325-328 6986940 SM 10-09

Service Manual
325/328 Compact Excavator
325 S/N AAC511001 & Above

325 S/N A9K011001 & Above
328 S/N A9K111001 & Above
6986940 (10-09) Printed in U.S.A. © Bobcat Company 2009

MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 B-19964 B-19959

Never service the Bobcat Excavator Use the correct procedure to lift Cleaning and maintenance are
without instructions. and support the excavator. required daily.
WRONG WRONG WRONG
B-19965 B-19960 B-19966

Have good ventilation when Vent exhaust to outside when Always lower the bucket and
welding or grinding painted parts. engine must be run for service. blade to the ground before doing
Wear dust mask when grinding Exhaust system must be tightly any maintenance.
painted parts. Toxic dust and gas sealed. Exhaust fumes can kill Never modify equipment or add
can be produced. without warning. attachments not approved by
Bobcat Company.
WRONG WRONG WRONG
B-19962 B-19958 B-19798

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, electrical flammable and explosive gases.
checking fluids. contact, hot parts and exhaust. Keep arcs, sparks, flames and
Never service or adjust machine Wear eye protection to guard from lighted tobacco away from
with the engine running unless battery acid, compressed springs, batteries.
instructed to do so in the fluids under pressure and flying Batteries contain acid which
manual. debris when engines are running burns eyes or skin on contact.
Avoid contact with leaking or tools are used. Use eye Wear protective clothing. If acid
hydraulic fluid or diesel fuel protections approved for type of contacts body, flush well with
under pressure. It can penetrate welding. water. For eye contact flush well
the skin or eyes. Keep tailgate closed except for and get immediate medical
Never fill fuel tank with engine service. Close and latch tailgate attention.
running, while smoking, or when before operating the excavator.
near open flame.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW28-0409
ALPHABETICAL INDEX
AIR CLEANER ............................................. 10-01, 60-01 FUEL TANK .............................................................40-01

AIR CLEANER SERVICE ....................................... 10-01 HEATER AIR FILTER (WITH CAB OPTION ONLY)
ALTERNATOR ....................................................... 50-01 .................................................................................10-01
ARM ........................................................................ 40-01 HEATER COIL .........................................................70-01
ARM CYLINDER ..................................................... 20-01 HEATER FAN ..........................................................70-01
HEATER UNIT .........................................................70-01
BATTERY................................................................ 50-01 HEATER VALVE ......................................................70-01
BLADE ................................................................... 30-01 HORN .....................................................................40-01
BLADE CONTROL.................................................. 40-01 HYDRAULIC CONTROL VALVE .............................20-01
BLADE CYLINDER ................................................. 20-01 HYDRAULIC CONNECTION SPECS ............... SPEC-01
BOOM ..................................................................... 40-01 HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01
BOOM CYLINDER .................................................. 20-01 HYDRAULIC FILTER MOUNT.................................20-01
BOOM SWING CYLINDER..................................... 20-01 HYDRAULIC PUMP ................................................20-01
BUCKET ................................................................. 40-01 HYDRAULIC PUMP START-UP ..............................20-01
BUCKET CYLINDER .............................................. 20-01 HYDRAULIC RESERVOIR......................................20-01
BUILD UP VALVE ................................................... 20-01 HYDRAULIC SYSTEM ............................................10-01
HYDRAULIC SYSTEM INFORMATION .................20-01
CAB......................................................................... 40-01
CASE DRAIN FILTER ............................................ 20-01 LEFT CONTROL LEVER (JOYSTICK) ...................20-01
CLAMP.................................................................... 40-01 LEFT CONSOLE .....................................................40-01
CLAMP CYLINDER ................................................ 20-01 LIFTING AND BLOCKING THE EXCAVATOR ........10-01
CONVERSIONS ...............................................SPEC-01 LIFTING THE EXCAVATOR ....................................10-01
CONTROL PATTERN SELECTOR VALVE ............20-01 LIGHTS....................................................................50-01
COOLING SYSTEM................................................ 10-01 LUBRICATION OF THE HYDRAULIC EXCAVATOR
CROSS PORT RELIEF VALVES ........................... 20-01 .................................................................................10-01
DELUXE INSTRUMENT PANEL SETUP................ 50-01 MAIN RELIEF VALVES............................................20-01

DIAGNOSTICS SERVICE CODE ........................... 50-01 MANIFOLD ASSEMBLY/ACCUMULATOR .............20-01
DIRECT TO TANK VALVE ...................................... 20-01 MUFFLER................................................................60-01
ELECTRICAL SYSTEM INFORMATION ................ 50-01 OIL COOLER...........................................................20-01

ENGINE .................................................................. 60-01 OPERATOR CAB (ROPS/TOPS) ............................10-01
ENGINE ACCESSORY DRIVE BELT .................... 10-01
ENGINE COMPONENTS AND TESTING .............. 60-01 PORT RELIEF VALVES...........................................20-01
ENGINE FLYWHEEL .............................................. 60-01 PRESSURE REDUCING VALVE.............................20-01
ENGINE LUBRICATION SYSTEM.......................... 10-01
ENGINE SPECIFICATIONS...............................SPEC-01 RADIATOR ..............................................................60-01
ENGINE SPEED CONTROL .................................. 40-01 RECONDITIONING THE ENGINE .........................60-01
RIGHT CONTROL LEVER (JOYSTICK) .................20-01
FLOOR MAT AND FLOOR PLATE ......................... 40-01 RIGHT CONSOLE ...................................................40-01
FUEL, COOLANT AND LUBRICANTS .............SPEC-01 RIGHT PEDAL AND LINKAGE ...............................40-01
FUEL LEVEL SENDER........................................... 50-01 RIGHT SIDE COVER ..................................10-01, 40-01
FUEL SYSTEM ....................................................... 10-01 ROPS CANOPY.......................................................40-01
Continued On Next Page
325/328 Service Manual

ALPHABETICAL INDEX (CONT’D)
SEAT BELT ............................................................ 10-01

SERVICE SCHEDULE ............................................10-01
SPARK ARRESTOR MUFFLER ..............................10-01
SPECIFICATIONS ............................................. SPEC-01
SUSPENSION SEAT AND SEAT MOUNT ..............40-01
STARTER ................................................................50-01
STANDARD SEAT AND SEAT MOUNT ..................40-01
SWING CIRCLE GEAR ...........................................30-01
SWING FRAME .......................................................40-01
SWING MOTOR .....................................................20-01
SWING MOTOR DRIVE CARRIER .........................20-01
SWIVEL JOINT .......................................................20-01
TAILGATE .....................................................10-01, 40-01

TORQUE SPECIFICATIONS ............................SPEC-01
TRACK DAMAGE IDENTIFICATION.......................30-01
TRACK FRAME ......................................................30-01
TRACK IDLER ........................................................30-01
TRACK ROLLER .....................................................30-01
TRACKS ..................................................................30-01
TRANSPORTING THE EXCAVATOR......................10-01
TRAVEL CONTROLS ..............................................40-01
TRAVEL MOTOR..........................................10-01, 20-01
TROUBLESHOOTING.............................................60-01
TWO SPEED SWITCH ............................................50-01
UPPERSTRUCTURE ..............................................40-01
UPPERSTRUCTURE SLEW LOCK .............10-01, 40-01
X-CHANGE..............................................................40-01
325/328 Service Manual

CONTENTS SAFETY AND
MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV HYDRAULIC

SYSTEM
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII

UNDERCARRIAGE
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
BOBCAT EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . X UPPERSTRUCTURE

& SWING
SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 SECTION
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

ELECTRICAL
SYSTEM AND
UNDERCARRIAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 ANALYSIS
UPPERSTRUCTURE & SWING SECTION . . . . . . . . . . . . . . . . 40-01

ENGINE
ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 50-01 SERVICE
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 HEATER
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
SPECIFICATIONS
I 325/328 Service Manual

FOREWORD
This manual is for the Bobcat excavator mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat excavator and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the excavator has had service or repair:
1. Check that the ROPS/TOPS/ 9. Safety treads must be in good
FOPS is in good condition condition.
and is not modified.
2. Check that ROPS/TOPS 10. Check for correct function of

mounting hardware is indicator lamps.
tightened and is Bobcat
approved.
3. The seat belt must be 11. Check hydraulic fluid level,

correctly installed, functional engine oil level and fuel
and in good condition. supply.
4. Machine signs (decals) must 12. Inspect for fuel, oil or

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

and foot pedals must return to
neutral. Check that the pedal
locks are in working order.
6. Check for correct function of 14. Check the condition of the

the work lights. battery and cables.
7. Enclosure door latches must 15. Inspect the air cleaner for
open and close freely. damage or leaks. Check the
condition of the element.
8. Attachment locking pins must 16. Check the electrical charging

function correctly and be in system.
good condition.
FW EXC-0509 SM
II 325/328 Service Manual

17. Check tracks for wear and 21. Check the control console
tension. Use only approved interlocks for correct function.
tracks.
18. Inspect for loose or broken 22. Inspect the X-Change™ for
parts or connections. wear or damage. Repair or
replace damaged parts.
19. Check for any field 23. Check function or condition of

modification not completed. all equipped options and
accessories (examples:
special applications kit,
motion alarm, etc.).
20. Operate the machine and 24. Recommend to the owner
check all functions. that all necessary corrections
be made before the machine
is returned to service.
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
III 325/328 Service Manual

SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903
operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
• The Compact Excavator Operator Training Course is
DANGER available through your local dealer or at

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

available from your Bobcat dealer or at
The signal word WARNING on the machine and in the www.training.bobcat.com or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI EXC-0308 SM
IV 325/328 Service Manual

SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner / operator review the

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

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

Dial 811 (USA Only)
1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI EXC-0308 SM
V 325/328 Service Manual

FIRE PREVENTION Hydraulic System
Check hydraulic tubes, hoses and fittings for damage

and leakage. Never use open flame or bare skin to check
for leaks. Hydraulic tubes and hoses must be properly
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage.
Maintenance Always clean fluid spills. Do not use gasoline or diesel

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

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.
cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting
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.
Do not use the machine where exhaust, arcs, sparks or

hot components can contact flammable material, Spark Arrestor Exhaust System
explosive dust or gases. The spark arrestor exhaust system is designed to control
the emission of hot particles from the engine and exhaust
Electrical system, but the muffler and the exhaust gases are still
hot.
Check the spark arrestor exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
Check all electrical wiring and connections for damage.
Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI EXC-0308 SM
VI 325/328 Service Manual

FIRE PREVENTION (CONT’D)
Welding And Grinding
Always clean the machine and attachment, disconnect

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

parts. Wear dust mask when grinding painted parts.
Toxic dust or gas can be produced.
Dust generated from repairing nonmetallic parts such as

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers
Know where fire extinguishers and first aid kits are

located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI EXC-0308 SM
VII 325/328 Service Manual

SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the excavator when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation. 1
Excavator Serial Number
Figure 1
P-49407
Figure 3
P-49278
1
The excavator serial number plate (Item 1) is located on
the frame of the machine in the location shown [Figure
1].
Explanation of Excavator Serial Number:

XXXX XXXXX
P-49406
Module 2. - Production
Sequence (Series)
The engine serial number (Item 1) [Figure 2] & [Figure
Module 1. - Model / Engine 3] is located on the engine in the locations shown.
Combination
1. The 4 digit Model/Engine Combination Module number

identifies the model number and engine combination.
2. The 5 digit Production Sequence Number identifies the

order which the excavator is produced.
VIII 325/328 Service Manual

DELIVERY REPORT
Figure 4
B-16315
The delivery report must be filled out by the dealer and

signed by the owner or operator when the Bobcat
Excavator is delivered. An explanation of the form must
be given to the owner. Make sure it is filled out
completely [Figure 4].
IX 325/328 Service Manual

BOBCAT EXCAVATOR IDENTIFICATION
OPERATOR
ARM HANDBOOK
LIFT
CYLINDER
POINT OPERATOR
SEAT WITH
SEAT BELT
AUXILIARY
QUICK
COUPLERS
CONTROL
LEVERS
BUCKET (JOYSTICKS)
CYLINDER
BUCKET BOOM
LINK CYLINDER
X-CHANGE
BLADE
CYLINDER
BUCKET
TIE DOWNS/
LIFT POINTS
RIGHT SIDE
COVER
BOOM
*CANOPY/CAB
(ROPS/TOPS)
ARM
TAILGATE
BLADE
TIE DOWN TRACK FRAME

UPPERSTRUCTURE
B-19951
B-19950
* FOGS (Falling Object Guards) is available from your Bobcat Excavator dealer.
X 325/328 Service Manual

SAFETY AND MAINTENANCE SAFETY AND
MAINTENANCE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Replacing The Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-3
ENGINE ACCESSORY DRIVE BELT . . . . . . . . . . . . . . . . . . 10-140-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-3
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-3
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . . 10-80-4
Removing Water From The Fuel Filter. . . . . . . . . . . . . . . . 10-80-2
HEATER AIR FILTER (WITH CAB OPTION ONLY) . . . . . . . . 10-61-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Checking And Adding Hydraulic Oil . . . . . . . . . . . . . . . . . 10-100-1
Diagnostic Couplers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Replacing The Case Drain Filter . . . . . . . . . . . . . . . . . . . 10-100-3
Replacing The Hydraulic Filter. . . . . . . . . . . . . . . . . . . . . 10-100-3
Replacing The Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . 10-100-2
LIFTING AND BLOCKING THE EXCAVATOR . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12-1
LUBRICATION OF THE HYDRAULIC EXCAVATOR . . . . . . 10-110-1
10-01 325/328 Service Manual

SAFETY AND MAINTENANCE (CONT’D)
MOTION ALARM SYSTEM (IF EQUIPPED). . . . . . . . . . . . . . 10-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Adjusting Switch Position. . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
OPERATOR CAB (ROPS/TOPS) . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-5
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Front Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
Right Side Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-4
RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41-1

Opening And Closing The Right Side Cover . . . . . . . . . . . 10-41-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-130-1
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Adjusting The Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Adjusting The Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Opening And Closing The Tailgate . . . . . . . . . . . . . . . . . . 10-40-1
TRANSPORTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . 10-30-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Draining The Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
UPPERSTRUCTURE SLEW LOCK . . . . . . . . . . . . . . . . . . . . 10-11-1

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS
OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD

ITEMS MAY VARY.

LIFTING AND BLOCKING THE EXCAVATOR
Procedure
Always park the machine on a level surface.
WARNING
Put jackstands under the blade and rear corners of
the undercarriage before working under the machine.
Failure to block up the machine may allow it to move
or fall and result in injury or death.
W-2218-1195
WARNING
AVOID INJURY
Keep fingers and hands out of pinch points when
checking the track tension.
W-2142-0903
Figure 10-10-1
P-49460
Raise one side of the machine approximately 4 in. (102

mm) using the boom and arm as shown in [Figure 10-10-
1].
Raise the blade fully and install jackstands (Item 1)

[Figure 10-10-1] under the blade and the track frame.
Lower the machine until all machine weight is on the
jackstands.
Stop the engine.
10-10-1 325/328 Service Manual

UPPERSTRUCTURE SLEW LOCK
Operation
WARNING
Figure 10-11-1
AVOID INJURY
The upperstructure slew lock lever must be engaged
when transporting the machine.
W-2197-0904
WARNING
AVOID INJURY OR DEATH
Never use attachments or buckets which are not
approved by Bobcat Company. Buckets and
attachments for safe loads of specified densities are
P-71480A approved for each model. Unapproved attachments
can cause injury or death.
W-2052-0907
Move the lever (Item 1) [Figure 10-11-1] up slightly, then
to the rear and down to engage the upperstructure slew
lock.
Figure 10-11-2
P-71527A
Move the lever (Item 1) [Figure 10-11-2] up and then

forward to disengage the upperstructure slew lock.
NOTE: Upperstructure must be in the straight forward

or straight rearward position for
upperstructure to lock.

