 Friction Plate
13
B-23945
1 Bolt
2 Thrust Washer
3 Planetary Gear
4 Roller Bearing
5 Inner Ring
6 Collar
7 Nut
8 Ball Bearing
9 Hub
2 1
10 Seal 3
11 Spindle 4
12 Pin
5
13 O-ring 2
14 Plug
15 Snap Ring 7
16 Cover 8 6
17 Steel Ball
9
18 Sun Gear
19 Carrier
14
15 13
16
12 13
13
3 2 1 17
4
5
19
18
15
18
B-23946
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1
Figure 20-70-4
P-89338
Figure 20-70-7
P-89004
1
Remove the plugs (Item 1) [Figure 20-70-4].
P-89005
Disassembly (Cont’d)
1
Figure 20-70-8
2
1
P-89010
Remove the roller bearing and inner ring from the carrier.
Remove the sun gear (Item 1) [Figure 20-70-8].
NOTE: Do not reuse the bolts holding the planetary
1
2
P-89011
P-89009
Disassembly (Cont’d)
Figure 20-70-12
1
1
2 P-89339
2
P-89014
P-89013
Disassembly (Cont’d)
Figure 20-70-16
P-89017
1
1
P-89018
Disassembly (Cont’d)
Figure 20-70-20
P-89021
P-89022
Disassembly (Cont’d)
Figure 20-70-24
1
1 2
P-89025
P-89026
P-89024
Disassembly (Cont’d)
Figure 20-70-28
P-89029
1
Remove the O-ring (Item 1) [Figure 20-70-30] from the
P-89027 plug.
Figure 20-70-31
Remove the plug (Item 1) [Figure 20-70-28] from the
rear flange. (Both sides)
Figure 20-70-29
P-89030
Disassembly (Cont’d)
Figure 20-70-32
1 P-89033
Remove the spring and valve (Item 1) [Figure 20-70-32]. Figure 20-70-35
P-89075
1
P-89032
Remove the spool (Item 1) [Figure 20-70-35] and spring.
Disassembly (Cont’d)
Figure 20-70-36
P-89037
Figure 20-70-39
Remove the piston by injecting low air pressure into the
access hole in the spindle [Figure 20-70-36].
Turn the motor on its side and drain the hydraulic fluid
into an approved container.
Figure 20-70-37
1 2
P-89038
1
P-89036
Disassembly (Cont’d)
Figure 20-70-40
1
2
1
2 1
P-89041
P-89040
Disassembly (Cont’d)
Figure 20-70-43
1
P-89045
3
P-89046
Remove the snap ring (Item 1), washer (Item 2), and
spring (Item 3) [Figure 20-70-43] and [Figure 20-70-44].
Disassembly (Cont’d)
Figure 20-70-47
1
2
P-89049
Figure 20-70-48
1
P-89052
P-89047
Disassembly (Cont’d)
Figure 20-70-51
1 1
P-89055
2
Remove the bearing (Item 1) [Figure 20-70-53] from
P-89053 both sides of the hub.
Figure 20-70-54
Separate the spindle (Item 1) from the hub (Item 2)
[Figure 20-70-51].
P-89056
2
Remove the seal ring assembly (Item 1) [Figure 20-70-
P-89054 54] from the spindle.
Disassembly (Cont’d)
Figure 20-70-55
P-89057
Assembly
1
Clean all parts in solvent and dry with compressed air.
Inspect all parts and replace those that are damaged. If
any of the planetary gears are damaged, replace all the
planetary gears and the sun gear from that planetary.
2
One damaged gear can cause a microscopic fatigue
crack in the mating teeth and cause premature failure
after servicing.
Apply oil to all O-rings (as noted) and light grease to the
ball and roller bearings before installation.
P-46426
Position the hub in a press.
Figure 20-70-56 Install the O-ring (Item 1) on both seal rings (Item 2)
[Figure 20-70-57].
Figure 20-70-58
P-89061
Apply a light film of grease onto the O-ring of the seal ring
assemblies. P-61811
Assembly (Cont’d)
Figure 20-70-59
P-87899
Figure 20-70-62
The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 20-70-59].
P-89053
Install the seal ring assembly (Item 1) [Figure 20-70-60]. Install the ring nut with the chamfer towards the bearing.
Assembly (Cont’d)
Figure 20-70-63
P-89067
P-89049 P-89068
Install the set screws (Item 1) [Figure 20-70-64]. Install the piston assembly (Item 1) [Figure 20-70-66]
into the spindle.
Tighten the set screws to 8 - 11 N•m (6 - 8 ft-lb).
Assembly (Cont’d)
Figure 20-70-67 1
P-89045
2
5
3
1
P-89043
P-89070
Install the washer (Item 1), spring (Item 2), washer (Item
3) and snap ring (Item 4) into the cylinder block (Item 5)
Install the shaft (Item 1) [Figure 20-70-68] into the [Figure 20-70-70].
spindle.
Assembly (Cont’d)
Figure 20-70-71
1
1
1
2
1
P-89039
Figure 20-70-74
Install the pins (Item 1) [Figure 20-70-71] into the
cylinder block.
P-61778
Assembly (Cont’d)
Figure 20-70-75
1
1
P-89073
Install the cylinder block assembly (Item 1) [Figure 20- NOTE: Immerse the friction plates in hydraulic fluid
70-75] onto the shaft. prior to installation.
1
1
P-89072 P-89035
Install the mating plate (Item 1) [Figure 20-70-76]. Install the O-ring onto the piston. Install the piston (Item
1) [Figure 20-70-78] into the spindle.
Assembly (Cont’d)
Figure 20-70-79
1
P-89028
Figure 20-70-80
P-89029
P-89031
Assembly (Cont’d)
Figure 20-70-83
P-89025
Figure 20-70-86
Install the spring retainer, spring and plug (both ends of
the spool) [Figure 20-70-83].
P-89074
1
Install the valve (Item 1) [Figure 20-70-86].
P-89026
Assembly (Cont’d)
Figure 20-70-87
1
1
P-89021
Figure 20-70-88
1
P-89340
1
Install the springs (Item 1) [Figure 20-70-90].
P-89023
Assembly (Cont’d)
Figure 20-70-91
1
1
P-89018
Install the O-rings (Item 1) [Figure 20-70-91] into the Tighten the bolts to 85 - 118 N•m (63 - 87 ft-lb) torque.
groove of the spindle.
P-89015
P-89019
Assembly (Cont’d)
Figure 20-70-95 1
P-89016
1
Figure 20-70-98
Tighten the valve (Item 1) [Figure 20-70-95] to 122 - 152
N•m (90 - 112 ft-lb) torque.
2 1
1 P-89011
Insert the sun gear (Item 1) into the carrier and install the
P-89014 snap ring (Item 2) [Figure 20-70-98].
Assembly (Cont’d)
Figure 20-70-99
P-89079
P-89080
Assembly (Cont’d)
Figure 20-70-103
1
P-89083
P-89084
Install the steel ball (Item 1) onto the sun gear (Item 2)
[Figure 20-70-106].
P-89082
Install the sun gear.
Install the thrust washers and new bolts (Item 1) [Figure Install the O-ring into the groove in the hub
20-70-104].
Assembly (Cont’d)
Figure 20-70-107
1
P-89087
P-89338
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-89335
Tilt the cab. (See Tilting The Cab on Page 10-210-1.)
Remove the center cover. (See Removal And Installation Attach a sling (Item 1) [Figure 20-80-2].
on Page 40-70-1.)
Figure 20-80-3
Mark the hoses.
2
Figure 20-80-1
1
1
1
P-89311
1
1
Remove the bolts (Item 1) and bottom access plate (Item
P-89310
2) [Figure 20-80-3].
Remove the hoses (Item 1) [Figure 20-80-1] from the top Mark the hoses for ease of installation.
of the swivel joint.
P-89314
P-89315
Figure 20-80-8 1
P-89317
Parts Identification
1. Plug
2. Rotor
3. Dust Seal 1
4. O-ring
5. Seal 2
6. Housing
7. Shim 6
8. Spacer
9. Retainer
10. Cover
11. Washer
12. Bolt
4 9
5 10
11
12
MS2788
Disassembly 2
3
Figure 20-80-10 1
1 1
1
1 1 NA1242
2
Remove the seals (Item 1), O-ring (Item 2) and dust seal
NA1240 (Item 3) [Figure 20-80-12] from the housing.
Figure 20-80-13
Remove the bolts (Item 1) and cover (Item 2) [Figure 20-
80-10].
Figure 20-80-11
1 1
1 NA1244
NA1241
Assembly 2
3
Clean all components in solvent and dry with 1
compressed air.
1
NOTE: Be careful not to scratch the rotor surface as
damage to the finished surface could cause
1
internal leakage.
Wrap the plugs with teflon tape. Install the seals (Item 1), O-ring (Item 2) and dust seal
(Item 3) [Figure 20-80-15] in the housing.
Figure 20-80-14
Figure 20-80-16
1
1
1 NA1243
NA1245
Assembly (Cont’d)
Figure 20-80-17
1 1
4 5
2
1 1
3 6
NA1240
1
Install the shim (Item 1), spacer (Item 2) and snap ring
(Item 3) [Figure 20-80-17].
Figure 20-90-1 1
P-87572
IMPORTANT P-87573
Figure 20-90-4
1 1
1 1
P-87575
1
1
1
P-87577
P-87575
Parts Identification
1. Relief Valve
2. Bolt
3. Plug
4. O-ring
5. Spring 3
1
6. Anticavitation Valve
7. End Cap
8. Bearing 2
9. Valve Plate
10. Spring 6
11. Brake Piston 7 5
12. Separation Plate
13. Friction Plate 3
8
14. Snap Ring
15. Washer 4
9
16. Cylinder Block
17. Ball Guide 10
18. Piston Assembly 11
19. Piston Retainer
4
20. Thrust Plate 4
15
17
18
19
2 20
21
23
22
8
14
NA-1044
Figure 20-90-8
2
2
1 1
P-87586
Figure 20-90-11
Remove the three bolts and remove the brake valve
(Item 1) [Figure 20-90-8].
1
1 1
P-87587
Figure 20-90-12
1
1
P-87590
Figure 20-90-15
Remove the O-ring (Item 1) [Figure 20-90-12] from both
plugs.
1
1
P-87591
Figure 20-90-16
1
P-87594
Figure 20-90-19
Remove the O-ring (Item 1) [Figure 20-90-16] from both
relief valves.
1
1
P-87596
1
Figure 20-90-20
1
P-87598
Figure 20-90-23
Remove the bearing (Item 1) [Figure 20-90-20].
P-87599
P-87602
Figure 20-90-27
Remove the friction plate (Item 1) [Figure 20-90-24].
1
1
P-86577
Figure 20-90-28 1
1
P-87605
Figure 20-90-31
Tip the housing and remove the rotating group (Item 1)
[Figure 20-90-28].
P-87606
Figure 20-90-32
2
1
P-87615
1
1
1
P-87616
P-87608
Remove the snap ring (Item 1) [Figure 20-90-35].
Remove the cylinder block from the press.
Remove the three pins (Item 1) [Figure 20-90-33].
Figure 20-90-36
1
3 2
1
P-87611
Figure 20-90-39
Remove the top washer (Item 1), spring (Item 2) and
bottom washer (Item 3) [Figure 20-90-36].
P-87612
Figure 20-90-40
P-87613
P-87614
Figure 20-91-1
P-87581
Figure 20-91-2
P-87581
Parts Identification
1. Snap Ring
2. Thrust Washer
3. Bearing Race
1
4. Needle Bearing 2
5. Planetary Gear
6. Sun Gear 3
7. Carrier 4
8. Screw 5
9. Thrust Plate 6
2
10. Collar 2
11. O-ring
12. Bearing 7
13. Seal
14. Housing
15. Plug
16. Dust Seal 6 2
17. Pinion Shaft
8
3
9 4
10
12
11
13
14
15
12
16
17
NA-1043
1 4
5
7 6
NA-1114
Remove the snap ring (Item 1), thrust washer (Item 2),
NA-1110 planetary gear (Item 3), bearing (Item 4) bearing race
(Item 5) and thrust washer (Item 6) [Figure 20-91-7].
Remove the sun gear (Item 1) [Figure 20-91-5]. Remove the sun gear thrust washer (Item 7) [Figure 20-
91-7].
1
1
NA-1111
NA-1112
Figure 20-91-9 2
1 4
3
NA-1116
NA-1117
NA-1115
Remove both halves of the collar (Item 1) [Figure 20-91-
12].
Heat the screws (Item 1) [Figure 20-91-10] to melt the
thread adhesive.
1 NA-1119
NA-1120
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
P-86429
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system. Remove the two bolts (Item 1) [Figure 20-100-1], lock
I-2003-0888 washers and flat washers.
P-86428 P-86430
Remove the eight hoses from the control pattern selector Lay the valve down and remove the spacer (Item 1)
valve (Item 1) [Figure 10-141-1]. [Figure 20-100-2].
Parts Identification
1. Set Screw
2. Spring
3. Ball
4. Screw
7
5. Washer
6. Spool
7. U Seal
8. Valve Block
3
2
1
MS-2811S
Disassembly
Figure 20-100-3
P-86431
1
Figure 20-100-6
Remove the set screw (Item 1) [Figure 20-100-3].
1
2
1
P-86434
Disassembly (Cont’d)
Figure 20-100-7
1 1
P-86435
Assembly
Figure 20-100-8
P-86431
P-86435
Figure 20-100-9
P-86432
Apply a light coat of grease to and install the ball (Item 1).
1 Install the spring (Item 2) [Figure 20-100-11].
2
P-86434
Assembly (Cont’d)
Figure 20-100-12
P-86433
Testing
Figure 20-110-1
P-86421
Find the pilot line of the control lever that is to be checked If the operating pressure is correct, check the valve
at the control valve assembly. section spool for proper operation. If the operating
pressure is incorrect, test the pressure reducing valve.
Figure 20-110-2 (See Testing And Adjusting The Pressure Reducing
Valve on Page 20-32-1.)
P-86420
P-86683
P-86684
P-86682
Handle Removal And Installation (Cont’d) Remove the right console cover. (See Console Cover
Removal And Installation on Page 40-50-1.)
Figure 20-110-8
Figure 20-110-10
P-86685 1
P-86681
190,5 mm
(7.50”)
1
P-86686 P-86663
Installation: Install the cable tie (Item 1) [Figure 20-110- Remove the bolts (Item 1) [Figure 20-110-11] and
9] at 190,5 mm (7.5 in) from the base of the handle. This washers from the blade control valve.
provides the correct amount of slack in the handle wire
harness. Reposition the blade control valve towards the rear of the
cab.
Figure 20-110-12
2 1
1
P-86689
1
Tilt the joystick (Item 1) towards the rear of the cab. Mark
P-86687 and remove the hoses (Item 2) [Figure 20-110-14].
P-86688
Parts Identification
1. Handle Assembly
2. Dust Boot
3. Connector Lock
4. Connector
5. Nut
6. Seal
7. Plug
8. O-ring
9. Push Rod
10. Spring Retainer
16
11. Spring Seat
12. Spring
13. Washer 6
14. Spool 6 17
7
15. Spring 7 8
16. Nut 8
17. Control Plate 9
18. Dust Boot 9 18
3 10
19. U-Joint 4 10
15
15
2
21 22
5
23
8
24
MS-2789S
Figure 20-110-15 2
3 P-86692
Figure 20-110-18
Remove the lock (Item 1) [Figure 20-110-15] from the
connector body.
1 190,5 mm
(7.50”)
P-86686
Figure 20-110-19 1
P-86695
P-86696
Figure 20-110-23
P-86699
Figure 20-110-24
2 1
P-86701
P-21730
Figure 20-110-27
2
3 1
1 P-86704
Remove the spring seat (Item 1), spring (Item 2), and
P-86702 washer (Item 3) [Figure 20-110-29] from the spool.
Figure 20-110-30
Remove the spool assemblies (Item 1) [Figure 20-110-
27].
1 1
P-86705
Testing
Figure 20-120-1
P-86421
Find the pilot line of the control lever that is to be checked If the operating pressure is correct, check the valve
at the control valve assembly. section spool for proper operation. If the operating
pressure is incorrect, test the pressure reducing valve.
Figure 20-120-2 (See Testing And Adjusting The Pressure Reducing
Valve on Page 20-32-1.)
P-86420
Figure 20-120-4
P-86769
Figure 20-120-5
P-86771
P-86768
Pull the harness (Item 1) [Figure 20-120-7] out of the
housing.
Remove the lock (Item 1) [Figure 20-120-5] from the
connector body.
Handle Removal And Installation (Cont’d) Remove the upper left console cover. (See Upper
Console Cover Removal And Installation on Page 40-60-
Figure 20-120-8 2.)
Figure 20-120-10
1 1
P-86685
P-86762
Loosen the nut (Item 1) [Figure 20-120-8] and unthread
the handle.
190,5 mm
(7.50”)
P-86686
Figure 20-120-11
P-86771
2 1
P-86772
Tilt the joystick (Item 1) towards the rear of the cab. Mark
and remove the hoses (Item 2) [Figure 20-120-12].
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Parts Identification
1. Handle Assembly
2. Dust Boot
3. Connector Lock
4. Connector
5. Nut
6. Seal
7. Plug
8. O-ring
9. Push Rod
10. Spring Retainer
16
11. Spring Seat
12. Spring
13. Washer 6
14. Spool 6 17
7
15. Spring 7 8
16. Nut 8
17. Control Plate 9
18. Dust Boot 9 18
3 10
19. U-Joint 4 10
20. Plate 11
11
15
15
2
21 22
5
23
8
24
MS-2789S
Figure 20-120-13
P-86692
Figure 20-120-16
Remove the lock (Item 1) [Figure 20-120-13] from the
connector body.
1 190,5 mm
(7.50”)
P-86686
Figure 20-120-17 1
P-86695
P-86696
Figure 20-120-21
P-86699
Figure 20-120-22
2 1
P-86701
P-21730
Figure 20-120-25
2
3 1
1 P-86704
Remove the spring seat (Item 1), spring (Item 2), and
P-86702 washer (Item 3) [Figure 20-120-27] from the spool.
Figure 20-120-28
Remove the spool assemblies (Item 1) [Figure 20-120-
25].
1 1
P-86705
1 1
P-86663
Figure 20-130-2
2
2
P-86664
Tilt the valve (Item 1) towards the rear of the cab. Mark
and remove the four hoses (Item 2) [Figure 20-130-2].
Parts Identification
1. Lever
2. Guide
3. Cover
4. Pushrod
5. Seal
6. Spring Keeper
7. Spring Seat
8. Spring
9. Washer 12
10. Spool
11. O-ring
12. Bushing 1
13. Dust Boot
14 Pin 13
15. Nut
16. Bolt
17. Bolt 2
14
18. Pin
19. Plug
4 16
17
5
18
6
19
7
20
8
9 21
10 22
11
23
MS-2796
Figure 20-130-3
1
1
P-86667
Figure 20-130-6
Remove the knob (Item 1) [Figure 20-130-3].
P-86668
Figure 20-130-7
1
1
P-86671
2
Figure 20-130-10
Remove the two bolts (Item 1) and cover (Item 2) [Figure
20-130-7].
2 1
P-86673
Figure 20-130-11
4 3 2 1
P-86674
Remove the spring seat (Item 1), spring (Item 2), and
P-86673 washer (Item 3) from the spool (Item 4) [Figure 20-130-
13].
1
1
P-86675
Figure 20-130-15
P-86676
P-86677
Figure 20-140-1
P-87212
P-87209 1
Figure 20-140-2
1
1
P-87247
1
P-87211
Figure 20-140-5
1
2
1 P-87216
1
1
P-87218
Figure 20-140-9
2 P-87251
P-87237
P-87217
1
1
P-87238
P-87252
Figure 20-140-16
1
1
P-86677
P-87583
Figure 20-160-3
P-86805
P-86806
Figure 20-160-4 1
P-86811
Figure 20-160-7
Remove the snap ring (Item 1) [Figure 20-160-4].
P-86812
Description
P-86437
IMPORTANT Remove the nut from both fittings (Item 1) [Figure 20-
170-2] and remove the valve.
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
Figure 20-170-1
1 1
1 P-86436
Parts Identification
1. Plug
2. O-ring
3. Back-up Ring
4. Ball
5. Valve Block
MS-2810S
1
1
1 P-86440
P-86439
1
WARNING
AVOID INJURY OR DEATH 2
Never work under the excavator cab without P-86471
installing an approved cab support device.
W-2435-0502
Remove the two fittings (Item 1) [Figure 20-180-2].
Figure 20-180-1
1
2
2
P-86472
1
P-86470
Parts Identification
1. Bolt
2. Pin
3. Dust Boot
4. Bolt
5. Cover
6. Spring Retainer
7. Spring Seat
8. Spring
9. Spring
10. Washer
11. Spool
12. Body 1
13. O-ring
14. Plug 20
15. Plug 2
16. O-ring
17. Seal 19
3
18. Pushrod
19. Screw
17
6 16
7
15
8
14
9
10
13
11
12
B-23950
Figure 20-180-4
1 1
P-86480
Figure 20-180-5
P-86481
Figure 20-180-8
1
3 1
P-86476
2
Figure 20-180-11
Remove the screw (Item 1) and pin (Item 2). Remove the
cam (Item 3) [Figure 20-180-8].
1
1
3
1
2
2 P-86477
Figure 20-180-12 2
4 3
P-86486
Remove the spring seat (Item 2), spring (Item 3), and
P-86478 washer (Item 4) [Figure 20-180-14] from the spool.
Figure 20-180-15
Remove the spool assemblies (Item 1) [Figure 20-180-
12].
1 P-86479
Figure 20-180-16
P-86487
P-86488
WARNING
AVOID INJURY OR DEATH 2
Never work under the excavator cab without P-86484
installing an approved cab support device.
W-2435-0502
Remove the fittings (Item 1) [Figure 20-190-2].
Figure 20-190-1
2
2
P-86522
1
Disengage the pedal lock (Item 1) and remove the two
1 bolts (Item 2) [Figure 20-190-3].
1
P-86483
Parts Identification
1. Bolt
2. Pin
3. Dust Boot
4. Bolt
5. Cover
6. Spring Retainer
7. Spring Seat
8. Spring
9. Spring
10. Washer 1
11. Spool
12. Body 20
13. O-ring 2
14. Plug
15. Plug 19
3
16. O-ring
17. Seal
18. Pushrod 4
19. Screw
6 16
7
15
8
14
9
10
13
11
12
B-23950
Figure 20-190-4
1 1
P-86480
Figure 20-190-5
P-86481
Figure 20-190-8
1
3 1
P-86476
2
Figure 20-190-11
Remove the screw (Item 1) and pin (Item 2). Remove the
cam (Item 3) [Figure 20-190-8].
1
1
3
1
2
2 P-86477
Figure 20-190-12 2
4 3
P-86486
Remove the spring seat (Item 2), spring (Item 3), and
P-86478 washer (Item 4) [Figure 20-190-14] from the spool.
Figure 20-190-15
Remove the spool assemblies (Item 1) [Figure 20-190-
12].
1 P-86479
Figure 20-190-16
P-86487
P-86488
WARNING
AVOID INJURY OR DEATH 2
Never work under the excavator cab without S37671
installing an approved cab support device.
W-2435-0502
Remove the two fittings (Item 1) [Figure 20-200-2].
Figure 20-200-1
2
2
S37672
1
Disengage the pedal lock (Item 1) and remove the two
bolts (Item 2) [Figure 20-200-3].
1
Remove the valve.
1
S37670
Parts Identification
1. Bolt
2. Pin
3. Dust Boot
4. Bolt
5. Cover
6. Spring Retainer
7. Spring Seat
8. Spring
9. Spring
10. Washer
1
11. Spool
12. Body 20
13. O-ring
2
14. Plug
15. Plug 19
16. O-ring 3
17. Seal
18. Pushrod 4
19. Screw
6 16
7
15
8
14
9
10
13
11
12
B-23950
Figure 20-200-4
1 1
P-86480
Figure 20-200-5
P-86481
Figure 20-200-8
1
3 1
P-86476
2
Figure 20-200-11
Remove the screw (Item 1) and pin (Item 2). Remove the
cam (Item 3) [Figure 20-200-8].
1
1
3
1
2
2 P-86477
Figure 20-200-12 2
4 3
P-86486
Figure 20-200-15
Remove the spool assemblies (Item 1) [Figure 20-200-
12].
1 P-86479
Figure 20-200-16
P-86487
P-86488
WARNING 2
Figure 20-210-3
IMPORTANT
1
Figure 20-210-1
P-86445
1 1
P-86443
Figure 20-210-4
P-86446
Parts Identification
2
21
3 20
5
19 28
6
18
7 17
8 16
15
9 10 11 12 13 14
B-23944
Figure 20-210-5 1
1
2
P-86450
Figure 20-210-6
1
P-86451
Figure 20-210-9
P-86454
Figure 20-210-12
Remove the cover / cam assembly (Item 1) [Figure 20-
210-9].
P-86455
Figure 20-210-13
P-86458
1
Using a blunt tool, push the pushrod (Item 1) [Figure 20-
P-86456 210-15] out of the plug.
Figure 20-210-16
Remove the pin (Item 1) from both cover / cam
assemblies. Remove the cam (Item 2) [Figure 20-210-
P-86459
Figure 20-210-17
2
P-86462
2
1
P-86463
P-86461
Remove the O-rings (Item 1) [Figure 20-210-20].
Figure 20-210-21
P-86467
1
Figure 20-210-24
Remove the spool / spring assemblies (Item 1) [Figure
20-210-21].
1 3 2 1
P-86469
1
Remove the spring (Item 1) and washer (Item 2) from the
P-86465 spool (Item 3) [Figure 20-210-24].
Figure 20-220-1 1
P-91763
Figure 20-220-2
P-86211B
Figure 20-220-4
1
1 P-91765
Figure 20-220-5
P-91766
P-91764
Figure 20-220-8
1
P-91768
1
P-91767
BLADE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Figure 30-10-1
2 P-87813
Figure 30-10-2
P-87810
Remove the right and left pivot pin retaining nuts (Item 1)
and bolt (Item 2) [Figure 30-10-1] and [Figure 30-10-2].
Figure 30-10-4
P-87811
Figure 30-10-5
P-87812
Remove the right and left pivot pin (Item 1) [Figure 30-
10-4] and [Figure 30-10-5] and shims.
Rubber Track
Figure 30-20-1
Straight Edge
Figure 30-20-2
10-15 mm
(0.39-0.59 in)
P-49234
Figure 30-20-5
Figure 30-20-3
10-15 mm
(0.39-0.59 in)
Track
Roller
Track
B-14067
1
1 Measure the clearance at the middle track roller. Do not
put your fingers into the pinch points between the track
and the track roller. Use a bolt or a dowel of the
P-86328A
appropriate size to check the gap between the contact
edge of the roller and the top edge of the track guide
Fully raise the blade and install jackstands (Item 1) [Figure 30-20-4] and [Figure 30-20-5].
[Figure 30-20-3] under the blade and track frame. Raise
the boom until all machine weight is on the jackstands. Track Clearance 10 - 15 mm
(0.39 - 0.59 in)
Stop the engine.
Adjusting Tension
Figure 30-20-6
1 2
1
P-86333A
WARNING
AVOID INJURY OR DEATH
• Do not loosen bleed fitting more than 1-1/2 turns.
• Do not loosen parts other than bleed fitting.
Grease is under high pressure.
W-2474-0104
1 WARNING
AVOID INJURY OR DEATH
• Do not loosen bleed fitting more than 1-1/2 turns.
Raise the boom. Slowly turn the track in the forward direction.
Figure 30-20-9
Figure 30-20-8
1
P-40669
P-40662
Figure 30-20-10
1
1
P-40888
Insert a second steel rod or pipe (Item 1) [Figure 30-20- Remove the track.