LIFTING THE EXCAVATOR Figure 10-12-2
Procedure
1
Figure 10-12-1
P-50050
Fasten chains to the ends of the blade (Item 1) [Figure

P-49456 10-12-1] and [Figure 10-12-2] and up to a lifting fixture
above the canopy/cab. The lifting fixture must extend
over the sides of the canopy/cab to prevent the chains
Fully extend the cylinders of the bucket, arm, and boom from hitting the ROPS/TOPS.
so that the excavator is in the position as shown [Figure
10-12-1]. Figure 10-12-3
Raise the blade all the way. 2
Put all the control levers in neutral.
WARNING
• Use a lifting fixture with sufficient capacity for
the weight of the excavator plus any added
attachments.
• Maintain center of gravity and balance when
N-23184
lifting.
• Do not swing boom or upperstructure. Engage
the upperstructure slew lock. Install a 1 in. (25 mm) bolt and nut (Grade 5 or 8) through
• Never lift with operator on machine. the holes in the boom (Item 2) [Figure 10-12-1] and
W-2202-0607
[Figure 10-12-3]. Fasten a chain from the bolt to the
lifting fixture.

OPERATOR CAB (ROPS/TOPS) Figure 10-20-3
Emergency Exit
The left door, front window and right rear window provide
exits.
Figure 10-20-1
P-49118
Exit through the window [Figure 10-20-3].

1
Figure 10-20-4
P-49176
Pull forward on the latch (Item 1) [Figure 10-20-1].
Figure 10-20-2
P-49127
1 Raise the front window and exit through the window

[Figure 10-20-4].
P-49177
Pull the latch/handle (Item 1) [Figure 10-20-2] forward to

open the window.
Push the handle back to close the window.

OPERATOR CAB (ROPS/TOPS) (CONT’D) Figure 10-20-7
Front Window
Figure 10-20-5
1
1
P-49098
Turn the two top latches (Item 1) [Figure 10-20-7] to the

P-49095 unlocked position.
Figure 10-20-8
The front window is equipped with a wiper (Item 1)
[Figure 10-20-5] and washer.
Opening The Front Window
Figure 10-20-6
P-49127
Use both window grab handles to pull the top of the

window in [Figure 10-20-8].
P-49097 Continue moving the window in and up over the

operator’s head until the window is fully raised.
Retract the two top window latch pins (Item 1) [Figure

10-20-6].

OPERATOR CAB (ROPS/TOPS) (CONT’D)
Front Window (Cont’d)
Figure 10-20-9
1
2
P-49099
When the window is fully raised, the latch (Item 1) will

close on the bracket. Turn the two top latches (Item 2)
[Figure 10-20-9] to the locked position.
Closing The Front Window
Support the window while releasing both window latch

pins and placing the pins in the unlocked position.
Support the window using the left grab handle and pull
down on the latch (Item 1) [Figure 10-20-9] to release
the window.
Use both window grab handles to pull the window down

[Figure 10-20-8 on Page 10-20-2].
Rotate the top latches (Item 1) [Figure 10-20-7 on Page

10-20-2] to the locked position (Item 1) [Figure 10-20-6
on Page 10-20-2].

OPERATOR CAB (ROPS/TOPS) (CONT’D) Figure 10-20-12
Right Side Windows
Opening the right rear window
Figure 10-20-10
P-49119
Pull back on the latch (Item 1) [Figure 10-20-12].

1
Figure 10-20-13
P-49176
Pull forward on the latch (Item 1) [Figure 10-20-10].
Figure 10-20-11
1
P-49120
1 Pull the latch/handle (Item 1) [Figure 10-20-13] back to

open the window.
P-49177 Push the handle forward to close the window.
Pull the latch/handle (Item 1) [Figure 10-20-11] forward

to open the window.
Push the handle back to close the window.
Opening the right front window

OPERATOR CAB (ROPS/TOPS) (CONT’D)
Cab Door
Figure 10-20-14
P-42570
The cab door (Item 1) [Figure 10-20-14] can be locked

with the same key as the starter switch (if equipped).
Figure 10-20-15
P-49283
Push the door all the way open until the latch engages to
hold the door in the open position [Figure 10-20-15].
Firmly pull the door away from the cab to disengage the
latch and close the door [Figure 10-20-15].

TRANSPORTING THE EXCAVATOR Put blocks at the front and rear of the tracks.
Procedure Figure 10-30-2
When transporting the machine, observe the rules, motor

vehicle laws, and vehicle limit ordinances. Use a
transport and towing vehicle of adequate length and
capacity.
Secure the parking brakes and block the wheels of the 1

transport vehicle.
Align the ramps with the center of the transport vehicle. 1

Secure the ramps to the truck bed and be sure ramp
angle does not exceed 15°.
Use metal loading ramps with a slip resistant surface.

P19508
Use ramps that are the correct length and width and can
support the weight of the machine.
Figure 10-30-3
The rear of the trailer must be blocked or supported when
loading or unloading the excavator to prevent the front of
the transport vehicle from raising.
Determine the direction of the track movement before

moving the machine (blade forward). 1
Engage the slew lock.
Figure 10-30-1
P-49459
Fasten chains to the front corners of the blade (Item 1)

[Figure 10-30-2] and to the tie down loop at the rear of
the track frame (Item 1) [Figure 10-30-3] to prevent it
from moving when going up or down slopes or during
sudden stops.
Use chain binders to tighten the chains and then safely

P-49458
tie the chain binder levers to prevent loosening.
Move the machine forward onto the transport vehicle

[Figure 10-30-1].
WARNING
Do not change direction of the machine while it is on the
ramps. AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
Lower the boom, arm, bucket, and blade to the transport needed to support the weight of the machine when
vehicle. loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
Stop the engine and remove the key (if equipped). W-2058-0807

TAILGATE Adjusting The Bumper
Opening And Closing The Tailgate Figure 10-40-2
WARNING
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
1
WARNING P-49409
Keep the rear door closed when operating the

machine. Failure to do so could seriously injure a The door bumper (Item 1) [Figure 10-40-2] can be
bystander. adjusted for alignment with the tailgate.
W-2020-1285
Close the tailgate before operating the excavator.
Figure PM-1
Adjusting The Latch
Figure 10-40-3
P-49408
Pull the latch (Item 1) [Figure PM-1] and pull the tailgate P-49410
open.
The door catch (Item 1) [Figure 10-40-3] can be adjusted
Push firmly to close the tailgate.
for alignment.
NOTE: The tailgate can be locked using the start key.
Close the tailgate before operating the excavator.

RIGHT SIDE COVER
Opening And Closing The Right Side Cover
Figure 10-41-1
P-49411
Pull the latch (Item 1) [Figure 10-41-1] and raise the right
side cover.
NOTE: The right side cover can be locked using the

start key.

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

■
ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000
Engine Coolant Check coolant level. Add premixed coolant as needed.
Engine Oil Check the engine oil level and add as needed.
Hydraulic Fluid, Hoses and Check the hydraulic fluid level and add as needed. Check for damage and
Tubelines, Reservoir Breather Cap leaks. Repair or replace as needed.
Engine Air Filter and Air System Check condition indicator and empty dust cup as needed. Check air system
for leaks.
Tracks Check and adjust track tension as needed.
Indicators and Lights Check for correct operation of all indicators and lights.
Operator Canopy / Cab Check condition. Check mounting hardware.
Seat Belt Check condition. Check mounting hardware.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Pivot Points Grease all machinery pivot points.
* Cab Heater Air Filter Clean the filter as needed.
Console Lockout Check console lockout for proper operation.
X-Change Lubricate and inspect for damage or loose parts.
Swing Circle and Pinion Grease two fittings
Fuel Tank & Filter Drain water and sediment from fuel tank and fuel filter.
Battery Check battery, cables, connections and electrolyte level. Add distilled water
as needed.
Accessory Drive Belt Check condition of belt and adjust as needed. ●
Spark Arrestor Muffler Clean the spark chamber.
Travel Motor Check the oil level in both travel motors.
Fuel Filter Replace fuel filter. ●
Engine Oil and Filter Replace oil and filter. Use CD or better grade oil and Bobcat filter. ▼
Radiator, Oil Cooler Clean debris from the radiator fins.
Primary Hydraulic Filter and Replace the primary hydraulic filter and reservoir breather. ^
reservoir breather
Case Drain Filter Replace the case drain filter. ^
Alternator & Starter Check the alternator and starter connections. ^
Engine Valves Check and adjust the engine valve clearance.
Hydraulic System Replace the hydraulic fluid and filters. Clean the reservoir.
Travel Motor Replace the lubricant in both travel motors. ^
Engine Coolant Drain and flush the cooling system. Replace the coolant. Every 2 years
* If equipped.
● Check after the first 50 hours, then as scheduled.
▼ First oil and filter change must occur at 50 hours; then as scheduled.
^ Check after the first 100 hours, then as scheduled.
■ Or every 12 months.

AIR CLEANER
See the Service Schedule for the correct service interval.

(See Chart on Page 10-50-1.)
Daily Check
Figure 10-60-1
P-49412
Check the condition indicator (Item 1) [Figure 10-60-1]. If

the red ring shows in the condition indicator, the filter
needs to be replaced.
Replace the inner filter every third time the outer filter is
replaced or as indicated.
Replacing The Filters
Outer Filter
Release the two fasteners (Item 2) [Figure 10-60-1].
Remove and clean the dust cup (Item 3) [Figure 10-60-

1].

AIR CLEANER (CONT’D) Inner Filter
Replacing The Filters (Cont’d) Only replace the inner filter under the following
conditions:
Figure 10-60-2
• Replace the inner filter every third time the outer filter
is replaced.
• After the outer filter has been replaced, press the

button (Item 3) [Figure 10-60-3] on the top of the
1 condition indicator and start the engine. Run at full
RPM, then reduce engine speed and stop the engine.
If the red ring shows in the condition indicator, replace
the inner filter.
Figure 10-60-4
P-49414
1
Pull the outer filter (Item 1) [Figure 10-60-2] from the air
cleaner housing.
Check the housing for damage.
Clean the housing and the seal surface. DO NOT use

compressed air.
Install a new filter.

P-49413
Figure 10-60-3
Remove the dust cup, outer filter and inner filter (Item 1)
[Figure 10-60-4].
3
NOTE: Make sure all sealing surfaces are free of dirt
and debris.
1
Install the new inner filter.
Install the outer filter and the dust cup.
2 Press the button on the condition indicator to remove the

red ring.
P-49412
Install the dust cup (Item 1) and engage the fasteners

(Item 2) [Figure 10-60-3].
Check the air intake hose and the air cleaner housing for
damage. Make sure all connections are tight.

HEATER AIR FILTER (WITH CAB OPTION ONLY) Figure 10-61-3
Removal And Installation
The heater filter must be cleaned regularly. The filter is

located at the left of the operator seat.
Figure 10-61-1 1
P-42168
2
Installation: Install the filter with the arrows that indicate

air flow direction (Item 1) [Figure 10-61-3] pointing
towards the heater housing.
P-42166
Remove the screw (Item 1) and cover (Item 2) [Figure

10-61-1].
Figure 10-61-2
P-42167
Pull the filter (Item 1) [Figure 10-61-2] away and out of

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

COOLING SYSTEM
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage.
Cleaning The Cooling System
NOTE: Allow the cooling system and engine to cool

before servicing or cleaning the cooling
system.
Open the tailgate.
Figure 10-70-1
P-49423
Use air pressure or water pressure to clean the radiator

and oil cooler (Item 1) [Figure 10-70-1]. Be careful not to
damage the fins when cleaning.

COOLING SYSTEM (CONT’D)
Checking Coolant Level

IMPORTANT
AVOID ENGINE DAMAGE
WARNING Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

AVOID BURNS efficiency and may cause serious premature engine
Do not remove radiator cap when the engine is hot. damage.
You can be seriously burned.
W-2070-1203 Too little antifreeze reduces the additives which
protect the internal engine components; reduces the
Open the right side cover. boiling point and freeze protection of the system.
Figure 10-70-2 Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
WARNING
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.
P-49425
• Engine is running.
• Tools are being used.
W-2019-0907
Check the coolant level in the coolant recovery tank (Item
1) [Figure 10-70-2].
The coolant level must be between the MIN and MAX

marks on the coolant recovery tank when the engine is
cold.
NOTE: The cooling system is factory filled with

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

COOLING SYSTEM (CONT’D) Figure 10-70-5
Replacing The Coolant

1
(See Chart on Page 10-50-1)
WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot.
W-2070-1203
P19225
Figure 10-70-3
Put a hose on the drain valve on the engine block. Open
the drain valve (Item 1) [Figure 10-70-5]. Drain the
coolant into a container.
1 After all the coolant is removed, close the drain valve.
Recycle or dispose of the used coolant in an

environmentally safe manner.
Mix the coolant in a separate container. See chart for

correct capacity. (See Chart on Page SPEC-60-1.)
NOTE: The cooling system is factory filled with

propylene glycol (purple color). DO NOT mix
P-49424 propylene glycol with ethylene glycol.
Add premixed coolant; 47% water and 53% propylene

When the engine is cool, loosen and remove the radiator glycol to the recovery tank if the coolant level is low.
cap (Item 1) [Figure 10-70-3].
One gallon and one pint of propylene glycol mixed with
Figure 10-70-4 one gallon of water is the correct mixture of coolant to
provide a -34×F (-37×C) freeze protection. (See
Checking Coolant Level on Page 10-70-2.)
Use a refractometer to check the condition of propylene

glycol in your cooling system.
Add premixed coolant until the level is correct.
Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level and add as needed.
Be sure the radiator cap is tight.
1
Add coolant to the recovery tank as needed.
P-49426 Close the right side cover.
Put a hose on the drain valve at the bottom of the

radiator. Open the drain valve (Item 1) [Figure 10-70-4]
and drain the coolant into a container.

FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is a suggested blending guideline which
should prevent fuel gelling problems during freezing • Biodiesel blend fuel is an excellent medium for
temperature microbial growth and contamination which can cause
corrosion and plugging of fuel system components.
Temp. F× (C×) No. 2 No. 1
Above +15× (-9×) 100% 0% • Use of biodiesel blend fuel may result in premature
failure of fuel system components, such as plugged
Down to -20× (-29×) 50% 50%
fuel filters and deteriorated fuel lines.
Below -20× (-29×) 0% 100%
• Shorter maintenance intervals may be required, such
At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel as cleaning the fuel system and replacing fuel filters
must be used in this machine. and fuel lines.
• Using biodiesel blended fuels containing more than

five percent biodiesel can affect engine life and cause
deterioration of hoses, tubelines, injectors, injector
pump and seals.
Apply the following guidelines if biodiesel blend fuel is

used:
The following fuels may also be used in this machine: • Ensure the fuel tank is as full as possible at all times
to prevent moisture from collecting in the fuel tank.
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.
• Ensure that the fuel tank cap is securely tightened.
• Biodiesel Blend Fuel - Must contain no more than five
percent biodiesel mixed with low sulfur or ultra low • Biodiesel blend fuel can damage painted surfaces,
sulfur petroleum based diesel. This is commonly remove all spilled fuel from painted surfaces
marketed as B5 blended diesel fuel. immediately.
• Drain all water from the fuel filter daily before

operating the machine.
WARNING
• Do not exceed engine oil change interval. Extended
AVOID INJURY OR DEATH oil change intervals can cause engine damage.
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an • Before vehicle storage; drain the fuel tank, refill with
explosion or fire. 100% petroleum diesel fuel, add fuel stabilizer and
W-2063-0807 run the engine for at least 30 minutes.
NOTE: Biodiesel blend fuel does not have long term

stability and should not be stored for more
WARNING than three months.