10], at a distance of two lugs, between the track and the
Figure 30-20-12
P-87929
Figure 30-20-13
P-87930
1. Idler
2. Support 6
3. Shaft
4. Bushing
5. Floating Seal
6. Pin
7. O-ring 2
8. Plug 7
5
8 1
4
4
5
6
7
E80-2120S
MS-
Idler Disassembly
Figure 30-20-14
P-89261
Figure 30-20-17
P-89259
P-89263
P-89260
Figure 30-20-18
P-89267
Figure 30-20-21
P-89264
P-89268
P-89266
Figure 30-20-22 1
P-89270
P-89271
P-89269
Remove the roll pin (Item 1). Remove the shaft (Item 2)
[Figure 30-20-23] from the support.
P-40754
Figure 30-20-29
1
1
P-89262
P-89276
Install the O-ring (Item 1) [Figure 30-20-27] on the seal
ring. Repeat this procedure on all four seal assemblies.
Shake off the excess alcohol and install the seal
The O-ring and seal ring must be clean and free of any assembly (Item 1) [Figure 30-20-29] in the idler.
dust, oil film and foreign matter.
Use firm, even pressure on the installation tool to pop the
O-ring into the housing.
Figure 30-20-30 2
P-89269
Install the shaft (Item 1) in the support. Install the roll pin
(Item 2) [Figure 30-20-32] through the shaft and support
P-89277 assembly.
Figure 30-20-33
The seal assembly stand off height must be equal and
the O-ring must not be twisted [Figure 30-20-30].
1
P-40754
Figure 30-20-34 1
P-89264
Figure 30-20-35
P-40754
Figure 30-20-38
1
P-89280
Figure 30-20-39
P-40754
Figure 30-20-42 1
P-89283
Figure 30-20-45
Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-20-42] in the idler.
89324
Add 0,101 - 0,139 L (3.4 - 4.7 U.S. fl oz) 30W oil to the
1
idler. Install the plug (Item 1) [Figure 30-20-45].
P-89282
The seal stand off height must be equal and the O-ring
(Item 1) [Figure 30-20-43] must not be twisted.
P-62574
P-87932
1. Piston Rod
2. Piston 6
3. Piston Ring 5
4. Back-up Ring 4
5. Packing
6. Snap Ring 3
7. Dust Seal
8. Cylinder 2
9. Spring Assembly
10. Grease Fitting
10
EM7807
P-62574
Figure 30-20-50
Remove the grease fitting and adapter (Item 1) [Figure
30-20-48].
2
1
P-87933
2 1
Use a 12 mm x 1,75 x 203 mm long bolt to thread the bolt
(Item 1) into the piston (Item 2) [Figure 30-20-50]. Pull
P-87928
the piston out of the cylinder.
Figure 30-20-51
P-87935
2
Figure 30-20-54
P-87937
Figure 30-20-52
1
1
P-87934
P-87936
Figure 30-20-55
P-89268
1
2 2
P-89285
Place a jack under the bottom roller (Item 1). Remove the
four bolts (Item 2) [Figure 30-20-58].
P-87912
Installation: Apply thread adhesive (Loctite® 242 or
equivalent) to the bolt threads. Tighten the bolts to 160 -
Loosen the nut (Item 1) [Figure 30-20-56] and bolt. 180 N•m (118 - 113 ft-lb) torque.
Remove the top roller.
Figure 30-20-59
P-89286
Lower the jack and remove the roller (Item 1) [Figure 30-
20-59].
1. Roller
2. Collar
3. Shaft
4. Bushing
5. Pin
6. Seal
7. O-ring 1
8. Plug
4
5
6
2
5
E80-2150S
P-89289
Drive the pin (Item 1) towards the top of the collar (Item
2) [Figure 30-20-60].
Figure 30-20-61
1
1
P-89290
P-89288
Figure 30-20-64
P-89293
1
Remove the seal assembly (Item 1) [Figure 30-20-66]
from the collar.
P-89291
Figure 30-20-67
P-89262
P-89296
1
Remove the O-ring (Item 1) [Figure 30-20-70].
1
P-89297
Figure 30-20-72
1
P-89295
Figure 30-20-75
Figure 30-20-73
P-89294
P-89296
Figure 30-20-76
1
P-89298
P-89262 Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-20-78] in the collar.
Install the O-ring (Item 1) [Figure 30-20-76] on the seal Use firm, even pressure on the installation tool to pop the
ring. Repeat this procedure on all four seal assemblies.
The O-ring and seal ring must be clean and free of any Remove the installation tool.
dust, oil film and foreign matter.
Figure 30-20-79
NOTE: Inspect the seal ring for burrs before
installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
any twists, gently pull a section of the O-ring
and let it snap back.
Figure 30-20-77
P-89299
P-40754
Figure 30-20-80
P-89301
Place the seal assembly (Item 1) [Figure 30-20-80] in NOTE: Do not get any oil on the rubber O-rings.
the installation tool.
Figure 30-20-81
P-89302
P-89300
Figure 30-20-84
P-89304
Figure 30-20-85
P-89305
P-89303
Figure 30-20-88
P-89307
Place the seal assembly in the installation tool (Item 1) NOTE: Do not get any oil on the rubber O-rings.
[Figure 30-20-88].
Figure 30-20-89
P-89308
Install the collar (Item 1) on the shaft. Install the pin (Item
1 2) [Figure 30-20-91] in the collar.
P-89306
Figure 30-20-92
P-89309
Push down on the collar until the pin bore of the collar is
aligned with the pin bore of the shaft. Fully seat the pin
1. Snap Ring
2. Pipe Plug
3. Cover
4. O-ring
5. Bearing
6. Roller
7. Seal 6
8. Shaft
9. Bolt
10. Nut
11. Mount
5
1
4
10
8
11
7
1
E80-2140S
Figure 30-20-93
1
P-87918
Figure 30-20-96
Remove the snap ring (Item 1) [Figure 30-20-93].
1
1
P-87919
1 P-87922
Figure 30-20-98
P-87923
1
Remove the seal (Item 1) [Figure 30-20-100] from the
roller.
P-87921
Figure 30-20-101
P-87924
P-87925
Figure 30-20-103
P-87908
Track Damage Identification When applied to rubber tracks under the following
circumstances, tension in excess of the breaking strength
The following pages show photos and illustrations of of the embedded steel cords causes steel cords to be
track damage and their probable cause. These pages are cut:
intended to be used for identifying the reason for track
damage and how to avoid future track damage. Figure 30-30-3
Figure 30-30-1
PI-13035
Prevention:
Steel Cords
The following preventions should be taken to minimize
the risk of this damage:
PI-13034
Periodical checking of the recommended track
tension. (See Checking Tension on Page 30-20-2.)
Damage:
Avoiding quick turns on bumpy and rocky fields.
Embedded steel cords are cut off [Figure 30-30-1] and
[Figure 30-30-2]. Drive carefully to prevent stones and other articles
from clogging the rubber tracks.
Replacement:
Driving over sharp objects should be avoided. If this is
Replacement is required. impossible, do not make turns while driving over
sharp objects.
Abrasion Of Embedded Metals When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Figure 30-30-4 inevitable. The following cases sometimes accelerate
their abrasion:
Prevention:
Figure 30-30-5
Abrasion
D D1 = 0.67D
PI-13037
Replacement:
Track Damage Identification (Cont’d) Embedded metals are adhered between the steel cords
and the rubber body. The following cases generate
Separation Of Embedded Metals external forces greater than the adhesion strength,
causing separation of the embedded metals:
Figure 30-30-6
Figure 30-30-7
Idler
Rubber
Track
P-4379
PI-13039
PI-13040
Figure 30-30-9
Abrasion
PI-13041
Prevention:
Figure 30-30-10
Separation of
bonded
rubber cover
PI-13043
Due to corrosion of embedded metals, the adhesion to Excessively salty fields, like the sea shore
the rubber body deteriorates, resulting in complete
separation [Figure 30-30-10]. Strong acidic or alkali soil conditions
Even a partial separation of embedded metals requires a On tracks that are out of adjustment, the track rollers,
rubber track replacement. idlers and sprockets will gradually wear the rubber
surface at the side of the track roller, causing exposure of
the embedded metals. Consequently the embedded
metals will corrode resulting in their separation from the
rubber body.
Prevention:
PI-13045
Construction sites
Demolition sites
Concrete ridges
Stumpy fields.
Track Damage Identification (Cont’d) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue causes cracks, especially on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
Figure 30-30-14 even small external cracks. When operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.
Prevention:
P-4380
Damage:
Replacement:
Track Damage Identification (Cont’d) Lug abrasion is inevitable. Even if lug abrasion is
proceeding, the rubber track can still be used. As the
Lug Abrasion traction performance deteriorates accordingly, it is highly
recommended to replace the abraded tracks with new
Figure 30-30-16 ones when the lug height becomes less than 5 mm
(0.197 in).
Prevention:
Lug abrasion
PI-13049
Damage:
Replacement:
No replacement is required.
PI-13051
Sometimes cracks and cuts on the lug side rubber at the Prevention:
edges of the embedded metals can be observed [Figure
30-30-18]. To avoid extensive stress applied to the lug root
where metals are embedded, machine operators are
Replacement: requested to avoid driving over stumps and ridges.
PI-13053
Prevention:
Track Damage Identification (Cont’d) This damage is caused by objects on the field or by
interference with the machine frame.
Cuts On The Edges Of Track Roller Side
Figure 30-30-24
Figure 30-30-22
PI-13056
P-4384
PI-13055
Damage:
Replacement:
Figure 30-30-25
Cut
Tear
PI-13057
Prevention:
Figure 30-40-1
P11599
Figure 30-40-2
P-89381
Figure 30-40-3
1
1
OUTER RACE
Soft zone is at
INNER RACE the Ball Bearing
Soft zone is filler plug
identified by a
letter “S”
stamped on ring
P-23504
P-89382
Parts Identification
1. Roller
2. Collar
3. Shaft
4. Bushing
5. Pin
6. Seal
7. O-ring 1
8. Plug
4
5
6
2
5
E802150S
Disassembly
Figure 30-50-1
P-89289
2
Figure 30-50-4
P-89287
P-89290
1
P-89288
Disassembly (Cont’d)
Figure 30-50-5
P-89293
1
Figure 30-50-8
Remove the shaft assembly (Item 1) [Figure 30-50-5]
from the roller.
P-89262
Disassembly (Cont’d)
1
Figure 30-50-9
P-89296
1
1
P-89297
Assembly
Figure 30-50-13
1
P-89295
Figure 30-50-16
Figure 30-50-14
P-89294
P-89296
Figure 30-50-17
1
P-89298
P-89262
Shake off the excess alcohol and install the seal
assembly (Item 1) [Figure 30-50-19] in the collar.
Install the O-ring (Item 1) [Figure 30-50-17] on the seal
ring. Repeat this procedure on all four seal assemblies. Use firm, even pressure on the installation tool to pop the
NOTE: Inspect the seal ring for burrs before Figure 30-50-20
installing the O-ring. Make sure that the O-ring
is not twisted when installing it. To remove
any twists, gently pull a section of the O-ring
and let it snap back.
Figure 30-50-18
P-89299
P-40754
Assembly (Cont’d)
Figure 30-50-21
P-89301
Figure 30-50-22
P-89302
P-89300
Assembly (Cont’d)
Figure 30-50-25
P-89304
Figure 30-50-28
Place the seal assembly in the installation tool (Item 1)
[Figure 30-50-25].
Figure 30-50-26
P-89305
P-89303
Assembly (Cont’d)
Figure 30-50-29
P-89307
Figure 30-50-30
P-89308
Install the collar (Item 1) on the shaft. Install the pin (Item
1
2) [Figure 30-50-32] in the collar.
P-89306
Assembly (Cont’d)
Figure 30-50-33
P-89309
Push down on the collar until the pin bore of the collar is
aligned with the pin bore of the shaft. Fully seat the pin
Parts Identification
1. Snap Ring
2. Pipe Plug
3. Cover
4. O-ring
5. Bearing
6. Roller
7. Seal 6
8. Shaft
9. Bolt
10. Nut
11. Mount
5
1
4
1 2
8
11
7
1
Figure 30-60-1
P-87918
1 1
P-87919
P-87916
Remove the O-ring (Item 1) [Figure 30-60-4].
Figure 30-60-5 1
1
P-87922
Figure 30-60-8
Remove the snap ring (Item 1) [Figure 30-60-5].
Figure 30-60-6
P-87923
1
Remove the seal (Item 1) [Figure 30-60-8] from the
roller.
P-87921
Figure 30-60-9
P-87924
P-87925
Figure 30-70-1
P11599
Figure 30-70-2
P-89381
Remove the 24 bolts and nuts that hold the swing bearing
on the track frame (Item 1) [Figure 30-70-2].
Figure 30-70-3
1
1
OUTER RACE
Soft zone is at
INNER RACE the Ball Bearing
Soft zone is filler plug
identified by a
letter “S”
stamped on ring
P-23504
P-89382
UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-3
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-15
Front Window Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-16
Lower Front Window Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-17
Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-18
Front Window Strut Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-23
Front Window Slide Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-24
Cab Tilt Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-25
SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Seat Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
Seat Mount Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-2
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1
Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-2
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Bucket Teeth Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Bucket Side Cutting Edge Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 40-170-2
Removal
Drain the fuel tank. (See Draining The Fuel Tank on Page
10-120-4.)
2
Remove the swing motor drive carrier. (See Removal
And Installation on Page 20-91-1.) 1
Figure 40-10-1
P-89376
Removal (Cont’d)
Figure 40-10-3 1
1
1 1
P-89376
P-89378
Installation
Figure 40-10-7
FRONT OF MACHINE
P-89380 B-13678
Rotate the swing bearing so the outside soft zone (Item Make three alignment pins by using M18 X 110 mm long
1) [Figure 40-10-7] and [Figure 40-10-8] is to the right bolts. Cut the head off these bolts at 90 mm (3.50 in),
hand side of the excavator. then taper the end of the bolts [Figure 40-10-10].
Installation (Cont’d)
Figure 40-10-11
1
1
1
N-15787
Figure 40-10-12 Install the swing motor drive carrier. (See Removal And
Installation on Page 20-91-1.)
B-13693
Figure 40-20-1
1
1
P-86415
2
2 2
1
1
1 P-86416
Remove the three bottom bolts (Item 1), flat washers and
lock washers. Remove the four top bolts (Item 2) [Figure
40-20-2], flat washers and lock washers.
Figure 40-21-1
1 1
P-86824
2 2
1
1
P-86827
Remove the three bottom bolts (Item 1), flat washers and
lock washers. Remove the three top bolts (Item 2)
[Figure 40-21-2], flat washers and lock washers.
Figure 40-30-4
P-87715
P-87728
Figure 40-30-2
P-87716
Figure 40-30-5
P-87721
1 P-87730
Figure 40-30-9
1
1
1 P-87734
Figure 40-30-12
P-87731
Figure 40-30-10
1 P-87735
P-87733
Figure 40-30-13
1
2
P-87738
1
Disconnect the wire harness (Item 1) from the upper duct
P-87736 controller and remove the controller (Item 2) [Figure 40-
30-15].
1 1
P-87737 P-87739
Remove the screws (Item 1) [Figure 40-30-13] and Remove the screw (Item 1) and duct (Item 2) [Figure 40-
[Figure 40-30-14]. 30-16].
Figure 40-30-17
P-87743
1
Figure 40-30-20
Figure 40-30-18
P-87744
P-87741
Figure 40-30-21
Remove the screws (Item 1) [Figure 40-30-17] and
[Figure 40-30-18].
1
P-87745
Figure 40-30-22
1 1
1 1
1 1
P-87749
2
Figure 40-30-25
Remove the bolts (Item 1) and relay cover (Item 2)
[Figure 40-30-22].
1 P-87749
1
Figure 40-30-26
2 P-87748
P-87751
Figure 40-30-27
2 1
2
1
1
P-87756
Figure 40-30-30
P-87752
P-87748
P-87758
Figure 40-30-31
1
1 2
1 1 1 1
P-87761
1 1 1 1 1
P-87748
P-87760
Disconnect the wires (Item 1) [Figure 40-30-34] from the
beeper.
Remove the screws (Item 1) [Figure 40-30-32].
Figure 40-30-35
1
1 1
2 P-87766
Figure 40-30-38
Remove the screws (Item 1) and controller (Item 2)
[Figure 40-30-35].
1 1
1
2
P-87748
1
1
P-87768
Figure 40-30-42
Disconnect the radio harness (Item 1) [Figure 40-30-39].
2
2 1
1 1
P-87770
1 1
1
P-87773
Figure 40-30-46
Disconnect the wire harness (Item 1) [Figure 40-30-43].
1 1
P-87774
Figure 40-30-47
1
1
1
1
P-87747
1
1
NA-1129
Figure 40-30-51
1
1
2
1 P-87792
P-87793
P-87791
Figure 40-30-55
1 1
P-87795
Figure 40-30-57
P-87794
P-87796
Figure 40-30-58
P-87666
Figure 40-30-59
1
P-87668
1
1
P-87669
P-87747 Tilt the front window and remove the roller (Item 1)
[Figure 40-30-62] (Both sides).
Remove the window slide bar bolts (Item 1) [Figure 40- Remove the window.
30-59] and [Figure 40-30-60].
Figure 40-30-63
P-87745
Glass Installation
Cut the tip of the adhesive tube to the desired shape and
size to provide a bead with sufficient height to give good
1
contact with the glass around the entire perimeter.
2
1
2 1 Figure 40-30-66
NA1156
MS1993
Glass Installation (Cont’d) NOTE: The door and front windows are supplied as
kits that include the glass, urethane adhesive,
Top, Right Side, Left Side And Rear Glass (Cont’d)
combo primer, glass cleaner and damper for
Figure 40-30-67 correctly installing the new glass.
Figure 40-30-68
MS1994
1
Install the glass and damper assembly (Item 1) [Figure
40-30-67]. Press the glass into the cab to make complete
contact with the adhesive. Tape the glass in place.
Remove the tape after the adhesive is cured. Remove the broken glass (Item 1) [Figure 40-30-68].
Figure 40-30-69
1
2
P-61218
Figure 40-30-70
P-89351
Figure 40-30-73
P-61219
Figure 40-30-71
P-89353
1
Install the dampers on the front window frame (Item 1)
[Figure 40-30-72] or on the door frame (Item 1) [Figure
40-30-73]. (The dampers are used to space the glass
away from the metal so there is no glass to metal
contact.)
P-61220
P-61224
Figure 40-30-75
P-89350
P-89352
Figure 40-30-77
Figure 40-30-78
P-87671
Figure 40-30-79
P-87672
Figure 40-30-80
1
P-87745
Figure 40-30-81
P-87674
Figure 40-30-83
1 P-89320
Figure 40-30-84
1 1 1
P-89320
1. Clip
2. Washer
3. Shim
4. Link
5. Plate
6. Pin
7. Bracket
8. Bolt
9. Grease Fitting
5
1
2 4
3 3
2
8
7 6
2
3
2
9
Figure 40-30-86
1 1
P-89322
1
1 2
P-89320
Figure 40-30-88
1
1
1
P-92416
2
Slide the radio out of the opening and disconnect the
P-92413 radio harness (Item 1) and antenna cable (Item 2)
[Figure 40-30-90].
1
1
P-92763
Figure 40-30-92
1
1
P-92768
Figure 40-30-95
Remove the speaker from the headliner and disconnect
the wires (Item 1) [Figure 40-30-92].
1 1
1 P-92770
Figure 40-30-96
1
1
1
1 1 1
1
P-92771
Figure 40-30-99
Remove the screws (Item 1) [Figure 40-30-96].
1
1
1
1
P-92772
Figure 40-30-100
P-92774
1
Remove the headliner (Item 1) [Figure 40-30-102].
P-92775
P-92773
Figure 40-40-1
1
2
1
2
P-87665
1 Figure 40-40-3
P-87664
Figure 40-40-4
P-87815
1
Remove the C-clip (Item 1) [Figure 40-40-6] from the left
console.
Figure 40-40-7
P-87715
1
P-87816
Figure 40-40-8
P-87820
Figure 40-40-10
P-87717
P-87716
Slide the seat mount to the rear and remove the bolts
(Item 1) [Figure 40-40-9] and [Figure 40-40-10].
Figure 40-40-11
P-87819
Figure 40-40-12
P-87818
Slide the seat mount forward and remove the bolts (Item
1) [Figure 40-40-11] and [Figure 40-40-12].
Figure 40-50-1
P-86658
Figure 40-50-4
Pull the dust boot (Item 1) [Figure 40-50-1] towards the
rear of the cab.
P-86661
Figure 40-50-5
P-86662
Tilt the cover towards the rear of the cab and disconnect
the key switch wire harness (Item 1) [Figure 40-50-5].
Figure 40-60-1
P-86765
Figure 40-60-4
P-86764
Figure 40-60-2
1 P-86766
P-866763
Figure 40-60-5
P-86758
Tilt the cover towards the rear of the cab and disconnect
P-86757 the wire harness (Item 1) [Figure 40-60-7].
P-86756
1 P-86780
1
P-86782
2
P-86778
Figure 40-60-12
1 1
P-86785
Figure 40-60-13
1
1
P-86788
Figure 40-60-16
Remove the snap ring (Item 1) [Figure 40-60-13].
P-86789
Figure 40-60-17
Figure 40-60-18
P-86784
Figure 40-70-1
P-86417
Figure 40-80-1
2
2
P-86813
Figure 40-90-1
P-89559
Figure 40-90-2
P-89561
Figure 40-90-4
P-93486
1
Install a lifting device to the lifting chains [Figure 40-90-
P-93537 6].
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.
P-93538
• Do not swing boom or upperstructure. Engage
the upperstructure slew lock.
Install lifting rings (Item 1) and chains (Item 2) [Figure • Never lift with operator on machine.
W-2202-0607
40-90-4] and [Figure 40-90-5].
Figure 40-90-7
P-89557
1
P-89558
Figure 40-100-1
P-86442
Figure 40-100-2
Articulated Boom
S37673
Figure 40-110-1
1 P-87223
Figure 40-110-4
Figure 40-110-2
P-87224
P-87222
P-87229
2
Figure 40-110-8
Loosen the hose clamp (Item 1) and remove the hose
(Item 2) [Figure 40-110-5].
1 P-87225
Figure 40-110-9
1 1
1 P-87242
1
Figure 40-110-12
P-87226
1
1
P-87241
P-87243
Figure 40-110-13
P-87226
Figure 40-110-14
P-87243
Figure 40-120-1
P-86441
Figure 40-130-1
P-87409
Figure 40-130-4
Figure 40-130-2
P-87410
1 2 1 1
P-87649
Figure 40-130-5
1
1
P-87655
2
1
2
P-87807
2
Install a porta-power between the top and bottom pins,
and press the top pin out [Figure 40-130-8].
P-87654
Figure 40-130-9
2 1
1
1 P-87657
Figure 40-130-12
Remove the bolts (Item 1) and plate (Item 2) [Figure 40-
130-9].
1
1
P-87659
Figure 40-130-13
P-87660
Bushing Removal 4
2
1
IMPORTANT
Do Not point (hammer) on the boom swing bracket.
Excess pressure can cause the casting to crack.
I-2095-1195 3
Tighten the bolt and nut to remove the bushing from the
casting.
Bushing Installation
Figure 40-130-15
P-23573
Figure 40-130-17
4
1
5 P-23571
Tighten the bolt and nut until the bushing is seated in the
casting.
1
1
1 1
S37676 S37677
Disconnect the wire harness (Item 1) [Figure 40-140-1] Mark and remove the hoses (Item 1) [Figure 40-140-3]
or [Figure 40-140-2]. or [Figure 40-140-4].
Figure 40-140-5
4
1 2 1
P-87084
P-87005
Remove the seals (Item 1) [Figure 40-140-7] from both
sides of the boom.
Remove the hose (Item 1) [Figure 40-140-5] (Both
sides). Remove the bushings from both sides of the boom.
1 5 mm (0.197 in)
TS-1614A
P-87006
Figure 40-141-1 1
2
2 1 4
S37808
Figure 40-141-2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
P-87005
Figure 40-141-4
5 mm (0.197 in)
TS-1614A
1
Install the bushings until they are seated 5 mm (0.197 in)
P-87084 in the pin boss [Figure 40-141-5].
With the engine off, turn the key to the ON position and
move both hydraulic control levers to relieve hydraulic P-87025
pressure.
Figure 40-150-1 Remove the nuts (Item 1) and bolt (Item 2) [Figure 40-
150-3].
Articulated Boom
Figure 40-150-4
P-87019 S37686
Support the boom with a chain hoist (Item 1) [Figure 40- P-87024
150-1].
S37809
Figure 40-150-5
2
1
P-87079
P-86891
Remove the seal (Item 1) and bushing (Item 2) [Figure
40-150-7] from both sides of the arm.
Remove the pivot pin (Item 1) [Figure 40-150-5].
Install the new bushings in the arm.
Figure 40-150-9
5 mm (0.197 in)
TS-1614A
2
Install the bushings until they are seated 5 mm (0.197 in)
P-87081 in the pin boss [Figure 40-150-11] (Both sides).
Figure 40-150-10
P-87080
Troubleshooting
Daily Inspection
Figure 40-160-1
P-72274
Figure 40-160-2
Unlatched Position Latched Position
P-72283
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
latching and unlatching the attachment quick
coupler.
W-2541-1106
WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist: 1
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used. P-72269
W-2019-0907
Parts Identification
1. Coupler Body
2. Spring
3. Locking Plate
4. Tool
4
2
P-88398
Disassembly
1
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• Pressurized fluids and springs or other stored
energy components.
• Flying debris or loose material is present.
• Engine is running. 1
• Tools are being used. P-72284
W-2505-0604
1
P-72285
Disassembly (Cont’d)
Figure 40-160-10
1 1
P-72295
P-72296
Assembly
Figure 40-160-12
P-72294
1
Install the partial circle hook end of the spring [Figure 40-
P-72296 160-14].
Figure 40-160-15
Install the latch (Item 1) [Figure 40-160-12].
2 1
1
P-72284
P-72295 Install the full circle end of the spring hook (Item 1)
[Figure 40-160-15] on the quick coupler.
Install the two roll pins (Item 1) [Figure 40-160-13]. Drive Do not lubricate the quick coupler. Lubrication will cause
the roll pins inwards until the roll pins are flush with the dirt to collect and interfere with proper movement of the
outside edge of the quick coupler. quick coupler.
Troubleshooting
Daily Inspection
Figure 40-161-1
P-88183
WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used. P-88000
W-2019-0907
Raise the arm and bucket link until the quick coupler is
Figure 40-161-2 free [Figure 40-161-4].
2
2
1
1
P-88003
Remove the four nuts (Items 1). Remove the two bolts
(Item 2) [Figure 40-161-2].
Figure 40-161-3
1
P-88001
2
2
P-88003
3
P-88001
1. Bolt
2. Lock Washer
3. Coupler Housing
4. Pressure Spring
5. Locking Mechanism 1
P-88114
Figure 40-161-8
P-88004
P-88005
1. Housing
2. Bushing
3. Bushing
4. O-ring
5. Cover
6. O-ring
7. O-ring 1
8. Reversing Lever
9. Threaded Pin
10. Pressure Spring 2
11. Pin
12. Pivoting Journal
13. Spring Washer
14. Bolt
15. Bearing Block 26 3
16. Locking Pin
4
17. Pressure Spring
18. Thrust Journal 3
19. Pin 25
20. O-ring 24
21. Driving Fork
21 10 11
20
19
12
20 17
19 18
16
15 13
14
P-88115
WARNING 1
P-88010
Figure 40-161-10
P-88009
2
Remove the eight bolts (Item 1) and cover (Item 2)
[Figure 40-161-10].
P-88011
Figure 40-161-11
Tilt the bearing block and pivoting journal (Item 1) up and
1 remove from the spring guide (Item 2) [Figure 40-161-
13].
P-88122
Figure 40-161-14
1
P-88013
2
1
P-88014
1
3
2
P-88018
Remove the snap ring (Item 1) and pin (Item 2). Remove
the spring guide (Item 3) from the driving fork (Item 4)
P-88015
[Figure 40-161-20].