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

FUEL SYSTEM (CONT’D) FUEL SYSTEM (CONT’D)
Filling The Fuel Tank Removing Water From The Fuel Filter
Open the right side cover. Open the tailgate.
Figure 10-80-1 Figure 10-80-2
1
P-49415 P-49416
Remove the fuel fill cap (Item 1) [Figure 10-80-1]. Loosen the drain (Item 1) [Figure 10-80-2] at the bottom
of the filter to drain water from the filter.
Use a clean, approved safety container to add fuel. Add
fuel only in an area that has a free movement of air and See the Service Schedule for the service interval when to
no flames or sparks. NO SMOKING! remove the water from the fuel filter. (See Chart on Page
10-50-1.)
Install and tighten the fuel fill cap.
Clean up any spilled fuel.
WARNING
explosion or fire.
W-2103-0508

Draining The Fuel Tank FUEL SYSTEM (CONT’D)
See the Service Schedule for the correct service interval. Fuel Filter
See the Service Schedule for the service interval when to
Figure 10-80-3 replace the fuel filter. (See Chart on Page 10-50-1.)
Figure 10-80-4
P-49417
P-49416
Remove the hose (Item 1) [Figure 10-80-3] from the fuel
injection pump. Route the hose to the bottom of the
engine compartment and out the tailgate. Remove the filter (Item 1) [Figure 10-80-4].
Drain the fuel into a container. Clean the area around the filter housing.
Reuse, recycle or dispose of fuel in an environmentally Put oil on the seal of the new filter.
safe manner.
Install the fuel filter, and hand tighten.
WARNING
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

Removing Air From The Fuel System
After replacing the fuel filter or when the fuel tank has run
out of fuel, air must be removed from the fuel system
before starting the engine.
Figure 10-80-5
1
P-49417
Open the fuel filter vent (Item 1) [Figure 10-80-5].
Operate the hand pump (priming bulb) (Item 2) [Figure

10-80-5] until the fuel flows from the vent with no air
bubbles.
Close the vent (Item 1) [Figure 10-80-5].
Start the engine. It may be necessary to open the vent

(Item 3) [Figure 10-80-5] (at the fuel injection pump)
briefly until the engine runs smoothly.

ENGINE LUBRICATION SYSTEM Oil Chart
Checking Engine Oil Figure 10-90-2
Check the engine oil after every 8-10 hours of operation

and before starting the engine.
Figure 10-90-1
P-49418
Open the tailgate and remove the dipstick (Item 1)

[Figure 10-90-1].
Use a good quality motor oil that meets the correct API
Service Classification. See the oil chart [Figure 10-90-2].
Keep the oil level between the marks on the dipstick.

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-90-5
Replacing Oil And Filter
See the Service Schedule for the service interval for

replacing the engine oil and filter. (See Chart on Page 10-
50-1.)
Run the engine until it is at operating temperature. Stop

the engine.
Open the tailgate.

1
Figure 10-90-3
P-49421
Remove the oil filter (Item 1) [Figure 10-90-5] and clean

the filter housing surface.
Use a genuine Bobcat replacement filter. Put clean oil on

the filter gasket. Install the filter and hand tighten.
Install and tighten the oil cap.
1 Figure 10-90-6
P-49419
Route the drain hose (Item 1) [Figure 10-90-3] out the

tailgate. 1
Figure 10-90-4
P-49422
Remove the fill cap (Item 1) [Figure 10-90-6].
Put oil in the engine. (See Chart on Page SPEC-60-1.)
1 Install the fill cap. Start the engine and let it run for
P-49420 several minutes.
Stop the engine. Check for leaks at the oil filter. Check
Remove the cap (Item 1) [Figure 10-90-4]. Drain the oil the oil level.
into a container.
Add oil as needed if it is not at the top mark on the
Recycle or dispose of used oil in an environmentally safe dipstick.
manner.

HYDRAULIC SYSTEM Add the correct fluid to the reservoir until it is visible in the
sight gauge. (See Chart on Page SPEC-60-1)
Checking And Adding Hydraulic Oil
Check the cap and clean as necessary. Replace the cap
Put the machine on a flat level surface. if damaged.
Retract the arm and bucket cylinders, put the bucket on Install the cap.
the ground and lower the blade. Stop the engine.
Close the tailgate.
Open the tailgate.
Figure 10-100-1
P-49431
Check the hydraulic fluid level, it must be visible in the

sight gauge (Item 1) [Figure 10-100-1].
Clean the surface around the reservoir (breather) cap

and remove the cap from the reservoir (Item 2) [Figure
10-100-1].
Figure 10-100-2
P-49432
Check the condition of the fill strainer screen (Item 1)

[Figure 10-100-2]. Clean or replace as necessary.
Be sure the screen is installed before adding fluid.

HYDRAULIC SYSTEM (CONT’D) Figure 10-100-4
Replacing The Hydraulic Oil

(See SERVICE SCHEDULE on Page 10-50-1)
WARNING
AVOID INJURY OR DEATH 1
Diesel fuel or hydraulic fluid under pressure can
death. Fluid leaks under pressure may not be visible. P-49434
enters skin or eyes, get immediate medical attention Open the bleed valve (Item 1) [Figure 10-100-4] on the
from a physician familiar with this injury. hydraulic pump. Close the valve after a steady stream of
W-2072-0807 hydraulic fluid free of any air bubbles drains from the
valve. Tighten the bleed valve.
Retract the arm and bucket cylinders, lower the bucket to
the ground. Stop the engine. DO NOT RUN THE MACHINE WITH THE BLEED
VALVE OPEN.
Open the tailgate.
Run the machine through the hydraulic functions. Stop
Figure 10-100-3 the engine. Check the fluid level and add as needed.
P-49433
Remove the drain plug (Item 1) [Figure 10-100-3].
Drain the fluid into a container.
Recycle or dispose of the fluid in an environmentally safe

manner.
Install the drain plug (Item 1) [Figure 10-100-3].
Add the correct fluid to the reservoir until it is visible in the

sight gauge. (See Chart on Page SPEC-60-1)

HYDRAULIC SYSTEM (CONT’D) Figure 10-100-6
Replacing The Hydraulic Filter

(See Chart on Page 10-50-1)
1
Open the right side cover.
Figure 10-100-5
1 1
P-49436
Diagnostic couplers (Item 1) [Figure 10-100-6] are

1 located on the hydraulic circuitry.
The couplers can be used to check circuit pressures.

2
P-49435
Remove the hydraulic filter (Item 1) [Figure 10-100-5].
Clean the housing where the filter gasket makes contact.
Put clean hydraulic fluid on the gasket. Install the new

filter and hand tighten only.
WARNING
explosion or fire.
W-2103-0508
Replacing The Case Drain Filter
Open the tailgate.
Remove the filter (Item 2) [Figure 10-100-5].
Clean the housing where the filter gasket makes contact.
Put clean hydraulic fluid on the gasket. Install the new

filter and hand tighten only.
Diagnostic Couplers
Open the right side cover and tailgate.

LUBRICATION OF THE HYDRAULIC EXCAVATOR Figure 10-110-2
Lubricate the hydraulic excavator as specified in the

Service Schedule for the best performance of the
machine. (See Chart on Page 10-50-1.) 5
Always use a good quality lithium based multipurpose

grease when lubricating the machine. Apply the lubricant 6 7
until extra grease shows.
6 6
Lubricate the following locations on the hydraulic
excavator EVERY 8-10 HOURS:
Figure 10-110-1 8
5 P-49452
4
5. Boom Swing Pin (2) [Figure 10-110-2]
6. Boom Swing Pivot (3) [Figure 10-110-2]
7. Boom Pivot (1) [Figure 10-110-2]

1
3 8. Boom Cylinder Base End (1) [Figure 10-110-2]
3 Figure 10-110-3
2
P-49451
10
Ref Description (# of Fittings)
1. Blade Cylinder Rod End (1) [Figure 10-110-1]
2. Blade Cylinder Base End (1) [Figure 10-110-1]
3. Blade Pivots (2) [Figure 10-110-1]

9
4. Boom Swing Cylinder Rod End (1) [Figure 10-110-1]
P-42463
9. Boom Cylinder Rod End (1) [Figure 10-110-3]
10. Arm Cylinder Base End (1) [Figure 10-110-3]

LUBRICATION OF THE HYDRAULIC EXCAVATOR Figure 10-110-6
(CONT’D)
Figure 10-110-4
11
12
18
17 18
13
P-19385
P-49453 17. X-Change Latch (1) [Figure 10-110-6] (if equipped)
18. X-Change Pivot Pin (2) [Figure 10-110-6] (if

11. Arm Cylinder Rod End (1) [Figure 10-110-4] equipped)
12. Arm Pivot (1) [Figure 10-110-4] Figure 10-110-7
13. Bucket Cylinder Base End (1) [Figure 10-110-4]
Figure 10-110-5
20
21
15 19
14
16
P-49454
19. Boom Swing Cylinder Base End (1) [Figure 10-110-7]

P19384
Lubricate the following locations on the hydraulic
excavator EVERY 50 HOURS:
14. Bucket Cylinder Rod End (1) [Figure 10-110-5]
20. Slew Circle (1) [Figure 10-110-7]
15. Bucket Link Pin (1) [Figure 10-110-5]
21. Slew Pinion (1) [Figure 10-110-7]
16. Bucket Pivot (1) [Figure 10-110-5]
(Install 3 - 4 pumps of grease then rotate the
upperstructure 90°. Install 3 - 4 pumps of grease and
again rotate the upperstructure 90°. Repeat this until the
swing pinion has been greased at four positions.)

LUBRICATION OF THE HYDRAULIC EXCAVATOR
(CONT’D)
Figure 10-110-8
22
22
P-49455
22. Tailgate Hinge (2) [Figure 10-110-8]

TRAVEL MOTOR Draining The Travel Motor
Checking Oil Level See the Service Schedule for the correct service interval.
Figure 10-120-1
Park the excavator on a level surface with the plugs (Item
1 & 2) [Figure 10-120-1] in the position shown. Remove
both plugs and drain the lubricant into a container.
1
WARNING
2
explosion or fire.
W-2103-0508
P-49184
Install the bottom plug (Item 2) [Figure 10-120-1]. Add

Park the excavator on a level surface with the plugs (Item lubricant through the top plug hole until the lube level is at
1 & 2) [Figure 10-120-1] in the position as shown. the bottom edge of the hole. (See Chart on Page SPEC-
60-1.)
Remove the plug (Item 1) [Figure 10-120-1]. The lube
level must be at the bottom edge of the hole. Install the plug (Item 1) [Figure 10-120-1].
Add lubricant through the hole if the lube level is low.

(See Chart on Page SPEC-60-1.)

SPARK ARRESTOR MUFFLER Figure 10-130-1

Do not operate the excavator with a defective exhaust

system.
IMPORTANT
1
This excavator is factory equipped with a U.S.D.A.
Forestry Service approved spark arrestor muffler. It
is necessary to do maintenance on this spark P-49437
arrestor muffler to keep it in working condition. The
spark arrestor muffler must be serviced by dumping
the spark chamber every 100 hours of operation. Remove the plug (Item 1) [Figure 10-130-1] from the
bottom of the muffler.
If this machine is operated on flammable forest,
brush or grass covered land, it must be equipped Start the engine and run for about ten seconds while a
with a spark arrestor attached to the exhaust system second person, wearing safety glasses, holds a piece of
and maintained in working order. Failure to do so will wood over the outlet of the muffler. The carbon deposits
be in violation of California State Law, Section 4442 will be forced out of the muffler plug hole (Item 1) [Figure
PRC. 10-130-1].
Make reference to local laws and regulations for Stop the engine. Install and tighten the plug.
spark arrestor requirements.
I-2061-0195 Close the tailgate.
WARNING
When the engine is running during service, the
steering levers must be in neutral.
Failure to do so can cause injury or death.

W-2203-0595
Stop the engine. Open the tailgate.

ENGINE ACCESSORY DRIVE BELT Belt Adjustment
Belt Tension Figure 10-140-2
Open the tailgate.
Figure 10-140-1
1 1
P-49430
Loosen the belt tensioner bolt (Item 1) [Figure 10-140-2]

P-49429 and move the tensioner away from the engine until the
belt tension is correct.
Using a belt tension gauge, measure the belt tension Tighten the bolt to 15 - 18 ft.-lb. (20 - 25 N•m) torque.
midway between the crankshaft pulley and alternator
pulley (Item 1) [Figure 10-140-1].
The tension is as follows:

New belt 56 - 60 (76 - 81 N•m)
Used belt 48 - 52 (65 - 71 N•m)

SEAT BELT Figure 10-150-1
Inspection And Maintenance
WARNING
Failure to properly inspect and maintain the seat belt
can cause lack of operator restraint resulting in
serious injury or death.
W-2466-0703
Check the seat belt daily for correct function.
Inspect the seat belt system thoroughly yearly or more

often if the machine is exposed to severe environmental
conditions or applications.
The seat belt system should be repaired or replaced if it

shows cuts, fraying, extreme or unusual wear, significant
discolorations due to ultraviolet (UV) rays from the sun,
dusty/dirty conditions, abrasion to the seat belt webbing,
or damage to the buckle, latch plate, retractor (if
equipped), or hardware.
B-22283
The items below are referenced in [Figure 10-150-1].
1. Check the seat belt webbing. If the system is

equipped with a retractor, pull the webbing completely
out and inspect the full length of the webbing. look for
cuts, wear, fraying, dirt and stiffness.
2. Check the buckle and latch for proper function. Make

sure latch plate is not excessively worn, deformed or
buckle is not damaged.
3. Check the retractor web storage device (if equipped)

by extending the seat belt webbing to determine if it
extends and retracts the webbing correctly.
4. Check webbing in areas exposed to ultraviolet (UV)

rays from the sun or extreme dust or dirt. If the original
color of the webbing in these areas is extremely faded
and / or the webbing is packed with dirt, the webbing
strength may have weakened.
See your Bobcat dealer for approved seat belt system

replacement parts for your machine.

MOTION ALARM SYSTEM (IF EQUIPPED) Figure 10-160-3
Description
This excavator may be equipped with a motion alarm

system. The motion alarm will sound when the operator
moves the travel control levers in the either the forward
or reverse direction
2
Figure 10-160-1
1 1
P-73827
Inspect the motion alarm electrical connections (Item 1)

[Figure 10-160-3], wire harness (Item 2) [Figure 10-160-
3] and motion alarm switches (Item 1) [Figure 10-160-4]
for tightness and damage. Repair or replace any
damaged components.
P-49757 If the motion alarm switch requires adjustment, see

information below.
Figure 10-160-2 Adjusting Switch Position
Stop the engine. Remove the floormat and floor plate.

(See Service Manual for procedure for floormat and floor
plate removal.)
1 Figure 10-160-4
Switch Roller Contacting Bearing
P-49758
2
Inspect for damaged or missing motion alarm decal (Item
1) [Figure 10-160-1] (cab machine) or (Item 1) [Figure 3
10-160-2] (canopy machine). Replace if required. 1
P-61516
Sit in the operator’s seat. Turn excavator key to ON
position but do not start the engine.
Loosen the screws (Item 2) [Figure 10-160-4] securing
Move the travel control levers (one lever at a time) in the the motion alarm switch.
forward direction. The motion alarm must sound. Move
the travel control levers (one lever at a time) in the Position the motion alarm switch roller (Item 1) so that it
reverse direction. The motion alarm must sound. makes contact with bearing (Item 3) until it opens the
switch circuit. (Listen for the click of the switch.) Torque
Turn excavator key to OFF position. the screws (Item 2) [Figure 10-160-4] securing the
switch to the bracket to 14 - 19 in.-lb. (1,6 - 2,1 N•m).
The motion alarm is mounted to the bottom rear of the
excavator at the louver opening. (The louver must be
removed to access the back-up alarm. See the Service
Manual for the correct procedure.)

HYDRAULIC SYSTEM
ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
HYDRAULIC
BLADE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1 SYSTEM
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1
BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-10
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-8
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
BOOM SWING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-6
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
BUCKET CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-5
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23-1
BUILD UP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-160-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
CASE DRAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

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

HYDRAULIC SYSTEM (CONT’D)
CLAMP CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-7
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25-1
CONTROL PATTERN SELECTOR VALVE . . . . . . . . . . . . . . . . . . . . . 20-100-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-100-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-100-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-100-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-100-1
CROSSPORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-32-1

Testing And Adjusting The Port Relief Valves . . . . . . . . . . . . . . . . .20-32-1
DIRECT TO TANK VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-150-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-150-2
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Arm Valve Section Disassembly And Assembly . . . . . . . . . . . . . . 20-40-34
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-59
Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . . . 20-40-42
Blade Valve Section Disassembly And Assembly . . . . . . . . . . . . . 20-40-50
Boom Swing Valve Section Disassembly And Assembly. . . . . . . . 20-40-18
Boom Valve Section Disassembly And Assembly . . . . . . . . . . . . . 20-40-25
Boost Valve Section Disassembly And Assembly . . . . . . . . . . . . . 20-40-46
Bucket Valve Section Disassembly And Assembly . . . . . . . . . . . . 20-40-38
Control Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-10
Left Travel Valve Section Disassembly And Assembly . . . . . . . . . 20-40-29
Right Travel Valve Section Disassembly And Assembly . . . . . . . . 20-40-12
Slew Valve Section Disassembly And Assembly . . . . . . . . . . . . . . 20-40-55
HYDRAULIC FILTER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

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

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

Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-13
Gear Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-17
Gear Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-14
Gear Pump Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-11
Hydraulic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-10
Piston Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-26
Piston Pump Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-20
Piston Pump Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-12
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-8
Testing Auxiliary Hydraulic Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-7
Testing The Gear Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-5
Testing The Piston Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Torque Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Glossary Of Hydraulic/Hydrostatic Symbols For Excavators . . . . . . . . . . . . . . 20-10-1
Troubleshooting The Cylinder Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
Troubleshooting The Hydraulic Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Troubleshooting The Swing (Upperstructure Slew) Circuit . . . . . . . . . . . . . . . 20-10-6
Troubleshooting The Travel Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-7
LEFT CONTROL LEVER (JOYSTICK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-13
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-8
Handle Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-2
Joystick Assembly Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . 20-111-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-7
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1
MAIN RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Testing And Adjusting The Main Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
MANIFOLD ASSEMBLY/ ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-17
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

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

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1

Testing And Adjusting The Port Relief Valves . . . . . . . . . . . . . . . . . . . . . . . . 20-31-1
PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-33-1

Testing And Adjusting The Pressure Reducing Valve . . . . . . . . . . . . . . . . . . 20-33-1
RIGHT CONTROL LEVER (JOYSTICK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-15
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-10
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2
Joystick Assembly, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-110-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-9
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
SLEW LOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-220-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-220-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-220-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-220-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-220-1
SWING MOTOR DRIVE CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-220-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-220-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-220-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-220-1
SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-4
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.

HYDRAULIC/HYDROSTATIC SCHEMATIC
325 (S/N AAC511001 AND ABOVE)
(S/N A9K011001 AND ABOVE)
328 (S/N A9K111001 AND ABOVE)
(PRINTED MAY 2009
V-0978legend
LEGEND
1 HYDRAULIC RESERVOIR 17 PORT RELIEF VALVE
(PRESSURIZED) with FILL Arm Cylinder (Base End)
STRAINER 2900 PSI (200 Bar)
Capacity . . . . . . 19.2 Qts. (18,2 L)
18 PORT RELIEF VALVE
2 PRESSURIZED BREATHER/FILL CAP Arm Cylinder (Rod End)
with FILTER 2900 PSI (200 Bar)
5 PSI (0,34 Bar) - Outlet
19 LOAD CHECK VALVE
0.435 PSI (0,03 Bar) - Inlet
Boom Swing Cylinder
3 SOLENOID VALVE - SYSTEM BY-PASS
20 PRESSURE REDUCING VALVE
435 PSI (30 Bar)
4 MAIN RELIEF VALVE
3800 PSI (262 Bar) 21 ACCUMULATOR
165 PSI (11,4 Bar)
5 AUXILIARY SELECTOR VALVE (Option) 22 PORT RELIEF VALVE
Blade Cylinder (Base End)
6 HYDRAULIC FILTER ELEMENT
3335 PSI (230 Bar)
15 Micron
23 ORIFICE . . . . . . . . 0.065" (1.75 mm)
7 FILTER BY-PASS 50 PSI (3,5 Bar)
24 ORIFICE . . . . . . . . 0.065" (1.75 mm)
8 SWING MOTOR CROSS PORT RELIEF
VALVE . . . . . . 1700 PSI (117 Bar) 25 HYDRAULIC FILTER ELEMENT
When Tested 2450 PSI (169 Bar) 25 Micron
9 26 TEST PORT - "F" Port - Factory Fill Port

HYDRAULIC PUMP . Triple Section -
Variable Displacement Piston Pump
27 TEST PORT - "G" Port - Gauge Test Port
Sections 1 & 2:
5.23 GPM (19,8 L/min.)
28 FILTER BY-PASS . . . . 20 PSI (1,38 Bar)
Gear Pump Section 3:
7.03 GPM (26,6 L/min.)
29 MAIN RELIEF VALVE 2650 PSI (183 Bar)
10 TRAVEL MOTOR SPOOL - RIGHT HAND
30 MAIN RELIEF VALVE 2900 PSI (200 Bar)
11 TRAVEL MOTOR SPOOL - LEFT HAND
12 CHECK VALVE 31 BUILD-UP VALVE 150 PSI (10,34 Bar)
13 PORT RELIEF VALVE 32 TEST PORT - "G1" Port - Pilot Pressure Test
Boom Cylinder (Rod End) Port
3335 PSI (230 Bar) 33 RELIEF VALVE - Boost 2540 PSI (175 Bar)
Boom Cylinder (Base End) 34 PORT RELIEF VALVE (OPTIONAL)
3335 PSI (230 Bar) Auxiliary (Male Coupler)
2900 PSI (200 Bar)
Bucket Cylinder (Rod End) 35 PORT RELIEF VALVE (OPTIONAL)
3335 PSI (230 Bar) Auxiliary (Female Coupler)
2900 PSI (200 Bar)
16 PORT RELIEF VALVE 36 PILOT ACTIVATED DIRECTIONAL
Bucket Cylinder (Base End) CONTROL VALVE – Slew Lock Valve
2900 PSI (200 Bar) (Used on S/N A9K011121 & Above ONLY
S/N A9K111122 & Above ONLY)
NOTE: Unless otherwise specified
Printed in U.S.A. springs have NO significant V-0978legend (5-6-09)
pressure value.
P1
HYDRAULIC/HYDROSTATIC SCHEMATIC
(S/N A9K011001 AND ABOVE) RH JOYSTICK
RH TRAVEL 1
L3
IS
L3
O
A
(PRINTED MAY 2009) 2
29 RIGHT FRONT
V-0978
L1
L1
B
IS
O
O
ST
IS
D
R1
FRONT
P
IS
1
O
R
BACK
BOOM
3
3
BOOM SWING T
R
R.H. TRAVEL MOTOR
IS
SWING 23 19
O
CYLINDER US OPTION
A ISO/STD CONVERTER REAR LEFT
(ISO SHOWN) 3
B
4
1
V
BOOM b
2
RIGHT FRONT
a
BOOM
T1, T2 P2 P1
CYLINDER A
P
14
10
B
13 T
CENTER SWIVEL JOINT P2 32

REAR LEFT
E G1
12 C 3
LH TRAVEL 4
B B LH JOYSTICK
A
D
B A
A
C PSI
H ARM b
F
27 20
ARM a
G
A
CYLINDER G
21
18 P1
V1 A1
B S1
17 PB
V2 P2
V3 P3 A2
BUCKET b
F
BLADE CYLINDER BUCKET
a A3
CYLINDER A
31 26
HYDRAULIC PUMP
15 3 9
T T1
L.H. TRAVEL MOTOR 4
B 16
2
DIRECT TO PRESSURIZED BREATHER
T1, T2 TANK VALVE
(EXCLUDE FOR AUX b
MALE (RETURN) U.S. OPTION)
5
a
A 1
V
34
FEMALE (PRESSURE)
B
35
30 33
P2 P1 A T1
11 B
OIL COOLER
BOOST b
MAIN FILTER WITH BY-PASS

a
A 7
22
B J2 J1
SLEW MOTOR
BLADE 36
8
ENCLOSURE A1 6
A A TOP
PUMP SUPPLY
B B1
B BOTTOM
WORKING CIRCUITS
SLEW CASE DRAIN FILTER
PILOT PRESSURE b
WITH BY-PASS
SLEW LOCK VALVE 8
SYSTEM RETURN LINES a (S/N A9K011121 & Above 28
& S/N A9K111122 & Above ONLY)
DIRECT TANK RETURN 24
P3
T2
25
V-0978 (5/6/09)
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators
MS-1892-1
MS-1892-1

HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic/Hydrostatic Symbols For Excavators (Cont’d)
MC-1892-2
MS-1892-2

Glossary Of Hydraulic/Hydrostatic Symbols For Excavators (Cont’d)
MS-1892-3
MS-1892-3

Troubleshooting The Hydraulic Circuit
TROUBLESHOOTING THE HYDRAULIC CIRCUIT

PROBLEM CAUSE CORRECTION
No hydraulic operation at one or Hydraulic oil level low. Refill with correct oil.
more circuits Hydraulic pump drive coupling damaged. Replace
Hydraulic pump defective. Check, repair or replace.
Main relief valve defective. Readjust or replace.
Hydraulic power insufficient to one Main relief valve pressure setting incorrect. Readjust or replace.
or more circuits.
Hydraulic speed too slow. Hydraulic oil level or viscosity incorrect. Refill or replace.
Engine RPM reduced. Readjust or replace.
Control valve linkage defective. Check, repair or replace
Hydraulic pump volume low. Check, repair or replace.
Oil temperature too high. Oil cooler or radiator fins plugged. Clean oil cooler external
surface.
Hydraulic oil level low. Refill or replace
Non recommended hydraulic oil Replace
Relief valve excessively activated. Use proper operating
procedures.
One or more relief valves not set correctly. Test, readjust or replace.
Extreme operating conditions. High ambient
temperature (IE: enclosed structure).

Troubleshooting The Cylinder Circuit
TROUBLESHOOTING THE CYLINDER CIRCUIT

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

Troubleshooting The Swing (Upperstructure Slew) Circuit
TROUBLESHOOTING THE SWING (UPPERSTRUCTURE SLEW) CIRCUIT

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

Troubleshooting The Travel Circuit
TROUBLESHOOTING THE TRAVEL CIRCUIT

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

BOOM CYLINDER Figure 20-20-3
Testing
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.
1
Figure 20-20-1
1
P-73044
Figure 20-20-4
P-73040
Support the boom with a chain hoist (Item 1) [Figure 20-

20-1].
1
Figure 20-20-2
P-73046
3
Slide the shield down until the keyhole (Item 1) [Figure
20-20-3] in the shield lines up with the mounting stud
2 (Item 1) [Figure 20-20-4] on the cylinder.
Remove the shield.
P-73041
Remove the boom shield bolt (Item 1), washer (Item 2)

and spacer (Item 3) [Figure 20-20-2].

BOOM CYLINDER (CONT’D) Figure 20-20-7
Testing (Cont’d)
Figure 20-20-5 1
P-53168
Lower the cylinder (Item 1) [Figure 20-20-7] until it rests

P-53167 on the blade.
Start the engine and fully retract the cylinder rod (Item 2)
Remove the snap ring (Item 1) [Figure 20-20-5] and [Figure 20-20-7].
washer.
Stop the engine. Relieve hydraulic pressure.
Figure 20-20-6
WARNING
1
Hydraulic fluid escaping under pressure can have
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
P-50699
Remove the rod end pin (Item 1) [Figure 20-20-6].

BOOM CYLINDER (CONT’D)
Testing (Cont’d)
Figure 20-20-8
P-22223
Remove the hose from the base end of the cylinder. Cap
the hose (Item 1) [Figure 20-20-8].
Start the engine and retract the boom cylinder.
If there is any oil leakage from the base end fitting (Item
2) [Figure 20-20-8], remove the cylinder for repair or
replacement.

pressure.
1
Figure 20-20-9
1
P-73044
Figure 20-20-12
P-73040

20-9].
1
Figure 20-20-10
P-73046
3
Slide the shield down until the keyhole (Item 1) [Figure
20-20-11] in the shield lines up with the mounting stud
2 (Item 1) [Figure 20-20-12] on the cylinder.
Remove the shield.
P-73041
Remove the boom shield bolt (Item 1), washer (Item 2)

and spacer (Item 3) [Figure 20-20-10].

Removal And Installation (Cont’d)
Figure 20-20-13 2
1
1
2
P-53168
Lower the cylinder (Item 1) [Figure 20-20-15] until it rests

P-53167 on the blade.
Mark and remove the hoses (Item 2) [Figure 20-20-15].

Remove the snap ring (Item 1) [Figure 20-20-13] and
washer.
Figure 20-20-14
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-50699

Figure 20-20-16
1
2
P-53169
Loosen the hose clamp (Item 1). Remove the snap ring
(Item 2) [Figure 20-20-16] and washer.
Remove the pin (Item 3) [Figure 20-20-16].
Figure 20-20-17
P-53170
Remove the shims (Item 1) [Figure 20-20-17] from both

sides of the cylinder.
Remove the cylinder.

Parts Identification
1. Grease Fitting
2. Bushing
3. Plug
4. O-Ring
5. Housing
6. Nut
7. Seal
8. Piston
9. Backup Ring
10. Head
1
11. Rod Seal
12. Wiper
13. Rod 3
5
2
4
4
3 6
4
7
8
4
9
4
10
11
12
1
13
PE3417S

Disassembly
Clean the outside of the boom cylinder before 2 3

disassembly.
1
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook

MEL1075 - Adjustable Gland Nut Wrench
MEL1075-1 - Standard Pins
Hold the hydraulic cylinder over a drain pan and move

the rod in and out slowly to remove the fluid from the
cylinder. P-81066
Put the base end of the cylinder in a vise.

Remove the head and the rod assembly from the cylinder
Figure 20-20-18 [Figure 20-20-19]. Put the rod end in a vise.
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-20-19].
Figure 20-20-20
1
3
2
1
1
N-22352
Insert the adjustable gland nut wrench into the holes

(Item 1) [Figure 20-20-18] to loosen the head.
N-22355
Remove the seal (Item 1) and O-ring (Item 2) from the

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

Disassembly (Cont’d)
Figure 20-20-21
3
2 2
1
1
P-81039
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-20-

N-22356 23].
Figure 20-20-24
Remove the O-ring (Item 1) and the back-up ring (Item 2)
[Figure 20-20-21].
Remove the O-ring (Item 3) [Figure 20-20-21].