Figure 40-161-19
P-88019
P-88016
Remove the locking pin assemblies [Figure 40-161-21].
Figure 40-161-22
3
4 6
5
2 1
P-88021
Remove the snap ring (Item 1) and pin (Item 2). Remove
the driving fork (Item 3) [Figure 40-161-22].
Figure 40-161-23
2 3
P-88022
Assembly (MS08)
Figure 40-161-24
2 1
P-88019
3
Install the locking pin assemblies [Figure 40-161-26].
P-88022
NOTE: Position the locking levers with the flat side
down and away from the cover.
Install bushing (Item 1), O-ring (Item 2) and bushing (Item
3) [Figure 40-161-24] in both locking pin bores. Figure 40-161-27
4 3
3 1
4
2
2
5 6 P-88018
P-88021
Install the driving fork (Item 1), pin (Item 2) and snap ring
(Item 3) on the spring guide (Item 4) [Figure 40-161-27].
Install reversing lever (Item 1), pin (Item 2) and snap ring
(Item 3) [Figure 40-161-25] on the locking pin.
Install the driving fork (Item 4), pin (Item 5) and snap ring
(Item 6) [Figure 40-161-25] on the reversing lever.
Repeat the procedure for the other locking pin.
Figure 40-161-28
P-88023
Figure 40-161-31
Install the O-rings (Item 1) [Figure 40-161-28].
Figure 40-161-29
P-88024
P-88015 Install the control shaft through the spring guide driving
fork (Item 1) [Figure 40-161-31].
Figure 40-161-32
1 P-88011
Install the control shaft through the second locking lever Figure 40-161-35
driving fork (Item 1) [Figure 40-161-32].
Figure 40-161-33
P-88010
1
Install the two bolts (Item 1) [Figure 40-161-35].
P-88013
Figure 40-161-36
P-88026
P-88009
WARNING 1
Figure 40-170-1 1
1
P-87316
Figure 40-170-4
P-87323
P-87198
1 Figure 40-180-4
P-87196
P-87021
Figure 40-180-5
1
2
P-87203
1
Figure 40-180-8
P-87200
Figure 40-180-6
2
P-87202
1
Remove the front and rear hinge pins (Item 1) [Figure
P-87201 40-180-7] and [Figure 40-180-8].
Figure 40-180-9
1
1
2
1
P-86943
P-87204
Loosen the nut (Item 1) and adjust the latch (Item 2)
[Figure 40-180-10]. Tighten the nut after the adjustment
Remove the spacers (Item 1) [Figure 40-180-9]. is made.
Figure 40-190-1
P-87207
Figure 40-190-4
P-92769
P-87206
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-5
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-5
Alternator Regulator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-7
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Boom Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
ADD. WORKING
RED
E80 (S/N AETB11001 AND ABOVE) FUEL GAUGE +
U 3 YEL/RED BLK
FUEL SENDER (L) BLK 87a
LIGHT RELAY LIGHT RELAY
87a
F - YEL
BLU/BLK YEL 30
(S/N AET311001 AND ABOVE) BACK LIGHTS 4 WHT/RED RED RED 87
30
87 RED/GRN
BLK/YEL E/G OIL PRESS SWITCH (R)
L17 L18 BLK BLK
5 0.85B BLK 85 86 LGN LGN 86 85 BLK
(PRINTED FEBRUARY 2011) PILOT BUZZER
BLK HEAD LIGHTS
WATER SEPARATOR RED
V-1316 WATER SEPARATOR 11
(L)
0
L16 BLK WHT/RED 2 RNG SPEAKER
6 6 I
AIR CLEANER BLK/WHT BLK INDICATOR -
Printable Version Click Here FUEL EMPTY
L3
7
+ 3 II
ANTENNA
(LH) (RH)
L5 BLK 10 9 WHT/RED
RED/BLU
9 + - + -
ENG OIL PRESS BLK/YEL 4 27 RED/BLU WHT/RED
BLK = BLACK L2 LIGHT SWITCH WHT/RED 3 8 GRY/RED
WATER TEMP. 10 BLU/BLK 5 1 GRN/YEL RADIO
BLU = BLUE
L6 GRN/YEL 18
BRN = BROWN BLK/YEL
CONTROL UNIT 2 RED/WHT
DBL = DARK BLUE CAR STEREO 1 GRY/BLU
8 RED/BLK RADIO SWITCH
DGN = DARK GREEN CHARGE 3
L1 (OPTION) 9 BLK/WHT
GRN = GREEN OVER LOAD 13 GRY/RED 9 10 0 7
GRY = GRAY L15 GRY 5
NOT USED 14 LGN 11 22 YEL/RED I 1 BLU/WHT 4 CD PLAYER
LBL = LIGHT BLUE L13
LGN = LIGHT GREEN PREHEAT 15 BLU/WHT 9 10 BLK (OPTION)
PNK = PINK L4 14 BLK
HIGH SPEED 16 YEL/RED 20
PUR = PURPLE L7 11
RED = RED ENGINE WARNING 20 BLK/WHT 6 BRN KET 18P
L12 + WHT/BLU 5
RNG = ORANGE WORKING LIGHT 18 RED 7 BRN/WHT CN4
TAN = TAN L11 AMP 040 28P SIG
21 BLK/RED 14 8 BLK/WHT
WHT = WHITE LCD TACH CN1 -
CAB LIGHT
WHT/RED
RED/GRN
YEL = YELLOW
BLU/WHT
BLU/RED
RED/BLU
PRESSURE SENSOR (OWD) HEATED SEAT (OPTION)
28 WHT/BLU B 10W E BLK
GAUGE PANEL
GRN
BLU
YEL
BRN
BLU/RED + BLK
7 0
5 1 2 3 4 5 6 7 8
BLK 28
OVER LOAD BLK 1 I 10A 10A 10A 10A 10A 10A 10A 10A
SEAT HEATER
10 9 WHT/RED
WARNING 15 16 17 WHT
WINDOW WASHER 0
1 BLU (OWD) OVER LOAD WARNING RED/WHT FUEL FEED PUMP BRN BRN
BLU/BLK BLU/BLK 5 I (OWD)SWITCH STARTER RELAY
FUSE BLOCK RED/BLU - +
DIODE 1
10 9 WHT/RED BLK BLU/RED
+
BLK
RED/BLU P 85 87 YEL
DIODE 6
P 17 BLU/WHT L WHT
WASHER SWITCH 86 30
18 S WHT BLK/YEL BLK/YEL WHT
- YEL
BLK BLK + 18 19 20 WHT/RED
ORN/WHT
BLU/WHT
BLK/WHT
WIPER SWITCH
BLU/BLK
STOP M 15A 15A 20A 20A 20A 30A
0
BLK D PP BLU BLK
15 BLU/RED 6 I 2 BLU B RUN -
9 10 11 12 13 14 STARTER
16 BLU/YEL 3 II SWITCH
ACC
C C B WHT WHT
10 9WHT/RED DIODE 5 AIR HEATER
WHT/RED
WHT/BLU
WIPER MOTOR E
RED/BLU
45A
BLU/BLK
ENG CONTROL DIAL BLK
22
12
23
BLK
2
WHT/RED R2
PREHEAT RELAY
WHT
FUSIBLE LINK 2
BLU
1 GRN/RED 38 B
LOW CW +5V
FUEL PUMP BRN
2 GRN 35 BLU
SIG BR
3 GRN/BLK WHT/RED WHT/BLU + - BLK R1
HIGH
06 LGN/YEL
P STARTER C
105D ECU
RNG/BLU 16 AUTO IDLE PRESSURE SWITCH BLK/GRN
(Electronic B
GRN/BLK Control Unit) LGN/WHT BLK GRN/ BLK/WHT RED
17 7 0
5 YEL
WATER TEMP. SENSOR BLK 1 I
30bar
30 10 9 WHT/RED
CAN
FUEL INJECTION PUMP 120ohm CAN-L 39 BLK 03 CHECKER RED/BLU 1 3 RED/WHT RED/WHT
CAN-H 40 WHT 02 04 AUTO IDLE SELECT SWITCH BLK 2 A
BLK
2 BLU/RED 19 01 POWER PLUG
ENGINE
HOUR METER
SPEED 1 BLU/GRN 18 WHT/RED 12V 2.3KW
SENSOR GND-RPM BLK
BLK/YEL BLK
08
COLD START DEVICE COIL (STARTING) - RED/BLU RED
YEL/BLK 41 44 BLK/GRN WHT/RED
(PRE-HEAT)
(ACC)
07 BLU/RED Dealer Copy -- Not for Resale + HORN RELAY
27A
FUSIBLE LINK 1
CN5-1 YEL/RED 20 BRN WHT HORN
(STARTER RELAY) 87a
34 GRN/BLK YEL/RED BLU/WHT 30
YEL/GRN BLU/RED 87 RED/BLK
DIODE 8
CN5-2 42 24
(Neutral)
0 7 TWO SPEED BLK
CN5-5 RED/BLU 43 5 BLU/WHT GRN 86 85 BLK
RACK RELAY WHT/RED SOLENOID
CN5-4 PNK/GRN 36 I 1 YEL/RED
VALVE CIRCUIT BREAKER BATTERY RELAY
87a WHT/RED 9 10 BLK HORN SWITCH
CN5-6 GRN/BLK 28 RED/ MAIN RELAY
GND-A BLK (ON L.H. JOYSTICK) B A
30 WHT WHT
RACK ACTUATOR 87 87a ONE WAY FLOW RELAY
RNG/ TWO SPEED SWITCH 87a
WHT/ 30 RNG BLK
BLK 85 86 RED BRN/WHT BR
33 87 BLU/WHT 30 ONE WAY FLOW
87 RED/BLU
NC SOLENOID VALVE BLK E
85 86 CONSOLE LOCKOUT
CN6-2 RED/BLK 48 1 YEL C BLU/WHT 86 85 BLK
SOLENOID VALVE BRN/WHT RED
RED/GRN YEL/GRN
A BLU/GRN 3 BLK NO (Pilot Cut Off)
CN6-1 YEL/GRN 01 13
ONE WAY FLOW SWITCH 0.85B
B CN6-4 YEL/BLU 11 9 BLK CONSOLE LOCKOUT (ON R.H. JOYSTICK)
EMERGENCY OFF SWITCH
DIODE 9
A CN6-3 YEL/RED 21 FCI 48P 47 BLK
STOP SWITCH (Pilot Cut Off) BLK
B CN6-6 RED 31 CN3 45 BLK BLK
CN6-5 RED/BLK
ROTATING SW
YEL/RED (ON JOYSTICK L.H)
QUICK CLAMP (Not Available Option) - +
EGR VALVE RED/BLK RED/BLK BLU/WHT 43E YEL/RED 12V 100AH
(R.H)
(Exhaust Gas
0.85LB (R.H)
Recirculation) 7 0 BATTERY
5 31B
0.85LR
11 WHT/RED 57B 0.85LB 57A 1 I
(L.H) 0.85B WHT
13 9 60L 0.85WR
LED GRN/YEL 10 BLU/WHT 43F YEL/BLU (L.H)
22 WHT/BLU 0.85B
RED/WHT
BLU 0.85B
REAR ACTUATOR QUICK CLAMP SWITCH
0.85B WHT
OPEN 2 GRY/GRN 18 10
SECOND AUXILIARY HYDRAULIC
CLOSE 3 GRY/YEL 19
M COMPRESSOR IG L P B(BATT)
MOTION ALARM (OPTION)
RELAY
RECEIVER DRIER
87a ROTATING BEACON (OPTION)
FACE ACTUATOR LOW PRESS HIGH PRESS
30 MOTION ALARM SWITCH
RNG/RED CUT OFF CUT OFF
OPEN 2 RNG 20 87 BLK/WHT PRESS SWITCH
7 0 5 0 7
BEACON BLU/RED BLU/RED 5
CLOSE 3 RNG/YEL 21 RED 1 I I 1 LGN/RED LGN/BLK LGN/BLK + IG
M RED/BLK 86 85
BLU/WHT 9 9
A/C CONTROL PANEL BLK BLK 10 WHT/RED WHT/RED 10 BLK -
DIODE 4
9 YEL/GRN COMPRESSOR
BUZZER L
AIRCON UNIT BEACON SWITCH
FOOT ACTUATOR F
6 E
FOOT 2 GRN/WHT 6 THERMOSTAT
DIODE 7
DEF. 3 GRN 7
M
RED/BLU 5 ALTERNATOR E
BLK
BLOWER RESISTOR
STARTER SWITCH CONNECTION 12V 60A
BLK 4
+ - HRS NO.GT7A-26PD-DS 26P AMP 040 28P
M BLK TML B BR R1 R2 C ACC
PST
22 21 20 19 18 17 8 7 6 5 4 3 2 1
OFF
13 12 11 2 1
RED RNG YEL 10 9 8 7 6 5 4 3
ON
WARM 4 LGN/WHT 14 26 25
28 27 26 25 24 23 16 15 14 13 12 11 10 9
2 1 3 24 23 22 21 20 19 18 17 16 15 14
START
COOL 6 LGN/BLK 15 BLU BLU
M (CN2) (CN1)
3 YEL/RED 2
1 YEL/WHT 16 86 87 87a 86 87 87a 86 87 87a
2 BLK 1
BLOWER RELAY
8 7 6 5 4 3 2 1 47 48
31 32 33 34 35 36 37 38 39 40
WATER VALVE ASS'Y 18 17 16 15 14 13 12 11 10 9
85 30 85 30 85 30 21 22 23 24 25 26 27 28 29 30
45 46
43 44
(CN4) 11 12 13 14 15 16 17 18 19 20
3 BLU/BLK (HI)
26 41 42
BLK HRS 26P 5 BLU/YEL (MID) 1 2 3 4 5 6 7 8 9 10
Troubleshooting Chart
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn engine. 2, 3, 4, 6, 7, 8, 9
Figure 50-10-2
1 1 2 3 4 5 6 7 8
9 10 11 12 13 14
P-86276
B-23955
The excavator has a 12 volt, negative ground electrical
system. The electrical system is protected by fuses
The fuses will protect the electrical system when there is REF DESCRIPTION AMP
an electrical overload. The reason for the overload must 1 Warning Light, Motion Alarm 10
be found before starting the engine again. 2 Two Speed, Console Lock, Cab Light 10
3 Wiper, Washer 10
The battery cables must be clean and tight. Check the 4 Stereo, ECU, Air Conditioning Control Panel 10
electrolyte level in the battery. Add distilled water as 5 Instrument Panel 10
needed. Remove acid or corrosion from the battery and 6 Horn, Breaker Switch, Beacon / Strobe Light 10
cables with a sodium bicarbonate and water solution. 7 EGR Valve 10
8 Starter 10
Put Battery Saver P/N 6664458 or grease on the battery 9 Can Checker 15
terminals and cable ends to prevent corrosion. 10 Power Plug 15
11 Condenser Fan, Compressor Clutch 20
12 Air Conditioner / Heater 20
13 Fuel Pump, Hour Meter 20
Figure 50-10-3
1 2 3 4 5 6 7 8 9 10
11 12
2 P-86246
Servicing
Figure 50-20-1
P9589 P9590
WARNING
AVOID INJURY OR DEATH
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
Figure 50-20-3
1 5
4
1 3
1 5
6
P-92918
2 Remove the two bolts and washers (Item 1), the retaining
2 plate (Item 2) [Figure 50-20-4] and the plastic cover.