1
Figure 20-20-22
2
1
P-81067
Remove the bushing (Item 1) [Figure 20-20-24] from the

cylinder base end.
N-22357
Remove the wiper seal (Item 1) and rod seal (Item 2)

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

Assembly
3
Clean all parts in solvent and dry with compressed air.
Inspect the cylinder parts for wear or damage. Replace 1

any worn or damaged parts. 2
Always install new O-rings and seals.
Lubricate all O-rings and seals with hydraulic oil during

installation.
Use the following tools to assemble the cylinder:

N-22355
MEL1396 - Universal Seal Expander
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor Install the O-ring (Item 1) and seal (Item 2) on the piston
MEL1075 - Adjustable Gland Nut Wrench (Item 3) [Figure 20-20-26].
Figure 20-20-27
Figure 20-20-25
N-22358
P-7424
Use a ring compressor to compress the seal to the

Install the new seal on the tool and slowly stretch it until it correct size. Leave the piston in the compressor for
fits the piston [Figure 20-20-25]. approximately three minutes [Figure 20-20-27].
Allow the seal to stretch for 30 seconds before installing it

on the piston.

Assembly (Cont’d)
Figure 20-20-28
N-22359
Install the wiper seal with the wiper (Item 1) [Figure 20-
P-7427 20-30] toward the outside of the head.
Figure 20-20-31
Install the rod seal on the rod seal tool [Figure 20-20-28].
NOTE: During installation the spring side of the seal

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

2
20-28]. 3
Figure 20-20-29
N-22356
Install the O-ring (Item 1) [Figure 20-20-31].
Install the back-up ring (Item 2) and O-ring (Item 3)

[Figure 20-20-31].
P-7425
Install the rod seal in the head [Figure 20-20-29].

BOOM CYLINDER (CONT’D) Tighten the plug to 37 ft.-lb. (50 N•m) torque.
Assembly (Cont’d) Put the base end of the cylinder in a vise.
Figure 20-20-32 Figure 20-20-34
2 1
3
1
P-81066 P-81032
Install the head (Item 1) and the piston (Item 2) [Figure Insert the adjustable gland nut wrench into the holes
20-20-32]. (Item 1) [Figure 20-20-34] to tighten the head. Tighten
the head until it is flush with the end of the housing.
Grease the piston where the nut contacts the piston. Do
not get grease on the threads. Figure 20-20-35
Provide an adequate support for the cylinder before

tightening.
NOTE: Clean and dry the rod threads. Install a NEW

1
NUT with pre-applied Loctite®.
Install the nut (Item 3) [Figure 20-20-32].
Tighten the nut to 850 ft.-lb. (1153 N•m) torque.
Figure 20-20-33
P-81067
Install the bushing and seal (Item 1) [Figure 20-20-35]

on both sides of the cylinder base end.
P-81039
Install O-ring (Item 1) and plug (Item 2) [Figure 20-20-

33].

ARM CYLINDER Figure 20-21-3
Testing
1
pressure.
2
Figure 20-21-1
1
P-56033

washer.
Figure 20-21-4
P-55989

21-1].
Figure 20-21-2
1
P-56034
Start the engine and fully retract the cylinder rod (Item 1)
[Figure 20-21-4].
P-56032
Support the arm cylinder (Item 1) [Figure 20-21-2].

ARM CYLINDER (CONT’D) Start the engine and retract the cylinder.
Testing (Cont’d) If there is any leakage from the base end fitting, remove
the cylinder for repair or replacement.
WARNING
immediately.
W-2145-0290
Figure 20-21-5
P-56035
Remove the hose (Item 1) [Figure 20-21-5] from the

base end of the cylinder.
Figure 20-21-6
P-56036
Install a plug (Item 1) [Figure 20-21-6] on the hose.

ARM CYLINDER (CONT’D) Figure 20-21-9
Lower the boom/bucket and blade to the ground. 1
pressure.
2
Figure 20-21-7
1
P-56033

washer.
P-55989
IMPORTANT
Support the boom with a chain hoist (Item 1) [Figure 20- When repairing hydrostatic and hydraulic systems,
21-7]. clean the work area before disassembly and keep all
Figure 20-21-8 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
1 Figure 20-21-10
P-56032 1
Support the arm cylinder (Item 1) [Figure 20-21-8].

P-56265
Remove the hose (Item 1) and hose clamp (Item 2)

[Figure 20-21-10].

ARM CYLINDER (CONT’D)
Figure 20-21-11
P-56035
Remove the hose (Item 1) [Figure 20-21-11].
Figure 20-21-12
P-56037
Remove the snap ring (Item 1), washer and base end pin
(Item 2) [Figure 20-21-12].

ARM CYLINDER (CONT’D)
1. Grease Fitting
2. Plug
3. O-Ring
4. Housing
5. Nut
6. Seal 1
7. Piston
8. Backup Ring
9. Spacer 4
10. Head
11. Rod Seal
12. Wiper
13. Rod 3
14. Bushing 3 2
2
6
7
5
3
3
8
9
3
10
11
12 1
13
14
PE3416S

Disassembly
Clean the outside of the arm cylinder before 2 3 4

disassembly. 1

MEL1075-2 - Special Offset Pins

cylinder. P-81064

Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-21-14].
Figure 20-21-15
1
3
1
P-81032
Insert the adjustable gland nut wrench into the two holes
N-22418


Figure 20-21-16
3
2 2
1
P-81039
Remove the plug (Item 1) and O-ring (Item 2) [Figure 20-

N-22356 21-18].
Figure 20-21-19
[Figure 20-21-16].
Figure 20-21-17
2
1
1
P16562
Remove the bushing (Item 1) [Figure 20-21-19].
N-22357


Assembly 3

1
Inspect all parts for wear or damage. Replace any worn
or damaged parts. 2
Always install new seals and O-rings. Lubricate all seals

and O-rings with clean hydraulic fluid before installation.

MEL1033 - Rod Seal Installation Tool N-22418
Piston Ring Compressor
MEL1075-2 - Special Offset Pins Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-21-21].
Figure 20-21-20
Figure 20-21-22
P-7424
N-22358
Install the seal on the tool and slowly stretch it until it fits
the piston [Figure 20-21-20]. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
Allow the seal to stretch for 30 seconds before installing it three minutes [Figure 20-21-22].
on the piston.

Assembly (Cont’d)
Figure 20-21-23
N-22359
Figure 20-21-26

1
Rotate the handles to collapse the rod seal [Figure 20-
21-23]. 2
3
Figure 20-21-24
N-22356

[Figure 20-21-26].
P-7425

ARM CYLINDER (CONT’D) Tighten the plug to 37 ft.-lb. (50 N•m) torque.
Assembly (Cont’d) Put the base end of the hydraulic cylinder in a vise.
Figure 20-21-27 Figure 20-21-29
3 2 1
4
1
P-81064 P-81032
Install the head (Item 1), spacer (Item 2) and the piston Insert the adjustable gland nut wrench into the two holes
(Item 3) [Figure 20-21-27] on the rod as shown. (Item 1) [Figure 20-21-29] to tighten the head. Head to
be torqued until flush with the end of the housing.

tightening.

Figure 20-21-28
1
P-81065
Install the bushing (Item 1) [Figure 20-21-30]. The

bushing must be aligned with the grease channel in the
rod end of the cylinder.
P-81039
Install O-ring (Item 1) and plug (Item 2) [Figure 20-21-

28].

BOOM SWING CYLINDER Figure 20-22-2
Testing
pressure.
Figure 20-22-1
P-55567
Support the rod end of cylinder [Figure 20-22-2].
P-55559

washer.
Remove the pivot pin (Item 2) [Figure 20-22-1].
Lower the control console and fasten the seat belt. Start
the engine and retract the boom swing cylinder.
Stop the engine. With the key in the ON position, move

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

BOOM SWING CYLINDER (CONT’D) Figure 20-22-4
Testing (Cont’d)
WARNING
Hydraulic fluid escaping under pressure can have 2
physician familiar with this injury is not received P-22221
immediately.
W-2145-0290
Install a cap (Item 1) [Figure 20-22-4] on the fitting and
tighten.
Figure 20-22-3
Lower the control console and fasten seat belt. Start the
engine and retract the boom swing cylinder.
If there is any leakage from the base end hose (Item 2)

[Figure 20-22-4] on the cylinder, remove the cylinder for
1 repair or replacement.
P-22220
Remove the boom swing cylinder base end hose (Item 1)

[Figure 20-22-3] at the hydraulic control valve.

BOOM SWING CYLINDER (CONT'D) Figure 20-22-6
pressure.
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
P-55557
tubelines and ports to keep dirt out. Dirt can quickly Remove the rod end hose (Item 1) [Figure 20-22-6] and
damage the system. orifice.
I-2003-0888
Figure 20-22-7
Remove the floor mat and floor plate. (See Removal And
Installation (Canopy Equipped Excavators) on Page 40-
110-1.) or (See Removal And Installation (Cab Equipped
Excavators) on Page 40-110-2.) 1
Figure 20-22-5
P-55558
1 Remove the base end hose (Item 1). Cut and remove the
tie strap (Item 2) [Figure 20-22-7].
NOTE: If the machine is equipped with a cab heater,

P-22217
access the base end hose from in front of the
floor pan (Item 2) [Figure 20-22-7].
washer.

BOOM SWING CYLINDER (CONT'D)
Figure 20-22-8
P-22956
Remove the bolt, washer and spacer (Item 1) [Figure 20-

22-8].
Figure 20-22-9
P-56266
Move the cylinder forward. Remove the hose (Item 1)

[Figure 20-22-9].

BOOM SWING CYLINDER (CONT'D)
1. Housing
2. Plug
3. O-Ring
4. Nut
5. Seal
6. Piston
7. Backup Ring 2
8. Head 3
9. Rod Seal
10. Wiper Seal
11. Rod
12. Bushing 1 2
13. Grease Fitting 3
4
3
5
6
3
7
3
8
9
10
11
12
13
PE3419S

BOOM SWING CYLINDER (CONT'D) Figure 20-22-11
Disassembly
3
Clean the outside of the boom swing cylinder before 2
disassembly. 1


cylinder. P-81063

Remove the head and rod assembly from the cylinder
3) [Figure 20-22-11].
Figure 20-22-12
1
3
2
1
1
P-81032
N-22367


Figure 20-22-13
1
2
1
2
1
P-81038
Remove plug (Item 1) and O-ring (Item 2) [Figure 20-22-

N-22356 15].
Figure 20-22-16
Remove the O-rings (Item 1) and the back-up ring (Item
2) from the head (Item 3) [Figure 20-22-13].
Figure 20-22-14
2
1
P-81065

N-22357


Assembly
3
Inspect all parts for wear or damage. Replace any worn 1

or damaged parts. 2


MEL1075-1 - Standard Pins Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-22-18].
Figure 20-22-17
Figure 20-22-19
P-7424
N-22358
on the piston.

Assembly (Cont’d)
Figure 20-22-20
N-22359
Figure 20-22-23

4
Rotate the handles to collapse the rod seal [Figure 20- 1

22-20]. 2
3
Figure 20-22-21
N-22356
Install the back-up ring (Item 2) and O-ring (Item 3) on

the head (Item 4) [Figure 20-22-23].
P-7425

BOOM SWING CYLINDER (CONT’D) Tighten the plug to 37 ft.-lb. (50 N•m) torque.
Figure 20-22-24 Figure 20-22-26
2 1
3
1
1
P-81063 P-81032
Install the head (Item 1) and the piston (Item 2) [Figure Insert the adjustable gland nut wrench into the two holes
20-22-24] on the rod as shown. (Item 1) [Figure 20-22-26] to tighten the head. Head to

tightening.

Figure 20-22-25
1
P-81065

P-81039
Install the O-ring (Item 1) and plug (Item 2) [Figure 20-

22-25].

BUCKET CYLINDER Figure 20-23-3
Testing
pressure.
Figure 20-23-1
1
P-22306
Remove the link (Item 1) [Figure 20-23-3].
Figure 20-23-4
N-23184
Support the boom using a chain hoist [Figure 20-23-1].
Figure 20-23-2
1
P-22307
1
the engine and retract the bucket cylinder [Figure 20-23-
4].
2
P-22305
Remove the retaining rings (Item 1), washers and plate

(Item 2) [Figure 20-23-2].

BUCKET CYLINDER (CONT’D) Figure 20-23-6
Testing (Cont’d)
WARNING 1
immediately.
W-2145-0290 P-22309
Figure 20-23-5 Install a plug (Item 1) [Figure 20-23-6] on the hose fitting
and tighten.
the engine and retract the bucket cylinder.
If there is any leakage from the base end fitting on the

1 bucket cylinder, remove the cylinder for repair or
replacement.
P-22308
Disconnect the bucket cylinder base end hose (Item 1)

[Figure 20-23-5].

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

the engine.
pressure.
IMPORTANT
P-22306

Figure 20-23-9
damage the system.
I-2003-0888
Install a chain hoist to the boom lift point.
Figure 20-23-7
1 3
1
2
1
P-6321
2
Disconnect the two hoses (Item 1) [Figure 20-23-9] from
the bucket cylinder.
P-22305 Remove the snap ring (Item 2) and washer (Item 3)

[Figure 20-23-9] from the cylinder base end pin.
Remove the snap rings (Item 1), washers and plate (Item Remove the cylinder base end pin.
2) [Figure 20-23-7].

BUCKET CYLINDER (CONT’D)
1. Grease Fitting
2. Plug
3. O-Ring
4. Housing
5. Nut
6. Seal
7. Piston 2
8. Piston 3
9. Head
1
10. Rod Seal
11. Wiper
12. Rod
13. Bushing
4
5
3
6
7
3
2
3
8
3
9 12
1
10
11
13
PE3418S

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


cylinder. N-22436
Figure 20-23-10
[Figure 20-23-11]. Put the rod end in a vise.
3) [Figure 20-23-11].
1
Figure 20-23-12
2
1 1
P-81032
N-22414


Figure 20-23-13
3
2 2
1
P-81039

N-22356 23-15].
Figure 20-23-16
[Figure 20-23-13].
Figure 20-23-14
1
1
P-81065
N-22357


Assembly
3

or damaged parts. 2


MEL1075-2 - Special Offset Pins Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-23-18].
Figure 20-23-17
Figure 20-23-19
P-7424
N-22358
on the piston.

Assembly (Cont’d)
Figure 20-23-20
N-22359
Figure 20-23-23

1
23-20]. 2
3
Figure 20-23-21
N-22356

[Figure 20-23-23].
P-7425

BUCKET CYLINDER (CONT’D) Tighten the plug to 37 ft.-lb. (50 N•m) torque.
Figure 20-23-24 Figure 20-23-26
1
2
3
1
N-22436 P-81032
Install the head (Item 1) and the piston (Item 2) [Figure Insert the adjustable gland nut wrench into the two holes
20-23-24] on the rod as shown. (Item 1) [Figure 20-23-26] to tighten the head. Head to

tightening.

Figure 20-23-25
1
P-81065

P-81039

23-25].

BLADE CYLINDER Figure 20-24-3
Testing
move the blade control lever to relieve hydraulic
pressure.
Figure 20-24-1
1
3
P-22249
Support the cylinder and remove the pin (Item 1) [Figure

20-24-3].
2
Figure 20-24-4
1
3
P-22247
Remove the two nuts (Item 1) [Figure 20-24-1] from the

studs.
Remove the two bolts and nuts (Item 2) [Figure 20-24-1]

from the cylinder shields.
Remove the shields (Item 3) [Figure 20-24-1].
Figure 20-24-2 P-22250
the engine and retract the blade cylinder [Figure 20-24-
4].

1
P-22248

washer from the cylinder rod end.