2 Disconnect the negative (-) cable (Item 3) [Figure 50-20-
3
P-86287 4] first.
Install the battery. Install the hold down clamp and tighten
the bolts.
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.
P-86284
WARNING
AVOID INJURY OR DEATH
Figure 50-20-6 Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
P-86285
See the Chart for the correct service interval. (See Chart
on Page 10-80-1.)
Figure 50-30-1 1
P-86293
1
P-86292
WARNING terminal.
Figure 50-30-5
P-87391
Start the engine. At low idle, the icon must be off. If the
P-87392 icon is on, inspect the alternator belt (Item 1) [Figure 50-
30-7] for correct tension.
If the icon does not illuminate, disconnect the harness If the icon flashes, inspect the diode positive (+) side.
(Item 1) [Figure 50-30-5] from the alternator.
P-86211B
P-87395
Figure 50-30-9
2 1
1
P-86282
P-86282
Run the engine at rated speed. Check to make sure that
all accessories are turned OFF. Connect the positive lead
If the icon is illuminated, measure the voltage at the of the voltmeter to the positive terminal (Item 1) of the
battery (Item 1) [Figure 50-30-9]. battery. Connect the negative lead of the volt meter to the
Figure 50-30-11
P-87392
P-87392
With the key in the OFF position, remove the L & IG
terminal connector (Item 1) [Figure 50-30-13] from the
Turn the engine OFF and remove the L & IG terminal alternator.
connector (Item 1) [Figure 50-30-11] from the alternator.
Figure 50-30-12
P-87394
Figure 50-30-14
2
1
P-87403
P-87393
Touch the IG terminal (Item 1) with a probe and the
ground (Item 2) [Figure 50-30-16] with another probe.
Figure 50-30-15
Figure 50-30-17
P-86282
P-87404
The voltage should be what the battery voltage is. If not, There should be continuity in one only direction. Meter
check the wire harness and relay. If the wire harness and readings should be different when probes are reversed. If
relay are ok, remove the alternator for replacement or there is no continuity or continuity in both directions,
repair. replace the regulator.
Figure 50-30-18
1
1
P-87397
2 Figure 50-30-21
P-87392
Figure 50-30-19 2
1
P-87398
P-87396
Figure 50-30-22
2
1
2
1
P-87402
Turn the alternator over and remove the screw (Item 1).
P-87399 Remove the ground wire (Item 2) [Figure 50-30-24].
Figure 50-30-23
P-87401
Parts Identification
1. Nut
2. Pulley
3. Case Half
4. Rotor
5. Stator
6. Case Half
7. Nut
8. Bolt
2 3
1
B-23973
Testing
Bat
S
M Cranking
Motor
Cranking
Motor
A-1991
The key switch must be in the OFF position. If the starter turns, the defect is in the solenoid.
If the starter turns but does not turn the engine, the
starter drive has a defect.
Figure 50-40-3 1 2
P-87463
P-87461
P-87464
P-87462
Figure 50-40-7
1
1 P-87466
Figure 50-40-9
P-87465
P-87519
Parts Identification
1. Rubber cover
2. Solenoid
3. Shims
4. Plunger
5. Torsion Spring 1
6. Shift Lever 2
7. Gear Housing
8. Bolt 3
9. Retaining Ring
10. Pinion Stop 5
11. Spring 6
12. Clutch Assembly
13. Bearing Retainer
14. Pinion Shaft 7
15. Rear Cover 4
16. O-ring
17. Brush Holder
18. Field Coil Assembly 10
19. Armature Assembly 11
12
16
17
18
19
E80025S
Figure 50-50-1
4
2
3
1 1
1
P-86654
P-86653
Remove the screws (Item 1) and bezel (Item 2). Pull the
lens (Item 3) [Figure 50-50-3] out of the housing.
Disconnect the wire harness (Item 1) [Figure 50-50-1].
NOTE: The lens must be installed with the word
Figure 50-50-4
2
1
P-86654
1
Remove the nut (Item 1) and washers. Remove the light
P-86656
(Item 2) [Figure 50-50-2] from the boom.
Figure 50-50-5
P-86655
Testing / Adjustment
Figure 50-60-1
P-86775
1
Figure 50-60-4
P-86773
Figure 50-60-2
1
P-86776
Loosen the nut (Item 1) and turn the stop (Item 2) [Figure
50-60-4] out to raise the stop, or in to lower the stop.
P-86654
Figure 50-60-5
Figure 50-60-6
P-86777
Figure 50-70-1
P-89565
Figure 50-70-4
Figure 50-70-2
1
P-89570
1
1
P-89564
Figure 50-80-1 The error codes will be displayed on the instrument panel
as flashing light sequences on icon (Item 1) [Figure 50-
80-1].
2
See the following chart for the codes, the conditions and
the flashing sequence.
P-86955A
When detecting these failures, the E-ECU (Engine control unit) flashes the engine check lamp to alert the operator to the
occurrence of failure conditions. The engine check lamp will illuminate for two sec. when the E-ECU is power on. This
allows checking if the E-ECU is supplied with power normally.
Flashing patterns of the engine check lamp are shown in [Figure 50-80-2]. When accelerator sensor failure (flashing five
times) and EGR valve failure (flashing 1-3 times) occur, the engine check lamp flashes as shown in [Figure 50-80-2].
When two or more failures have occurred simultaneously, the engine check lamp scrolls through all the failure modes,
then repeats.
Figure 50-80-2
Software Installation
Windows XP Home
P-95356
Windows XP Tablet PC Edition
Windows Vista When the Yanmar Diagnostic Tool screen pops up, click
once on the next icon (Item 1) [Figure 50-90-2].
Figure 50-90-1
Figure 50-90-3
Figure 50-90-4
1
1
2 P-95360
Figure 50-90-5
P-95359
Installation
Figure 50-90-7
1
1 1
P-95322
Figure 50-90-10
Tilt the seat back forward and remove the four screws
(Item 1). Remove the cover (Item 2) [Figure 50-90-7].
1
1
P-95323
Installation (Cont’d)
Figure 50-90-11
1
P-95308
Figure 50-90-12
1
P-95369
Installation (Cont’d)
Figure 50-90-15
P-95367
1 2
3
4
5
6
1
P-95361
If the Service PC is running windows XP, or a newer Enter a user ID (Item 1) and password (Item 2). Reenter
program, click once on the continue anyway icon (Item 1) the password (Item 3) [Figure 50-90-18].
[Figure 50-90-16] to continue the driver installation.
Select the expert authority level (Item 4). Enter the
license key (Item 5) [Figure 50-90-18] that is printed on
the CD label.
Code Retrieval
Figure 50-90-19
2
1
P-95344
Figure 50-90-22
P-95343
P-95346
Figure 50-90-23
2
1
P-95349
1
1
P-95348
P-95350
2 3 4 5 6 7
1 2 3 4
P-95353
Figure 50-90-29
1
1
P-95350
Figure 50-90-30
P-95325
Figure 50-100-1 1
P-87727
1
Disconnect the two wire harness connectors (Item 1)
P-87725 [Figure 50-100-3].
P-87726
Figure 50-100-4
1
1
P-87680
Figure 50-100-7
Remove the four screws (Item 1) and bracket (Item 2)
[Figure 50-100-4].
1 P-87681
Figure 50-100-8 1
1 1
P-87684
1
Figure 50-100-11
Remove the six screws (Item 1) [Figure 50-100-8].
P-887685
Figure 50-100-12 1
2
1 1
P-87687
Figure 50-100-15
Pull up on and remove the gauge indicators (Item 1 and
2) [Figure 50-100-12].
1
Figure 50-100-13
2
1
1
P-87686
P-87688
Figure 50-110-1
1
P-86680
P-86678
Figure 50-110-2
P-86679
Figure 50-120-1
1
P-87693
P-87694
Removal And Installation (Cont’d) NOTE: The removal of the two speed switch is
shown, all rocker switch removal is the same.
Figure 50-120-5
Figure 50-120-6
P-87695
P-87696
Figure 50-120-7
P-87697
1
1
P-87701
P-87698
P-87700
P-87699
Figure 50-120-12 1
P-87704
P-87703
1
P-87706
Remove the nut (Item 1) and remove the upper arm (Item
P-87705 2) [Figure 50-130-3].
Figure 50-130-4
Disconnect the washer hose (Item 1) [Figure 50-130-1]
inside the cab.
P-87708
Figure 50-130-5
1
1
1
P-87711
P-87710
Inspecting
Figure 50-140-1
P-86211C
WARNING
AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-0807
Sit in the operator’s seat and fasten the seat belt. Start
the engine. (See the Operation & Maintenance Manual
for the correct procedure.)
Inspecting (Cont’d) Stop the engine. Raise the operator cab. (See Tilting The
Cab on Page 10-210-1.)
The motion alarm is located inside the lower part of the
engine compartment. Figure 50-140-4
Figure 50-140-3
2 1
1
P-86915 P-86551
Inspect the motion alarm electrical connector (Item 1) The motion alarm switch (Item 1) [Figure 50-140-4] is
and wire harness (Item 2) [Figure 50-140-3] for damage. hydraulic pressure activated and located under the
WARNING
This machine is equipped with a motion alarm.
ALARM MUST SOUND!
when operating forward or backward.
Figure 50-150-1 2
1 2 1
P-92652
Figure 50-150-4
Remove the tie strap (Item 1) [Figure 50-150-1].
1 1
P-92642
Figure 50-150-5
P-92639
Figure 50-160-1
P-91759
Figure 50-160-2
P-91760
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Specifications
All dimensions are given in millimeters. Respective Imperial dimensions are given in inches enclosed by
parentheses.
Opening Pressure 21600 - 22600 kPa (216 - 226 Bar) (3133 - 3278 psi)
Fuel Tightness Nozzle Seat Dry Nozzle just below opening psi for 5 seconds.
Cylinder Head
Valves
Specifications (Cont’d)
Valve Springs
Camshaft
Specifications (Cont’d)
Tappet
Push Rod
Cylinders
Piston Rings
Specifications (Cont’d)
Pistons
Connecting Rods
Oil Pump
Oil Pressure @ Rated rpm 290 - 309 kPa (2,9 - 3,9 Bar) (42 - 57 psi)
Idle Speed Allowable Limit 60 kPa (0,6 Bar) (9 psi)
Outer Rotor Outside Clearance 0,100 - 0,155 mm (0.0039 - 0.0061 in)
Outer Rotor Outside Clearance Limit 0,25 mm (0.0098 in)
Outer Rotor Side Clearance 0,05 - 0,10 mm (0.0020 - 0.0039 in)
Outer Rotor Side Clearance Limit 0,15 mm (0.0059 in)
Outer Rotor To Inner Rotor Tip Clearance 0,16 mm (0.0063 in)
Gear Boss Diameter 53,05 - 53,15 mm (2.0886 - 2.0925 in)
Rotor Diameter 53,45 - 53,55 mm (2.1043 - 2.1083 in)
Gearboss / Rotor Clearance 0,3 - 0,5 mm (0.012 - 0.020 in)
Gear Boss / Rotor Clearance Allowable Limit 0,6 mm (0.024 in)
Width Across Flat Of Gear Boss 49,45 - 49,75 mm (1.9468 - 1.9587 in)
Width Across Flat Of Rotor 49,95 - 50,05 mm (1.9665 - 1.9705 in)
Width Clearance Across Flat Of Gear Boss / Flat Of rotor 0,2 - 0,5 mm (0.008 - 0.020 in)
Width Clearance Across Flat Of Gear Boss / Flat Of 0,7 mm (0.028 in)
Rotor Allowable Limit
Specifications (Cont’d)
Crankshaft
Crankshaft Alignment Allowable Limit (1/2 Dial Gauge 0,02 mm (0.0008 in)
Reading)
Connecting Rod Journal O.D. 57,952 - 57,962 mm (2.2816 - 2.2820 in)
Connecting Rod Journal O.D. Allowable Limit 57,902 mm (2.2796 in)
Connecting Rod Bearing I.D. 58,0 - 58,026 mm (2.2835 - 2.2845 in)
Connecting Rod Bearing Thickness 1,492 - 1,5 mm (0.0587 - 0.0591 in)
Oil Clearance Between Connecting Rod Journal And 0,038 - 0,074 mm (0.0015 - 0.0029 in)
Bearing
Oil Clearance Between Connecting Rod Journal And 0,150 mm (0.0059 in)
Bearing Allowable Limit
Main Bearing Journal O.D. 64,952 - 64,962 mm (2.5572 - 2.5576 in)
Main Bearing Journal O.D. Allowable Limit 64,902 mm (2.5552 in)
Main Bearing I.D. 65,0 - 65,020 mm (2.5590 - 2.5598 in)
Main Bearing Thickness 1,995 - 2,010 mm (0.0785 - 0.0791 in)
Thrust Bearing
Specifications (Cont’d)
Torque Values
N•m ft-lb
*Cylinder Head Bolt 101,1 - 112,9 76 - 83
*Connecting rod Bolt 53,9 - 58,8 40 - 43
*Flywheel Bolt 186,2 - 205,8 137 - 152
*Main Bearing Cap Bolt 108,1 - 117,9 80 - 87
Troubleshooting
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common.
PROBLEM CAUSE
Slow cranking speed 1, 2, 3, 4
Engine will not start 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28, 29
Engine is mis-firing 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure 4, 33, 36
Overheating 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure 22, 27, 29, 30, 40, 49
Poor compression 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Figure 60-10-2
4
2
2
1 P-87533
3
2 3
1
P-87536
2
3 Loosen the nut (Item 1). Loosen the adjustment bolt (Item
P-87534 2) and remove the belt (Item 3) [Figure 60-10-7] from the
A/C compressor pulley.
Cut and remove the cable ties (Item 1). Loosen the hose Figure 60-10-8
clamps (Item 2) and remove the fuel lines (Item 3)
2
1 2
P-87577
Figure 60-10-9
1 1
1 P-87463
Figure 60-10-12
Remove the bolt (Item 1) [Figure 60-10-9] and lower the
compressor to the excavator frame.
3 2 2
P-87519
Figure 60-10-13
4
3
2
1
P-87542
1
Reinstall the bolt (Item 1) in the engine lifting bracket.
P-87540 Remove the bolt (Item 2) and clamp. Loosen the hose
clamp and remove the fuel line (Item 3). Remove the nut
and disconnect the manifold heater cable (Item 4)
Cut and remove the cable tie (Item 1). Remove the bolts [Figure 60-10-15].
(Item 2) [Figure 60-10-13] and clamps.
2
1
1 1
P-87543
P-87541
Figure 60-10-17
1 1
1
P-87546
2
Remove the three bolts (Item 1) [Figure 60-10-19] and
P-87544 clamps.
Figure 60-10-20
Remove the bolt (Item 1) and reposition the fuel filter
(Item 2) [Figure 60-10-17].
1
1
P-87547
Remove the two bolts (Item 1) and remove the fuel pump
bracket (Item 2) [Figure 60-10-18].
1
P-87520
1
Install a lifting hoist (Item 1) [Figure 60-10-23] and chain
P-87548 on the engine lifting points.
Figure 60-10-24
Disconnect the wire harness connectors (Item 1).
Remove the bolt (Item 2) [Figure 60-10-21].
1
2
P-87522
Figure 60-10-25
P-87602
Figure 60-10-26
P-87521
Compression - Testing
1
The tools listed will be needed to do the following
procedure:
Figure 60-10-28
P-91032
Figure 60-10-30
P-91031
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 60-10-31
NA1387
Adjustment
Figure 60-20-1
1 Engine Control
Dial
2 ECU (Engine
Control Unit)
2 1
EM7804
Adjustment (Cont’d)
Figure 60-20-2
S9597
Figure 60-30-1 1
P-87527
P-87525
Figure 60-30-2
P-87296
Figure 60-40-1
3
1
2 1
P-87295
Figure 60-40-2
P-87296
Figure 60-50-3
1
1 2
P-89409
P-89410
Remove the clamps (Item 1) and top radiator hose (Item
2) [Figure 60-50-1].
Remove the clamps (Item 1) and lower radiator hose
(Item 2) [Figure 60-50-3].
Figure 60-50-4
2
1
P-89413
Figure 60-50-7
Remove the bolts (Item 1) and fan shield (Item 2) [Figure
60-50-4].
2
1
P-89414
P-89412 Lift and remove the coolant reservoir (Item 1) [Figure 60-
50-7].
Figure 60-50-8
P-89417
1
1
P-89418
Figure 60-50-12
1 1
P-89432
Figure 60-50-15
Remove the bolt (Item 1) [Figure 60-50-12].
1
1
P-89433
Figure 60-50-16
1
2
P-89425
1 1
2
P-89421
1
1
1
2
P-89422
1
1
P-89427
Figure 60-50-23
1
1
P-89424
Figure 60-50-24
P-89423
Figure 60-50-25
1 1
2
P-89475
1
2
1 1
1
P-89480 P-89477
Remove the bolts (Item 1) and fan shroud (Item 2) Remove the bolts (Item 1) [Figure 60-50-28].
[Figure 60-50-25] and [Figure 60-50-26].
Figure 60-50-29
1 1
P-89476
1 1
P-89478
Figure 60-50-31
1
1
P-87530
Slide the fan towards the radiator and remove the spacer
P-87528 (Item 1) [Figure 60-50-33].
P-87259
Figure 60-50-34
1 1
P-86884
1 1
P-86885
Figure 60-50-36
1
2
S9605
Remove the fan (Item 1), spacer (Item 2) and pulley (Item
3) [Figure 60-50-36].
1. Thermostat Cover
2. Gasket
3. Thermostat
4. O-ring
5. O-ring
6. Water Pump
7. Temperature Switch
8. Gasket
9. Gasket
10. Belt
11. Pulley
12. Spacer 14
13. Fan
14. Bolt 1
2
3
5 4
9 1
11
12
10
14
13
S9600
Figure 60-50-37 3
1
1
3 2
2
6 4
5
S9607
Figure 60-50-39
2
2
1
1
S9609
S9608
Install the thermostat (Item 1) and an accurate
thermometer (Item 2) [Figure 60-50-40] in hot water.
Connect an electric resistor to the coupler of the water
temperature sensor (Item 1) [Figure 60-50-39]. Slowly increase the temperature of the fluid.
RESISTANCE
WATER TEMPERATURE
(K OHM)
20°C (68°F) 2.45 (+/- 0.13)
80°C (176°F) 0.318 (+/- 0.008)
0.008°C (32°F) (0.1836)
Figure 60-50-41
S9610
Figure 60-60-1
1
2
NA1084
Figure 60-60-2
3
2
NA1090
Remove the bolts (Item 1), oil pickup tube (Item 2) and O-
ring (Item 3) [Figure 60-60-2].
S9386
1
Remove the engine cooling fan guard, engine cooling fan
(Item 1), spacer (Item 2), pulley (Item 3) and belt (Item 4)
2
[Figure 60-60-4].
4
S9385
2 S9387
Figure 60-60-6
2 S9393
Wash the oil pump, oil pressure regulator and oil pump
cavity with clean solvent. Inspect for wear or damage. 1
Replace if necessary. 2
Figure 60-60-7
1
S9389
2
Figure 60-60-9
0,1 - 1,155 mm
Clearance 1
(0.0039 - 0.0061 in)
Allowable Limit 0,25 mm (0.0098 in) 2
S9390
0,05 - 0,10 mm
Side Clearance
(0.002 - 0.0039 in)
Allowable Limit 0,15 mm (0.0059 in)
Figure 60-60-10
S9391
12,980 - 13,020 mm
Gear Case Bearing I.D.
(0.5110 - 0.5126 in)
Allowable Limit 13,050 mm (0.5138 in)
12,955 - 13,020 mm
Rotor Shaft O.D.
(0.5100 - 0.5104 in)
Allowable Limit 12,945 mm (0.5096 in)
0,015 - 0,065 mm
Rotor Clearance
(0.0006 - 0.0026 in)
Allowable Limit 0,105 mm (0.0041 in)
Figure 60-60-11
WARNING
AVOID INJURY OR DEATH 1
1
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. P-91048
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 Disconnect the three wire harness connectors (Item 1).
from a physician familiar with this injury. Remove the three rear bolts (Item 2) [Figure 60-70-2].
W-2072-0807
Figure 60-70-1
P-91047
Figure 60-70-3 3
1 1
1 2 NA1359
Remove the oil line (Item 1) and clamp (Item 2). Locate
the mark (Item 3) [Figure 60-70-5] on the boss of the
P-91032 injection pump and make a corresponding mark on the
gear case.
1
1
P-91033 NA1360
Remove the high pressure fuel lines (Item 1) [Figure 60- Remove the seven front cover bolts and cover (Item 1)
70-3] and [Figure 60-70-4] from the injection pump and [Figure 60-70-6].
injectors.
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 60-70-7
NA1363
3
1
2
NA1362
NA1359
Figure 60-70-11
1
2
NA1365
Figure 60-70-13
NA1366
NA1363
Figure 60-70-14
1
Rotate the top of the fuel injection pump away from the
engine until the +0.5° mark (Item 1) aligns with the pump
NA1366 mark (Item 2) [Figure 60-70-15].
Figure 60-70-16
Figure 60-70-19
Locate the timing index number (Item 1) [Figure 60-70-
16] located on the engine side of the fuel injection pump.
1
P-91042
P-91051
NA1374
Figure 60-70-23
Figure 60-70-21
P-91050
P-91052
Figure 60-70-24
1
2
NA1379
NA1376
Figure 60-70-27
1
2
P-91048
Figure 60-70-30
Slowly rotate the crankshaft clockwise until the dial
indicator (Item 1) [Figure 60-70-27] shows a plunger lift
NA1371
2
1 6
P-91032
Figure 60-70-32
1
1 Use a flat blade screw driver to pry the fuel injector
grommet (Item 1) out of the valve cover. Remove the
valve cover nuts (Item 2) and O-rings (Item 3). Remove
the valve cover (Item 4) and gasket (Item 5). Remove the
return fuel line (Item 6) [Figure 60-70-33].
P-91033
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 60-70-34
5
4
NA1386
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 NA1382
NA1360
Figure 60-70-37
6
5
4
3
NA1385
Remove the nozzle body (Item 2), nozzle valve (Item 3),
spacer (Item 4), spring seat (Item 5), spring (Item 6), and
shims (Item 7) from the body (Item 8) [Figure 60-70-37].
Figure 60-80-1
NA1072
Cylinder No. 1 2 3 4
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
Rotate the crankshaft until the number 4 cylinder (radiator end) is at TDC. Adjust the following valves.
Cylinder No. 1 2 3 4
Valve Intake Exhaust Intake Exhaust Intake Exhaust Intake Exhaust
No. 4 Cylinder at X X X X
TDC Compression
Figure 60-80-2
1
2
1
NA1077
Figure 60-80-5
Loosen the valve bridge adjustment screw (Item 1) until
there is visible clearance (Item 2) [Figure 60-80-2]
3
NA1078
Apply light downward pressure on the valve bridge and Tighten the lock nut (Item 1) [Figure 60-80-5].
adjust the valve bridge adjusting screw until there is zero
clearance between the screw and front valve. Tighten the Check and adjust the rest of the valves.
back nut and verify that there is still no clearance (Item 1)
[Figure 60-80-3].
3 3
1 5
2
NA1046
Remove the bolts (Item 1). Remove the rocker arm and
NA1045 shaft assembly from the head. Remove the push rods
(Item 2). Remove the valve bridge assemblies (Item 3)
and seats (Item 4) [Figure 60-80-8].
Remove the high pressure fuel lines. Use a flat bladed
screwdriver to remove the fuel injection line grommets NOTE: Mark the push rods and rocker arms so the
Figure 60-80-7
2
2
4
3 1
4 2
3
N-1047
4
5 6
Remove the studs (Item 1) from the supports (Item 2).
Slide the supports, washers (Item 3), rocker arms (Item
4) and fuel injector retainers (Item 5) off the shaft (Item 6)
[Figure 60-80-9].
NA1386
Figure 60-80-10
1
7 16 14 6
1 9 18 12 4
A
3 11 17 10 2
5 13 15 8
NA1050
NA1048
Use a valve spring compressor tool (Item 1) [Figure 60-
80-12] to compress the valve spring.
Loosen the cylinder head bolts in the sequence shown
[Figure 60-80-10]. Figure 60-80-13
Figure 60-80-11
4
2
NA1051
Cylinder Head Disassembly And Assembly (Cont’d) Clean the surface of the cylinder head.
1
1
NA1052 NA1057
Use a drift and hammer to drive the valve guides (Item 1) Put a straight edge (Item 1) [Figure 60-80-15] on the
[Figure 60-80-14] out of the head. cylinder head.
Figure 60-80-16
PI-9988
Figure 60-80-17
NA1056
P-87490 NOTE: Measure the valve guides while they are still
installed in the cylinder head.
PI-9990
Figure 60-80-20
1
1 1
1 1
NA-1059
NA1058
Place the valve stem on an inspection block. Use a feeler
gauge (Item 1) [Figure 60-80-21] to measure the gap.
Measure the valve stem diameter (Item 1) [Figure 60-80-
20] where shown. Intake Valve Stem Bend 0,040 - 0,070 mm
Figure 60-80-22
NA1065
NA1062
Measure the valve spring free length [Figure 60-80-24].
Inspect the valve. The contact pattern should be Free Length 39,7 mm
approximately centered on the valve face (Item 1) (1.563 in)
Figure 60-80-25
150°
1
40°
NA1063
NA1064
The valve seat diameter (Item 1) [Figure 60-80-23] can
be adjusted by top grinding with a 150° stone to make the
seat diameter smaller, and bottom grinding using a 40° Use a flat surface and square to check the springs for
stone to make the seat diameter larger. squareness [Figure 60-80-25].
Figure 60-80-26 2
1 1
2
NA1055
NA1054
Figure 60-80-29
1
1
NA1066
Figure 60-90-1
3
4
7
6
NA1091
NA1094
Measure the connecting rod side clearance [Figure 60-
Figure 60-90-3
22 mm
(0.8661 in)
NA1085
Measure the connecting rod wrist pin bore and wrist pin Piston OD 97,93 - 97,96 mm
diameter [Figure 60-90-3]. (3.8555 - 3.8567 in)
P-47272
Figure 60-90-6
B3622
Remove the carbon from the ring grooves. Measure the If the gap exceeds the allowable limit, replace the ring.
clearance between the ring and groove with a feeler
Figure 60-90-8
NA1096
B-4066
Install a dial indicator on the cylinder block [Figure 60-
90-10]. Move the crankshaft back and forth to measure
Use a gauge to measure the inside of the cylinder bore end play.