BLADE CYLINDER (CONT’D) Figure 20-24-6
Testing (Cont’d)
WARNING
physician familiar with this injury is not received 1
immediately.
W-2145-0290
P-22251
Figure 20-24-5
Install a plug (Item 1) [Figure 20-24-6] on the hose fitting
and tighten.
Lower control console and fasten seat belt. Start the

engine and retract the blade cylinder.
If there is any leakage from the base end fitting on the

cylinder, remove the cylinder for repair or replacement.
P-22252
Remove the base end hose (Item 1) [Figure 20-24-5].

move the blade control lever to relieve hydraulic
pressure.
Figure 20-24-7
1
3
P-22249
Support the cylinder and remove the pin (Item 1) [Figure

20-24-9].
2
Figure 20-24-10
1
3
P-22247 1
Remove the nuts (Item 1) [Figure 20-24-7] from the

studs. 2
Remove the bolts and nuts (Item 2) [Figure 20-24-7]

from the cylinder shields.
Remove the shields (Item 3) [Figure 20-24-7]. 1

3
Figure 20-24-8 P-22250
Remove the hoses (Item 1) [Figure 20-24-10].
Remove the base end snap ring and washer (Item 2)

[Figure 20-24-10].
Remove the base end pin (Item 3) [Figure 20-24-10].

1
P-22248

washer from the cylinder rod end.

BLADE CYLINDER (CONT’D)
1. Grease Fitting
2. Plug
3. O-Ring
4. Housing
5. Nut
6. Seal
7. Piston
8. Backup Ring
9. Head
10. Rod Seal 1
4
11. Wiper 2
12. Rod 3
5
3
6
3
2
7
3
8
3
9 1
10
11
12
PE3420S

Disassembly
Clean the outside of the blade cylinder before

disassembly. 3
2
Use the following tools to disassemble the cylinder: 1


cylinder. P-81090

3) [Figure 20-24-12].
Figure 20-24-13
1
2
1
1
P-81032
N-22414


Figure 20-24-14
3
2 2
1
P-81039

N-22356 24-16].

[Figure 20-24-14].
Figure 20-24-15
N-22357


Assembly
3

or damaged parts. 2


MEL1075-1 - Standard Pins Install the O-ring (Item 1) and seal (Item 2) on the piston
(Item 3) [Figure 20-24-18].
Figure 20-24-17
Figure 20-24-19
P-7424
N-22358
on the piston.

Assembly (Cont’d)
Figure 20-24-20
N-22359
Figure 20-24-23

1
24-20]. 2
3
Figure 20-24-21
N-22356

[Figure 20-24-23].
P-7425

BLADE CYLINDER (CONT’D) Tighten the plug to 37 ft.-lb. (50 N•m) torque.
Figure 20-24-24 Figure 20-24-26
1
2
3 1
1
P-81090 N-22442
Install the head (Item 1) and piston (Item 2) [Figure 20- Insert the adjustable gland nut wrench into the two holes
24-24] on the rod as shown. (Item 1) [Figure 20-24-26] to tighten the head. Head to
not get grease on the threads.

tightening.

Figure 20-24-25
P-81039

24-25].

CLAMP CYLINDER Figure 20-25-3
Testing
Figure 20-25-1
2
1
N-23268
1
Disconnect the hydraulic hose (Item 1) [Figure 20-25-3]
N-15514 from the base end of the cylinder.
Cap the hose (Item 1) [Figure 20-25-3].

Remove the snap ring and washer (Item 1) [Figure 20-
25-1] from the clamp cylinder pin. Start the and retract the cylinder.
Remove the pin from the rod end of the clamp cylinder If there is any oil leakage from the base end fitting (Item
[Figure 20-25-1]. 2) [Figure 20-25-3] on the cylinder, remove the cylinder
for repair or replacement.
Figure 20-25-2
N-23267
Start the engine and retract the clamp cylinder (Item 1)

[Figure 20-25-2].
Stop the engine.

CLAMP CYLINDER (CONT'D)
Figure 20-25-4
N-15514

25-4] from the cylinder pin.
Remove the pin from the rod end of the cylinder [Figure
20-25-4].
Figure 20-25-5
2
1
N-23274
Disconnect the quick couplers (Item 1) [Figure 20-25-5].

25-5].
Remove the base end cylinder pin [Figure 20-25-5].

1. Grease Fitting
2. Plug
3. O-Ring
4. Housing
5. Nut
6. Seal
7. Piston
8. Backup Ring 1
9. Head
10. Rod Seal
11. Wiper 4
12. Rod
3
2
5
6
3 3
2
7
3
8
3
9
10
11
12
PE3415S

CLAMP CYLINDER (CONT'D) Figure 20-25-7
Disassembly
NOTE: The drawings may appear different. The

procedure is the same.
Clean the outside of the clamp cylinder before

disassembly.
The following tools will be needed to disassemble and

assemble the cylinders:
1. MEL1075 - Adjustable Gland Nut Wrench

2. MEL1074 - O-Ring Seal Hook
3. MEL1396 - Seal Installation Tool B-7001
4. MEL1033 - Rod Seal Installation Tool
Put the base end of the hydraulic cylinder in a drain pan. Remove the rod assembly from the cylinder housing
[Figure 20-25-7].
Move the rod in and out to remove the fluid from the
cylinder. Move the rod slowly so the fluid will go directly Remove the cylinder housing from the vise.
into the drain pan.
Put the rod end in the vise.
Figure 20-25-8
Figure 20-25-6
B-13816
B-7000
Loosen the nut from the piston end of the rod [Figure 20-
Use the adjustable gland nut wrench to loosen the head 25-8].
[Figure 20-25-6].

Disassembly (Cont'd)
Figure 20-25-9
1 2
B-7005
Remove the wiper seal [Figure 20-25-11].

B-13817
Figure 20-25-12
Remove the piston (Item 1) and head (Item 2) [Figure

20-25-9].
Figure 20-25-10
B-7006
Remove the oil seal from the head [Figure 20-25-12].
B-13743
Remove the O-ring and back-up ring from the head with
seal hook [Figure 20-25-10].

Figure 20-25-13
B-3689
Cut the old teflon seal and remove the seal from the
piston [Figure 20-25-13].
Figure 20-25-14
B-3703
Remove the O-ring from the piston [Figure 20-25-14].

Assembly

or damaged parts.

Figure 20-25-15
B-12813
Install the seal on the piston [Figure 20-25-17].
Figure 20-25-18
B-12812
Install the O-ring on the piston [Figure 20-25-15].
NOTE: Do not overstretch the seal.
Figure 20-25-16
B-12811
Use a ring compressor to compress the seal to the

correct size [Figure 20-25-18].
Leave the piston in the ring compressor for three

minutes.
B-12809
Install the seal on the tool and stretch it until it fits the
piston [Figure 20-25-16].
Allow the seal to stretch for 30 seconds before removing

it from the tool.

Assembly (Cont'd)
Figure 20-25-19
O-Ring
B-3682
Side
Install the wiper seal with the lip toward the outside of the
B-3702 head [Figure 20-25-21].
Figure 20-25-22
Install the oil seal on the rod seal tool [Figure 20-25-19].
NOTE: The O-ring side of the oil seal goes toward the
inside of the cylinder.
Figure 20-25-20
1
B-7008
Install the O-ring (Item 1) [Figure 20-25-22] on the head.
B-3671
Install the oil seal in the head [Figure 20-25-20].

Assembly (Cont'd)
2
Figure 20-25-23
B-7198
1
Inspect the beveled edge of the rod for nicks or sharp

B-7200 edges (Item 1) [Figure 20-25-25]. Remove these with a
file prior to installing the head on the rod or damage to
the seals may occur.
Install the back-up ring (Item 1) [Figure 20-25-23] on the
head. Install the head (Item 2) [Figure 20-25-25] on the rod.
Figure 20-25-24 Install the piston (Item 3) [Figure 20-25-25] on the rod.
Clean and dry the cylinder rod threads. Grease the

shoulder of the cylinder rod.
1
B-7007
Install the O-ring (Item 1) [Figure 20-25-24] on the head.
Apply grease to the inside of the head and to the lips of

the seals.

Assembly (Cont'd)
Figure 20-25-26
B-7013
Apply oil to the seal surface of the housing [Figure 20-

1 25-27].
B-7002
Figure 20-25-28
Tighten the nut (Item 1) [Figure 20-25-26] to 850 ft.-lb.
(1153 N•m) torque.
Inspect the inside of the cylinder housing for nicks and

scratches. If the cylinder housing has minor scuffing the
cylinder housing can be honed. Use a flexible hone and
lubricate with oil during the honing process.
The following hones can be ordered from OTC Service

Tools:
MEL1418 - 2 in.
OEM6275 - 2 3/4 in. - 3 in.
OEM6270 - 3 in. - 3 1/2 in.
OEM6271 - 3 1/2 in. - 4 in. B-7012
Thoroughly wash the inside of the housing after the

honing process. Apply oil to the Teflon seal on the piston [Figure 20-25-
28].

Assembly (Cont’d)
Figure 20-25-29
B-7000
Use the adjustable gland nut wrench to tighten the head

B-7001 [Figure 20-25-31].
NOTE: Tighten gland until it is flush with the end of

Install the rod assembly in the housing [Figure 20-25- the housing.
29].
Move rod in and out of cylinder housing and make sure
Figure 20-25-30 that it moves freely.
B-7014
Apply oil to the seals on the head [Figure 20-25-30].
Apply oil to the threads of the head.

MAIN RELIEF VALVES The following tools will be needed for the testing at the
diagnostic coupler:
Testing And Adjusting The Main Relief Valves
MEL1355 - Test Kit includes the following:
All testing is done with the hydraulic oil at operating MEL1355-3 - 5000 PSI Gauge
temperature and the at high idle speed. (See Engine on MEL1355-12 - Coupler
Page SPEC-10-4.) MEL1355-9 - Thermometer
Figure 20-30-1 System Pressures At Gauge Port Specifications
TEST CONDITIONS
1. Engine High Idle Speed
2. Warm oil over relief function to minimum 150° F (66 °

2 C). Cycle all functions during warm up procedure.
3 Warm oil until the pressure build-up valve stabilizes
1 near its target pressure.
3. Activate function until cylinder movement stops. Hold

over relief for 5 - 10 seconds.
Record pressure.
P-36740
There is one diagnostic coupler (Item 1) that is used to

check all three main relief valves. The second coupler
(Item 2) is used in assembly of the excavator. The third
coupler (Item 3) [Figure 20-30-1] is used to check the
pressure reducing valve.
FUNCTION TO CIRCUIT TEST TARGET ACCEPTABLE

SYSTEM CHECK ENGAGE PRESSURIZED PORT (PSI) RANGE (PSI)
JOYSTICK PILOT PRESSURE ANY JOYSTICK JOYSTICK PILOT GI 428 406 - 450
FUNCTION
PRESSURE BUILD - UP VALVE NONE - CONSOLE P3 G 450 308 - 520
DOWN
SYSTEM BY - PASS NONE - CONSOLE DUMP TO TANK G 60 MAX ALLOWABLE
UP 100
MAIN RELIEF ON MANIFOLD SLEW AND ARM P3 & P2 G 3800 3700 - 3850
BLOCK
MAIN RELIEF ON CONTROL BOOM SWING P1 G 2650 2550 - 2700
VALVE - FRONT
MAIN RELIEF ON CONTROL ARM P3 & P2 G 2900 2800 - 2950
VALVE - REAR
SWING MOTOR - CROSS PORT SLEW RIGHT P3 G 2450 2300 - 2600
RELIEF
SWING MOTOR - CROSS PORT SLEW LEFT P3 G 2450 2300 - 2600
RELIEF

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

(Cont’d)

1
Figure 20-30-2
1 P-50545
Connect the test gauge coupler and 5000 PSI (345 bar)
gauge to the diagnostic coupler (Item 1) [Figure 20-30-
3].
P-50540 Front Relief Valve (Right Hand Travel, Boom Swing and
Boom Valve Sections)
Connect the test gauge coupler and 1000 PSI (69 bar) Engage the boom swing circuit over relief and record the
gauge from the test kit to the diagnostic coupler (Item 1) pressure.
[Figure 20-30-2].
Figure 20-30-4
Lower the control console and fasten the seat belt.
Start the engine and run at full RPM until hydraulic fluid is
at operating temperatures 150° F (66° C).
With the console lowered, and the engine at full RPM

there is pressure buildup valve pressure of 600 PSI (41 1
bar).
Remove the gauge.
P-50541
The main relief valve (Item 1) [Figure 20-30-4] pressure

should be as follows:
A target pressure of 2650 PSI (183 bar) with an

acceptable range of 2550 - 2700 PSI (176 - 186 bar).
Stop the engine.

MAIN RELIEF VALVES (CONT’D) Rear Relief Valve (Left Hand Travel, Arm, Bucket And
Auxiliary Valve Sections)
(Cont’d) Engage the arm retract circuit over relief and record the
pressure.
Figure 20-30-5
Figure 20-30-6
P-50542
P-50543
If adjustment is needed, loosen the nut (Item 1) [Figure

20-30-5]. The main relief valve (Item 1) [Figure 20-30-6] pressure
Turn the adjustment screw (Item 2) [Figure 20-30-5]
clockwise to increase the pressure or counterclockwise A target pressure of 2900 PSI (200 bar) with an
to decrease the pressure. acceptable range of 2800 - 2950 PSI (193 - 203 bar).
NOTE: 1/4 turn is approximately 100 PSI (6,9 bar). Stop the engine.
Tighten the nut (Item 1) [Figure 20-30-5].
Retest the main relief valve after adjustment.

MAIN RELIEF VALVES (CONT’D) Figure 20-30-8

(Cont’d)
Figure 20-30-7
1
P-35846
1
The main relief valve (Item 1) [Figure 20-30-8] pressure

P-50544 acceptable range of 3700 - 3850 PSI (255 - 266 bar).
Stop the engine.

If adjustment is needed, loosen the nut (Item 1) [Figure
20-30-7].
Figure 20-30-9
clockwise to increase the pressure or counterclockwise
to decrease the pressure.
NOTE: 1/4 turn is approximately 100 PSI (6,9 Bar). 2
Retest the main relief valve after adjustment. 1
Manifold Relief Valve (Boost, Blade And Upperstructure

Slew Valve Sections)
P-35847
Engage the upperstructure slew lock lever to prevent the
upperstructure from turning. (See Operation on Page 10-
11-1.) Engage the slew circuit and arm retract circuit over If adjustment is needed, loosen the nut (Item 1) [Figure
relief at the same time and record the pressure. 20-30-9].

NOTE: 1/4 turn is approximately 100 PSI (6,9 Bar).
Retest the main relief valve after adjustment.