[Figure 60-90-8].
A-2717
NA1099
Remove the oil seal retainer bolts (Item 3), oil seal
retainer (Item 4) and seal (Item 5) [Figure 60-90-11].
Figure 60-90-12
NA1098
Figure 60-90-14
A2716
Figure 60-100-1
Remove the bolts (Item 1). Remove the timing gear case
(Item 2). Clean all of the old sealant off the cylinder block
and timing gear case. Remove the O-rings (Item 3)
[Figure 60-100-1].
Figure 60-100-2
1
3
2
4
NA1081
5
6 Install a dial indicator and rotate the idler gear back and
NA1080 forth to check the idler gear to crankshaft backlash
[Figure 60-100-3]. Check the remainder of the gears
using the above procedure.
Before removing the timing gears, measure the backlash
to determine wear.
Figure 60-100-4
1 NA1086
4
Install a dial indicator on the cylinder block. Move the
2 camshaft back and forth to measure end play [Figure 60-
NA1082
100-5].
Remove the bolts (Item 1) from the idler gear shaft (Item Camshaft End Play 0,05 - 0,20 mm
2) and bushing (Item 3). Remove the idler gear (Item 4) (0.0020 - 0.0079 in)
Camshaft - Servicing
Figure 60-100-7
B-5001
Figure 60-100-10
A-2761
Description
Figure 60-110-1
P-91040
Figure 60-110-2
P-91041
1
P-91039
Pull the boot back and disconnect the wire harness (Item
1) [Figure 60-110-2].
Description
Figure 60-120-1
NA1360
Figure 60-120-4
P-91042
Testing
Figure 60-120-2
NA1358
P-91043
1 4
3
2 1
P-91046
P-91043
Remove the two nuts (Item 1), bolts (Item 2) and pipe Disconnect the wire harness (Item 1) [Figure 60-120-6].
(Item 3) [Figure 60-120-5]. Remove the gaskets.
Turn the key to the run position and observe the valve
functions through the exhaust gas inlet (Item 4) [Figure
60-120-5]. 1
3 4
NOTE: When the key is first turned to the run
position, the ECU checks valve operation by
opening and shutting the valve. 5
2
Remove the two nuts (Item 1), bolts (Item 2) and pipe
(Item 3). Remove the coolant lines (Item 4). Remove the
two bolts (Item 5) [Figure 60-120-7] and remove the
valve assembly.
Figure 60-130-1
1
1
P-91036
Figure 60-130-2
P-91034
Figure 60-140-1
1
1
P-87488
Figure 60-140-4
2
P-87483
Figure 60-140-2
1 P-87489
P-87487
Figure 60-140-5
WARNING
AVOID INJURY OR DEATH
1 Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
1
• Engine is running.
• Tools are being used.
W-2019-0907
1
The ring gear on the flywheel is an interference fit. Heat
the ring gear enough to expand it and hit it with a
P-87490
hammer evenly to remove it.
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 70-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 70-30-1
The Compressor Operates Improperly Or Not At All . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 70-10-2.) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) (See Chart on Page 70-10-2.).
Ambient air passing through the condenser removes the heat from the refrigerant, resulting in a physical state change in
the refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver/drier (Item 3) (See Chart on Page 70-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) Page (See Chart on Page 70-10-2.).
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 70-10-2.). As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) (See Chart on Page 70-10-2.). Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4 Expansion Valve
Blower 6
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Desiccant
3 Receiver Drier
Components
Figure 70-10-1
1
P-86814
Figure 70-10-2
P-86814
Components (Cont’d) 3 2
Figure 70-10-5
P-87074
1
1 1
P-87067 P-87068
Expansion Valve: The expansion valve (Item 1) [Figure Heater / Evaporator Blower: The blower (Item 1) [Figure
70-10-6] controls the amount of refrigerant entering the 70-10-8] pushes air through the heater and evaporator
evaporator coil. coils and into the cab.
Components (Cont’d)
Figure 70-10-9
6 3 5 5
1
P-86818
2
4
Heater Valve: The heater valve (Item 1) [Figure 70-10-
P-86817 10] is used to control the amount of engine coolant that
flows to the heater coil.
Safety Equipment
Figure 70-10-11
P-16399
Filters
Belt Adjustment 1
Loosen the lock nut (Item 1) and adjust the bolt (Item 2)
Figure 70-20-2
WARNING
AVOID INJURY OR DEATH
• Do Not Operate with damaged or missing
1 screens, shields or rubber deflectors.
• Stop engine before cleaning or servicing.
• Contact with moving parts or flying objects can
cause injury or death.
W-2528-0406
P-86921
Belt Replacement
Figure 70-20-4
2
1
1
P-86920
Loosen the lock nut (Item 1) and the bolt (Item 2) [Figure
P-86922 70-20-6] until the belt can be removed.
WARNING
AVOID INJURY OR DEATH
• Do Not Operate with damaged or missing
screens, shields or rubber deflectors.
P-86921 • Stop engine before cleaning or servicing.
• Contact with moving parts or flying objects can
cause injury or death.
Loosen the belt idler mounting bolt (Item 1) [Figure 70- W-2528-0406
20-5].
Condenser
Figure 70-20-7
1
P-86814
Figure 70-20-8
P-87074
Figure 70-20-9
P-87073
Figure 70-30-1 Install the gauge set on the low pressure port (Item 1)
and the high pressure port (Item 2) [Figure 70-30-1].
1
P-86825
High Pressure 790 - 980 kPa (7,9 - 9,8 bar) (114 - 142 psi)
Low Pressure 90 kPa (0,9 bar) (14 psi)
High Pressure 1970 - 2450 kPa (19,7 - 24,5 bar) (285 - 355 psi)
Low Pressure 240 - 340 kPa (2,4 - 3,4 bar) (35 - 50 psi)
Turn on air conditioning, set blower switch to high, turn air conditioner OFF and wait 10 minutes. Re-check High / Low
pressure readings.
High Pressure 1280 - 1860 kPa (12,8 - 18,6 bar) (185 - 270 psi)
Low Pressure 140 - 320 kPa (1,4 - 3,2 bar) (21 - 47 psi)
High Pressure 590 - 1770 kPa (5,9 - 17,7 bar) (85 - 256 psi)
Low Pressure 500 mm Hg (19.7 in Hg) (Negative Pressure)
High Pressure over 690 - 1080 kPa (6,9 - 10,8 bar) (100 - 156 psi)
Low Pressure 390 - 590 kPa (3,9 - 5,9 bar) (57 - 85 psi)
Evaporator
Pressures represent gas temperatures inside the coil, not the coil surface. For an estimate of the temperature of the air
coming off the coil add -12.5 ± -0.5°C (9 ± 1°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4°C (40°F) to the ambient temperature to
get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature.
32°C (90°F)
+ 4°C (40°F)
54°C (130°F) condenser temperature = 1379 kPa (14 bar) (200 psig)
Figure 70-30-2 1
1
P-86951
Figure 70-30-5
P-86229
N-22411
Check the A/C evaporator coil for dirt or mud, and clean if
necessary. (See Evaporator / Heater Coil on Page 70-20-
5.)
Figure 70-30-6
P-86816
Figure 70-40-1
N-23024
Figure 70-40-4
Remove the protective cap and connect the Refrigerant
Figure 70-40-5
N-22381
Figure 70-40-6
N-22292
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500 P-52658
Figure 70-40-8
Connect the Yellow hose (Item 1) [Figure 70-40-9] to the
vacuum pump.
2
1
3
P-87052
Figure 70-40-10
P-87051
Figure 70-40-11 Run the vacuum pump for at least 45 minutes to insure
that all the moisture is boiled out of the system.
P-87052
Determine the problem with the A/C system and repair it.
Figure 70-40-13 1
3
1 2 3
P-86817
Figure 70-40-14 Watch the scale and run the system until the
predetermined amount of refrigerant is added to the A/C
system.
P-87054
Figure 70-50-1
P-86823
Figure 70-50-4
2 1
P-86877
2
Remove the bolt (Item 1) [Figure 70-50-4] and the hoses
1 from the compressor.
P-86822
Figure 70-50-5
1
1
2
P-86873
1
Remove the three screws (Item 1) and remove the dust
P-86871 cover (Item 2) [Figure 70-50-7].
Figure 70-50-8
Remove the seal washers (Item 1) [Figure 70-50-5] from
the tubelines.
1 P-86875
Figure 70-50-9
1
P-86877
1 P-86874
The compressor (Item 1) [Figure 70-50-11] is factory
filled with 0,266 L (9.0 U.S. fl oz) of PAG oil (Polyalkelene
Remove the three bolts (Item 1) [Figure 70-50-9] and the Glycol).
compressor from the excavator.
Oil Check
P-16534A
Figure 70-50-14
P-86878
1
Add new compressor oil through the suction side
N-22246 connector (Item 1) [Figure 70-50-15].
Figure 70-60-1
2 1
P-86822
3
Figure 70-60-3
1
P-86879
P-86823
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 70-60-4
1
1
1
1 P-86883
1 P-86887
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.
P-86888
P-86886
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas. P-87059
W-2371-0500
Figure 70-80-1 2
P-87060
1
Figure 70-80-4
P-87061
Inspection
2
NOTE: The thermostat is not serviceable separately.
The procedure shown is for inspection
purposes.
Figure 70-90-1
1
1
P-87074
Figure 70-90-2
P-87073
Figure 70-100-1
P-87064
2
Figure 70-100-4
Figure 70-100-2
1
P-87065
1
P-87063
Figure 70-100-5 1 2
1 2
P-87075
1
P-87070
Figure 70-110-1
P-87064
1
Figure 70-110-4
P-87062
Figure 70-110-2
1
1
1 P-87065
P-87063
Figure 70-110-5
1
1
P-87071
Figure 70-110-8
Remove the heater core / evaporator (Item 1) [Figure 70-
110-5] from the top cover.
3
2
1 1
P-87068
Remove the eight screws (Item 1) [Figure 70-110-6]. Remove the resistor block (Item 3) [Figure 70-110-8].
Figure 70-120-1
1
P-87407
1 1 Figure 70-120-4
P-87405
P-87408
1
P-87406
P-86761
P-86759
Figure 70-130-2
P-86760
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Machine Dimensions
• All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
70°
55°
737 mm
2638 mm (29.0 in) 2085 mm
(103.9 in) (82.1 in)
446 mm
648 mm 410 mm (17.3 in)
450 mm (17.6 in)
(17.7 in) (25.5 in)
362 mm 1912 mm
1850 mm (75.3 in)
(72.8 in) (14.3 in) 2200 mm
(86.6 in)
2300 mm
2823 mm
(90.6 in)
(111.1 in)
3282 mm
(129.2 in)
MS2791
70°
55°
2580 mm
737 mm (101.6 in)
2605 mm
(29.0 in)
(102.6 in)
• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
2480 mm
(97.6 in)
7375 mm
(290.4 in)
4105 mm
(161.6 in)
7180 mm
(282.7 in)
EM6972
• All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
2700 mm
(106.3 in)
7070 mm
(278.3 in)
3730 mm
(146.9 in)
4675 mm
(184.0 in)
7480 mm
(294.5 in)
MS2792A
• All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
2700 mm
(106.3 in)
7070 mm
(278.3 in)
3730 mm
(146.9 in)
4675 mm
(184.0 in)
7480 mm
(294.5 in)
MS2792A
Performance
Operating weight w/ cab, steel tracks and 610 mm 8380 kg(18475 lb)
(24 in) bucket
If equipped with long arm, add: 60 kg (133 lb)
If equipped with articulated boom option, add: 920 kg (2028 lb)
Travel Speed Low Range 2,9 km/h (1.8 mph)
High Range 4,6 km/h (2.9 mph)
Digging Force (per ISO 6015)
Arm (Standard) 40855 N (9185 lbf)
Arm (Long Arm Option) 34068 N (7659 lbf)
Arm (Articulated Boom Option) 40855 N (9185 lbf)
Bucket 54623 N (12280 lbf)
Boom Swing (Offset) Left 70° Right 55°
Controls
Engine
Hydraulic System
Pump Type Engine driven, variable displacement dual piston pump with pressure
compensating, load sensing and torque limiter controls.
Two gear pumps.
Piston Pump Capacity 2 @ 70 L/min (18.5 U.S. gpm)
Gear Pump Capacity 70 L/min (18.5 U.S. gpm)
Gear Pump Capacity 9,9 L/min (2.6 U.S. gpm)
Auxiliary Flow 120 L/min (31.7 U.S. gpm)
Control Valve 12 spool closed centre
System Relief Pressure
Travel Circuits 30000 kPa (300 bar) (4278 psi)
Slew Circuit, Boom Swing, Blade,
Travel Straight, Secondary
Auxiliaries (If equipped) 30000 kPa (300 bar) (4278 psi)
Boom, Arm, Bucket,
Primary Auxiliary Hydraulics 30000 kPa (300 bar) (4278 psi)
Joystick Control Pressure 2940 kPa (29,4 bar) (427 psi)
Hydraulic Cylinders
Electrical
Drive System
Slew System
Undercarriage
Crawler Track Design Sealed track rollers with boxed section track, Roller frame, Grease type track
adjuster
Capacities
Tracks
Ground Pressure
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.
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-30-1].
Figure SPEC-30-3
1
Nut Nut
Washer
Washer
O-ring
O-ring
TS-1619A
Tighten the nut until it makes contact with the seat. Make
Lubricate the O-ring before installing the fitting. Loosen a mark across the flats of both the male and female parts
the jam nut and install the fitting. Tighten the jam nut until
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Specifications
WARNING
AVOID INJURY OR DEATH
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
COVER
ALPHABETICAL INDEX
FOREWORD
20-01
20-190 Added
40-01
40-30
40-160
40-170
50-01
50-130 Added
50-140 Added
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
COVER 50-01
MAINTENANCE SAFETY 50-81 Added
ALPHABETICAL INDEX 50-130 Added
50-140 Added
10-01
10-30 SPEC-10
10-50
20-30
20-40
20-50
20-51
20-70
20-190 Added
40-01
40-130
40-131 Added
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.