PORT RELIEF VALVES Arm Port Relief set at:
Rod End (Item 3) [Figure 20-31-1] & [Figure 20-31-
Testing And Adjusting The Port Relief Valves 2] 2900 PSI (200 bar)
Base End (Item 4) [Figure 20-31-1] & [Figure 20-31-
Figure 20-31-1 2] 2900 PSI (200 bar)
Bucket Port Relief set at:

2] 3335 PSI (230 bar)
2] 2900 PSI (200 bar)
Blade Port Relief set at:

5 3 2] 3335 PSI (230 bar)
2
When testing the port relief valves with a hydraulic hand
7 6 4 pump, slowly pressurize the valve. If the hand pump is
1
pumped fast, the pressure will be altered by as much as
P-35960 50 PSI (3,5 bar).
When testing port relief valves with a hydraulic hand

Figure 20-31-2 pump, valve crack pressure should be observed.
For 2900 PSI (200 bar) relief valves, crack pressure is

2765 ± 50 PSI (191 ± 3,5 bar).
2
5 For 3335 PSI (230 bar) relief valves, crack pressure is
3 3220 ± PSI (222 ± 3,5 bar).
1 A portable hydraulic hand pump will be used to test the

work port relief valves. The hand pump must have clean
7 6 hydraulic fluid that is compatible with the Bobcat
4
hydraulic fluid.
P-33865
Boom Port Relief set at:

2] 3335 PSI (230 bar)
2] 3335 PSI (230 bar)

PORT RELIEF VALVES (CONT’D)
Testing And Adjusting Port Relief Valves (Cont’d)
Figure 20-31-3
P-35965
Install the hand pump hose and a pressure gauge

(minimum of 5000 PSI [345 bar]) into the valve section
work port in which the port relief valve is located [Figure
20-31-3]. Slowly pressurize this section with the hand
pump until the port relief valve opens and make a note of
the pressure reading.
Relief valves are non-adjustable. When testing the relief

valves and pressure is not per the above pressure
settings, remove and replace the relief valve.
WARNING
W-2019-0907

CROSSPORT RELIEF VALVES The following tools will be needed for the testing at the
diagnostic coupler:
Testing And Adjusting The Crossport Relief Valves
MEL1355 - Test Kit includes the following:
All testing is done with the hydraulic oil at operating MEL1355-3 - 5000 PSI Gauge
temperature and the at high idle speed. See Engine on MEL1355-12 - Coupler
Page SPEC-10-4 MEL1355-9 - Thermometer
Figure 20-32-1 System Pressures At Gauge Port Specifications
TEST CONDITIONS
1. Engine High Idle Speed
2. Warm oil over relief function to minimum 150° F (66°

C). Cycle all functions during warm up procedure.
2
Warm oil until the pressure build-up valve stabilizes
3 near its target pressure.
1
3. Activate function until cylinder movement stops. Hold
over relief for 5 - 10 seconds.
Record pressure.
P-36740
There is one diagnostic coupler (Item 1) that is used to

check the crossport relief valves. The second coupler
(Item 2) is used in assembly of the excavator. The third
coupler (Item 3) [Figure 20-32-1] is used to check the
pressure reducing valve.
FUNCTION TO CIRCUIT TEST TARGET ACCEPTABLE

SYSTEM CHECK ENGAGE PRESSURIZED PORT (PSI) RANGE (PSI)
JOYSTICK PILOT PRESSURE ANY JOYSTICK JOYSTICK PILOT GI 428 406 - 450
FUNCTION
PRESSURE BUILD - UP VALVE NONE - CONSOLE P3 G 450 308 - 520
DOWN
SYSTEM BY - PASS NONE - CONSOLE DUMP TO TANK G 60 MAX ALLOWABLE
UP 100
MAIN RELIEF ON MANIFOLD SLEW AND ARM P3 & P2 G 3800 3700 - 3850
BLOCK
MAIN RELIEF ON CONTROL BOOM SWING P1 G 2650 2550 - 2700
VALVE - FRONT
MAIN RELIEF ON CONTROL ARM P3 & P2 G 2900 2800 - 2950
VALVE - REAR
SWING MOTOR - CROSS PORT SLEW RIGHT P3 G 2450 2300 - 2600
RELIEF
SWING MOTOR - CROSS PORT SLEW LEFT P3 G 2450 2300 - 2600
RELIEF

CROSSPORT RELIEF VALVES (CONT’D) If the relief valves need adjustment, remove the floor mat
and floor panel.(See FLOOR MAT AND FLOOR PLATE
Testing And Adjusting The Crossport Relief Valves on Page 40-110-1.)
(Cont’d)
Figure 20-32-3
Figure 20-32-2
P-50552
1
P-36744 Remove the two bolts (Item 1) [Figure 20-32-3].
Figure 20-32-4
Connect the test gauge coupler and 5000 PSI (345 bar)
gauge from the test kit to the diagnostic coupler (Item 1)
[Figure 20-32-2].
2
Lower control console and fasten the seat belt.
Start the engine and run at full RPM until the hydraulic
fluid is at a minimum operating temperature of 150° F
(66° C).
1 1
With the console lowered, and the engine at full RPM
there is pressure buildup valve pressure of 600 PSI (42 1 1
bar).
The crossport relief valves are preset to 1700 PSI (117 P-50432
bar). Adding the pressure buildup valve pressure raises
the gauge readings.
Remove the four bolts (Item 1) and vent assembly (Item
Engage the upperstructure slew lock to prevent the 2) [Figure 20-32-4].
upperstructure from turning. (See Operation on Page 10-
11-1.)
Engage the slew circuit to the right, over the relief and
record the pressure.
Repeat the procedure to the left and record the pressure.
The crossport relief valve pressure should be as follows:

acceptable range of 2300 - 2600 PSI (159 - 179 bar).
Stop the engine.

CROSSPORT RELIEF VALVES (CONT’D) Figure 20-32-7

(Cont’d)
Figure 20-32-5
1 1
P-50554
Slide the plate/right foot pedal assembly towards the

center of the cab to access the relief valves (Item 1)
P-50431 [Figure 20-32-7].
Remove the right side cover stop bolt and nut (Item 1)
[Figure 20-32-5].
Figure 20-32-6
P-50430
Open the right side cover and remove the bolt (Item 1)
[Figure 20-32-6].
NOTE: Canopy equipped excavators have two bolts

installed.

CROSSPORT RELIEF VALVES (CONT’D) Figure 20-32-9

(Cont’d)
Figure 20-32-8
1
P-50425
Loosen the nut (Item 1) [Figure 20-32-9].

1
P-50553 Turn the adjustment screw (Item 2) [Figure 20-32-9]
to decrease pressure.
The front relief valve (Item 1) [Figure 20-32-8]. is slew
left. NOTE: 1/4 turn is 100 PSI (6,9 bar)
The rear relief valve (Item 2) [Figure 20-32-8]. is slew Tighten the nut (Item 1) [Figure 20-32-9], reinstall the
right. right floor panel and retest the crossport relief valves.
NOTE: Left and right as viewed from the operator’s

seat.

PRESSURE REDUCING VALVE Figure 20-33-2
Testing And Adjusting The Pressure Reducing Valve
The pressure reducing valve supplies lower hydraulic

pressure to joysticks.
The following tools will be needed for testing the pressure

reducing valve:
MEL 1355 - Test Kit includes the following

MEL 1355-2 - 1000 PSI Gauge
MEL 1355-9 - Thermometer
Figure 20-33-1
P-50419
Install a 1000 PSI (69 Bar) gauge on the diagnostic port

(Item 1) [Figure 20-33-2].
Lower the control console and fasten the seat belt.

1
Start the engine and warm the hydraulic fluid to a
minimum operating temperature of 150° F (66° C).
With the hydraulic fluid at operating temperature, run the

engine at full RPM.
P-36740 Engage the bucket curl circuit and fully curl the bucket.
The pressure reducing valve pressure should be as

The diagnostic port (Item 1) [Figure 20-33-1] located on follows:
the end of the manifold block will be used to check the
pressure reducing valve. A target pressure of 428 PSI (26 Bar) with an acceptable
range of 406 - 450 PSI (28 - 31 Bar).
With the engine off, and the key in the run position, lower
the left console and move both joysticks to relieve Move the engine speed control to low idle speed.
hydraulic pressure.
Stop the engine.
With the engine off, and the key in the run position, lower
the left console and move both joysticks to relieve
hydraulic pressure.

PRESSURE REDUCING VALVE (CONT’D) If the pressure is still incorrect, relieve hydraulic pressure
and remove the pressure reducing valve from the
Testing And Adjusting The Pressure Reducing Valve manifold assembly for inspection or repair.
(Cont’d)
If the amount of oil pressure is at or over the service
Figure 20-33-3 limits, it is an indication of worn O-rings and back-up
rings on the pressure reducing valve or a stuck pressure
reducing valve.
Inspect the port of the pressure reducing valve (Item 1)

[Figure 20-33-4] on the manifold assembly to verify no
damage. If damaged replace the manifold assembly.
Figure 20-33-5
P-50421
If adjustment is needed, remove the cap (Item 1) [Figure

20-33-3].
P-35527
Figure 20-33-4
Inspect the O-rings and back-up rings on the pressure

reducing valve [Figure 20-33-5]. If O-rings and back-up
2 rings are worn or damaged, replace O-rings and back-up
rings.
Re-install the pressure reducing valve in the manifold

assembly.
Repeat the pressure reducing valve test.

1 If the O-rings and back-rings were not worn or damaged
and the correct pressure could not be achieved, replace
the pressure reducing valve.
P-50420
Loosen the nut (Item 1) [Figure 20-33-4].

NOTE: 1/2 turn is approximately 30 PSI (2.1 Bar).
Retest the pressure reducing valve after adjustment.

HYDRAULIC CONTROL VALVE Figure 20-40-1
Description
The hydraulic control valve has two main relief valves.

2
The front main relief valve operates at 2650 PSI (183
Bar), the rear main relief valve operates at 2900 PSI (200
Bar). The boom, arm, bucket and blade sections have
2900 PSI (200 Bar) and/or 3335 PSI (230 Bar) work port
1 1
reliefs.
Stop the engine. P-55425
With the engine off, turn the start key to the ON position
and move both hydraulic control levers to relieve Remove the bolts (Item 1) and louver (Item 2) [Figure
hydraulic pressure. 20-40-1].
Figure 20-40-2
IMPORTANT
damage the system. 1
I-2003-0888
Drain the hydraulic reservoir. (See Replacing The

Hydraulic Oil on Page 10-100-2.)
Remove the right console cover. (See Console Cover P-56495

Removal And Installation on Page 40-50-1.)
Remove the bolts (Item 1) [Figure 20-40-2] and nuts
from the stop.
Mark all tubelines and hoses for proper installation.

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-40-5
Figure 20-40-3
1 1
P-56498

P-56496
Figure 20-40-6
1 1 1
Figure 20-40-4
1 1
P-56499

P-56497

Figure 20-40-7
1 1
P-56502

P-56500
Figure 20-40-10
Remove the tubeline (Item 1) [Figure 20-40-7].
Figure 20-40-8
1 1
1 1
1
P-56503
Disconnect the wire harness (Item 1) [Figure 20-40-10]

P-56501 from the left and right travel switches.

Figure 20-40-11
2
P-56506
Remove the cotter pin (Item 1), clevis pin (Item 2) and
P-56504 linkage (Item 3) [Figure 20-40-13].
Figure 20-40-14
Remove the tubeline (Item 1) [Figure 20-40-11].
Figure 20-40-12
2 1
1
P-56507
P-56505 Remove the cotter pins and clevis pins (Item 1) [Figure
20-40-14].
Remove the nut (Item 1) and bolt from the blade control
linkage (Item 2) [Figure 20-40-12].
Turn the blade control linkage 90°.

Figure 20-40-15
1
1
P-56510

P-56508
Figure 20-40-18
Remove the hoses (Item 1) [Figure 20-40-15]. 1
Figure 20-40-16
P-56520
1
1
Remove the nuts (Item 1) from the fuel fill (Item 2)
P-56509 [Figure 20-40-18].
Relocate the fuel fill.


Figure 20-40-19
1 P-55767
Remove the bolts (Item 1) from the windshield washer

P-56512 fluid reservoir mount bracket (Item 2) [Figure 20-40-21]
(if equipped). Relocate the reservoir and mount.
Remove the nut (Item 1) [Figure 20-40-19], washer and Figure 20-40-22
rubber washer from the control valve.
Figure 20-40-20
1
P-56514
P-56513 Remove the nut (Item 1) [Figure 20-40-22], washer and

rubber washer.
Remove the nut (Item 1) [Figure 20-40-20], washer and

rubber washer.

Figure 20-40-23 1
1 1
P-56516
Install a sling (Item 1) [Figure 20-40-25] around the

P-56515 control valve and connect to a chain hoist.
Figure 20-40-26
Loosen the nuts (Item 1) [Figure 20-40-23].
Figure 20-40-24
1 1
P-56517
P-55769 Remove the nuts (Item 1) [Figure 20-40-26], washers,

and rubber washers.
NOTE: Access the head of the bolt (Item 1) [Figure 20-

40-24] through the right console in the cab to
loosen the nut (Item 2) [Figure 20-40-23].

HYDRAULIC CONTROL VALVE (CONT’D)
Figure 20-40-27
P-56518
Raise the hoist and remove the control valve from the
excavator [Figure 20-40-27].

Control Valve Identification
Item Description
1. Right Travel Section
2. Boom Swing Section
3. Boom Section
4. Left Travel Section
5. Arm Section
6. Bucket Section
7. Auxiliary Section
8. Boost Section
9. Blade Section
10. Slew Section
11. Main Relief Valve 2650 PSI (183 Bar)
12. Main Relief Valve 2900 PSI (183 Bar)
13. Port Relief Valve 3335 PSI (230 Bar)
14. Port Relief Valve 2900 PSI (200 Bar)
13 14 13
12
11
10 9 8 7 6 5 4 3 2 1
13
14 14 13
MS-1118

Disassembly
Clean the outside of the control valve before

disassembly.
1
Mark the outside of the control valve for ease of
assembly.
IMPORTANT
P-33866
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-40-29
damage the system.
I-2003-0888
P-33867
Remove the three bolts and nuts (Item 1) [Figure 20-40-

28] & [Figure 20-40-29] from the mount.

Figure 20-40-30
P-33869
1 Remove the tie rod nuts (Item 1) [Figure 20-40-32] and

P-33865 lock washers.
Remove the mount (Item 1) [Figure 20-40-30] and

fittings.
Figure 20-40-31
2
10 8 6 4
9 7 5 3 1
P-33868
Mark the valve sections for ease of assembly [Figure 20-

40-31].
1. Right Travel Valve

2. Boom Swing Valve
3. Boom Valve
4. Left Travel Valve
5. Arm Valve
6. Bucket Valve
7. Auxiliary Valve
8. Boost Valve
9. Blade Valve
10. Slew Valve

Right Travel Valve Section Disassembly And 1

Assembly
IMPORTANT
damage the system.
I-2003-0888 P-33871
Clean the outside of the right travel valve before Remove the plug (Item 1) [Figure 20-40-34] from the
disassembly. right travel valve section.
Figure 20-40-33 Installation: Tighten the plug to 18 ft.-lb. (24 N•m)

torque.
Figure 20-40-35
1
P-33870
Remove the right travel valve section (Item 1) [Figure P-33872

20-40-33] from the valve assembly.
Remove the O-ring (Item 1) [Figure 20-40-35] from the

plug.

Right Travel Section Disassembly And Assembly

(Cont’d)
1
Figure 20-40-36
P-33906
1
Installation: Make sure the lip (Item 1) of the seal fits

inside the lip on the retaining plate (Item 2) [Figure 20-
P-33873 40-38].
Figure 20-40-39
Remove the bolts (Item 1) [Figure 20-40-36].
Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m)

torque.
Figure 20-40-37
1 2
P-33876
Remove the bolts (Item 1) [Figure 20-40-39] on the two

2 speed switch.
P-33874 Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m)

torque.
Remove the retaining plate (Item 1) and seal (Item 2)

[Figure 20-40-37].


(Cont’d)
Figure 20-40-40
P-33881

1 switch.
P-33877
Figure 20-40-43
Remove the two speed switch (Item 1) [Figure 20-40-

40].
Figure 20-40-41
3
1 P-33882
Remove the washer (Item 1) and O-ring (Item 2) from the

spool (Item 3) [Figure 20-40-43].
P-33878
Remove the O-ring (Item 1) and electrical switch (Item 2)

[Figure 20-40-41].
Installation: Tighten the switch to 31 ft.-lb. (42 N•m)

torque.


(Cont’d)
Figure 20-40-44
2
1
3
P-33885
1
Remove the spool assembly (Item 1), washer (Item 2)
and O-ring (Item 3) [Figure 20-40-46].
P-33883
The spool and valve block are not serviced separately.
Remove the bolts (Item 1) [Figure 20-40-44] on the cap. NOTE: When the spool is removed, use care not to
scratch the spool surface. Do not interchange
Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m) spools and valve blocks.
torque.
Figure 20-40-45
1
P-33884
Remove the cap (Item 1) [Figure 20-40-45].

HYDRAULIC CONTROL VALVE (CONT’D) Installation: Tighten the spring assembly to 7 ft.-lb. (9,8
N•m) torque.
(Cont’d) Figure 20-40-49
Figure 20-40-47
Cut
2.0”
0.5625”
P-33887
1.500”
0.750” B-14674
Remove the fitting (Item 1) [Figure 20-40-49].
To remove the spring assembly from the spool a holding Installation: Tighten the fitting to 31 ft.-lb. (42 N•m)
fixture will have to be made from a 0.750 in. thick x 1.500 torque.
in. wide x 2.0 in. long (19 mm thick x 38 mm wide x 51
mm long) piece of hardwood. Drill a 0.5625 in. (14 mm) Figure 20-40-50
hole in the center of the hardwood block. Cut the block
lengthwise [Figure 20-40-47].
Figure 20-40-48 1
2
2
1
P-33888
1
Remove the O-rings (Item 1) and backup ring (Item 2)
P-33886 [Figure 20-40-50] from the fitting.
Using the wood blocks clamp the spool (Item 1) [Figure

20-40-48] in a vise.
NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged.
Remove the spring assembly (Item 2) [Figure 20-40-48]

from the spool.


(Cont’d)
Figure 20-40-51
P-33890
Remove the plug (Item 1) [Figure 20-40-51].
Installation: Tighten the plug to 31 ft.-lb. (42 N•m)

torque.
Figure 20-40-52
1
2
1
P-33891
Remove the O-rings (Item 1) and back up ring (Item 2)

[Figure 20-40-52] from the plug.

or damaged parts.


Boom Swing Valve Section Disassembly And

Assembly
Clean the outside of the boom swing valve before

disassembly.
IMPORTANT
P-33895
damage the system.
I-2003-0888 Remove the O-rings (Item 1) [Figure 20-40-54] from the
boom swing valve section.
Figure 20-40-53
Figure 20-40-55
P-33894
P-33896
Remove the boom swing valve section (Item 1) [Figure

20-40-53] from the valve assembly. Remove the bolts (Item 1) [Figure 20-40-55] on the
spool control block.

torque.


Assembly (Cont’d)
Figure 20-40-56
P-33899
Remove the plugs (Item 1) [Figure 20-40-58].
P-33897 Installation: Tighten the plugs to 31 ft.-lb. (42 N•m)

torque.
Mark the control block for correct installation. Remove Figure 20-40-59
the control block (Item 1) [Figure 20-40-56].
Figure 20-40-57
1 1
P-33900
1
P-33898 Remove the spool (Item 1) [Figure 20-40-59].
Remove the O-rings (Item 1) [Figure 20-40-57].


Assembly (Cont’d)
1
Figure 20-40-60
P-33872

plug.
P-33901
Figure 20-40-63
Remove the O-rings (Item 1) [Figure 20-40-60] from the

plugs.
1
Figure 20-40-61
P-33904

torque.

torque.


Assembly (Cont’d)
Figure 20-40-64
2
1
P-33907
Remove the washer (Item 1) and O-ring (Item 2) [Figure

2 20-40-66] from the actuating end of the spool.
P-33905
Figure 20-40-67
Remove the retainer (Item 1) and seal (Item 2) [Figure

20-40-64].
Figure 20-40-65
1
2 1
1
P-33908

torque.
Installation: Make sure the lip (Item 1) on the seal fits

into the lip on the retainer (Item 2) [Figure 20-40-65].


Assembly (Cont’d) Cut
Figure 20-40-68
2.0”
0.5625”
1.500”
0.750” B-14674
To remove the spring assembly form the spool a holding

fixture will have to be made from a 0.750 in. thick x 1.500
P-33909 in. wide x 2.0 in. long (19 mm thick x 38 mm wide x 51
mm long) piece of hardwood. Drill a 0.5625 in. (14 mm)
Remove the cover (Item 1) [Figure 20-40-68]. lengthwise [Figure 20-40-70].
Figure 20-40-69 Figure 20-40-71
2
1
P-33910 P-33886
Remove the spool assembly (Item 1), washer (Item 2) Using the wood block, clamp the spool (Item 1) in a vise
and O-ring (Item 3) [Figure 20-40-69]. and remove the spring assembly (Item 2) [Figure 20-40-
71].
NOTE: When the spool is removed, use care not to blocks to grip the spool, or the spool will be
scratch the spool surface. Do not interchange damaged.
spools and valve blocks.
Installation: Tighten the spring assembly to 7 ft.-lb. (9,8
N•m) torque.


Assembly (Cont’d)
1
Figure 20-40-72 2
1
P-33915

[Figure 20-40-74].
P-33912
Figure 20-40-75
Remove the main relief valve (Item 1) [Figure 20-40-72].
Installation: Tighten the main relief valve to 31 ft.-lb. (42

N•m) torque.
Figure 20-40-73
1
1
P-33917

torque.
P-33913
Remove the seal (Item 1) [Figure 20-40-73] from the

main relief valve.


Assembly (Cont’d)
Figure 20-40-76
P-33891


or damaged parts.


Boom Valve Section Disassembly And Assembly
Clean the outside of the boom valve before disassembly.
IMPORTANT
damage the system.
P-33919
I-2003-0888
Figure 20-40-77 Remove the O-rings (Item 1) [Figure 20-40-78] from the
right side of the boom valve section.
Figure 20-40-79
1
1
P-33918
Remove the boom valve section (Item 1) [Figure 20-40- P-33920

77] from the control valve assembly.

left side of the boom valve section.


(Cont’d)
Figure 20-40-80
1 1
P-33923

torque.
Remove the load check valve (Item 1) [Figure 20-40-80]. Figure 20-40-83
Installation: Tighten the load check valve to 18 ft.-lb. (24

N•m) torque.
Figure 20-40-81 5
3
1
1
4
2
P-33924
Remove the spool cover (Item 1), spring retainer (Item 2),
spring (Item 3) and spring seat (Item 4) [Figure 20-40-
P-33922 83].

load check valve.


(Cont’d) 5
Figure 20-40-84
3
4
2
1 1
P-33928
P-33925 86].

Installation: Make sure the lip (Item 1) [Figure 20-40-
84] on the spring seat fits over the spool. Figure 20-40-87
Figure 20-40-85
1
1
P-33925
P-33927
86] on the spring seat fits over the spool.

torque.


(Cont’d) 1
Figure 20-40-88
2
P-33931
Remove the spring (Item 1) and spring assembly (Item 2)

[Figure 20-40-90] from both relief valve ports.
1
P-33929
Figure 20-40-91
Remove the spool (Item 1) [Figure 20-40-88].
The spool and valve block are not serviced separately. 1

NOTE: When the spool is removed, use care not to
Figure 20-40-89
P-33932
1 Remove the O-ring (Item 1) [Figure 20-40-91].

or damaged parts. Always install new seals and O-rings.
Lubricate all seals and O-rings with clean hydraulic fluid
1 before installation.
P-33930
Remove the relief valve plug (Item 1) [Figure 20-40-89]

(both sides). IMPORTANT
Installation: Tighten the relief valve to 18 ft.-lb. (24 N•m) When repairing hydrostatic and hydraulic systems,
torque. clean the work area before disassembly and keep all
damage the system.
I-2003-0888

Left Travel Valve Section Disassembly And

Assembly
1
Clean the outside of the left travel valve before
disassembly.
Figure 20-40-92
P-33872

plug.
1 Figure 20-40-95
P-33933
Remove the left travel section (Item 1) [Figure 20-40-92]

from the valve assembly.
Figure 20-40-93 1
P-33935
Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m).
P-33934
Remove the plug (Item 1) [Figure 20-40-93] from the left

travel valve section.

torque.


Assembly (Cont’d)
Figure 20-40-96
1
P-33937
2 Remove the bolts (Item 1) [Figure 20-40-98] on the two

speed switch.
1 P-33936
torque.
Remove the retainer (Item 1) and seal (Item 2) from the
spool (Item 3) [Figure 20-40-96]. Figure 20-40-99
Figure 20-40-97
1
P-33938
P-33906
Remove the switch assembly (Item 1) [Figure 20-40-99].
Installation: Make sure the lip (Item 1) of the seal fits

inside the retainer (Item 2) [Figure 20-40-97].


Assembly (Cont’d)
Figure 20-40-100 3
1
2
1
2 P-33939
Remove the washer (Item 1) and O-ring (Item 2) from the

actuating end of the spool (Item 3) [Figure 20-40-102].
P-33878
Figure 20-40-103
Remove the electrical connector (Item 1) and O-ring

(Item 2) [Figure 20-40-100].
Installation: Tighten the electrical connector to 31 ft.-lb.

(42 N•m) torque.
1
Figure 20-40-101
P-33940
1
Remove the bolts (Item 1) [Figure 20-40-103] on the
cover.

torque.
P-33881

electrical connector.


Assembly (Cont’d)
Figure 20-40-104
3
2
1
P-33886
4
2 Using the wood blocks clamp the spool (Item 1) [Figure

20-40-106] in a vise.
P-35041
Remove the cover (Item 1), spool assembly (Item 2), damaged.
washer (Item 3) and O-ring (Item 4) [Figure 20-40-104].
Remove the spring assembly (Item 2) [Figure 20-40-
The spool and valve block are not serviced separately. 106].
NOTE: When the spool is removed, use care not to Installation: Tighten the spring assembly to 7 ft.-lb. (9,8
scratch the spool surface. Do not interchange N•m) torque.
Figure 20-40-107
Figure 20-40-105
Cut
1
2.0”
0.5625”
1.500” P-35042
0.750” B-14674

To remove the spring assembly from the spool a holding
fixture will have to be made from a 0.750 in. thick x 1.500 Installation: Tighten the fitting to 31 ft.-lb. (42 N•m)
in. wide x 2.0 in. long (19 mm thick x 38 mm wide x 51 torque.
mm long) piece of hardwood block. Drill a 0.5625 in. (14
mm) hole in the center of the hardwood block. Cut the
block lengthwise [Figure 20-40-105].


Assembly (Cont’d)
2
Figure 20-40-108
1
2
1 1
P-33891
1
P-35043
Remove the O-rings (Item 1) and backup ring (Item 2) Inspect all parts for wear or damage. Replace any worn
[Figure 20-40-108] from the fitting. or damaged parts.
Figure 20-40-109 Always install new seals and O-rings. Lubricate all seals
P-35044

torque.

Arm Valve Section Disassembly And Assembly 1
Clean the outside of the am valve before disassembly.
IMPORTANT
damage the system.
P-35047
I-2003-0888
Figure 20-40-111 Remove the load check valve (Item 1) [Figure 20-40-
113].

N•m) torque.
Figure 20-40-114
1
P-35045
Remove the arm valve section (Item 1) [Figure 20-40-

111] from the valve assembly.
Figure 20-40-112 P-33922

load check valve.
P-35046

arm valve section.

Arm Valve Section Disassembly And Assembly

(Cont’d)
Figure 20-40-115
1 P-33925
1

P-35048
Figure 20-40-118

torque.
Figure 20-40-116
5 1
P-35050
4
3 Remove the bolts (Item 1) [Figure 20-40-118].
2
1 Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m)
torque.
P-35049
116].


(Cont’d)
Figure 20-40-119
1
P-35052
4
3
2
1
P-35051 The spool and valve block are not serviced separately.
NOTE: When spool is removed, use care not to

Remove the spool cover (Item 1), spring retainer (Item 2), scratch the spool surface. Do not interchange
spring (Item 3) and spring seat (Item 4) [Figure 20-40- spools and valve blocks.
119].
Figure 20-40-122
Figure 20-40-120
1
P-35053
P-33925 Remove the relief valve plug (Item 1) [Figure 20-40-

122]. (Both ends)
Installation: Make sure the lip (Item 1) [Figure 20-40- Installation: Tighten the relief valve to 18 ft.-lb. (24 N•m)
120] on the spring seat fits over the spool. torque.


(Cont’d)
Figure 20-40-123
2
1
P-35054
Remove the springs (Item 1) and spring assemblies (Item

2) [Figure 20-40-123].
Figure 20-40-124
P-33932

or damaged parts.


Bucket Valve Section Disassembly And Assembly
Clean the outside of the bucket valve before

disassembly.
IMPORTANT
P-35056
damage the system.
I-2003-0888
Remove the O-rings (Item 1) [Figure 20-40-126] from
Figure 20-40-125 the bucket valve section.
Figure 20-40-127
P-35055
P-35047
Remove the bucket valve section (Item 1) [Figure 20-40-
Remove the load check valve (Item 1) [Figure 20-40-
127].


(Cont’d)
5
Figure 20-40-128
1
4
3
2
1
P-35049
P-33922 130].

load check valve. Figure 20-40-131
Figure 20-40-129
1
P-33925
P-35048

torque.


(Cont’d)
Figure 20-40-132
1 P-33925
1
P-35050
Figure 20-40-135
Installation: Tighten the bolts to 5 ft.-lb.(6,6 N•m) torque.
Figure 20-40-133
P-35052
4
3
2 Remove the spool (Item 1) [Figure 20-40-135].
1
The spool and valve are not serviced separately.
P-35051
Remove the spool cover (Item 1), spring retainer (Item 2), spools and valve blocks.
133].


(Cont’d)
1
Figure 20-40-136
P-33932

1
P-35053 Clean all parts in solvent and dry with compressed air.

Remove the relief valve plug (Item 1) [Figure 20-40-136] or damaged parts.
(both ends.)
Installation: Tighten the relief valve to 18 ft.-lb. (24 N•m) and O-rings with clean hydraulic fluid before installation.
torque.
Figure 20-40-137
P-35054
Remove springs (Item 1) and spring assemblies (Item 2)

[Figure 20-40-137].

Auxiliary Valve Section Disassembly And Assembly
Clean the outside of the auxiliary valve before

disassembly.
IMPORTANT
1
P-35058
damage the system.
I-2003-0888
Figure 20-40-139 the right side of the auxiliary valve section.
Figure 20-40-141
1
1
P-35057
P-35059
Remove the auxiliary valve section (Item 1) [Figure 20-
40-139] from the valve assembly.
the left side of the auxiliary valve section.


(Cont’d)
Figure 20-40-142
1
1
P-35061

torque.
Remove the load check valve assembly (Item 1) [Figure Figure 20-40-145
20-40-142].

N•m) torque. 5
Figure 20-40-143 2
1
4
3
1
P-35062
145].
P-33922

load check valve.


(Cont’d)
Figure 20-40-146
5
4
3
2
1
1
P-35064
P-33925 148].

146] on the spring seat fits over the spool. Figure 20-40-149
Figure 20-40-147
1
1
P-33925
P-35063

torque.


1
(Cont’d)
1
Figure 20-40-150
2
P-35068

[Figure 20-40-152] from the plugs.
1 Clean all parts in solvent and dry with compressed air.

P-35065
or damaged parts.
Figure 20-40-151
P-35066
Remove the plugs (Item 1) [Figure 20-40-151] (both

ends.)
Installation: Tighten the plugs to 18 ft.-lb. (24 N•m)

torque.

Boost Valve Section Disassembly And Assembly 1

Clean the outside of the boost valve before disassembly.
Figure 20-40-153
P-35071
1
Figure 20-40-156
P-35069
Remove the boost valve section (Item 1) [Figure 20-40- 1

153].
Figure 20-40-154
P-33872

1 plug.
P-35070

the boost valve section.

Boost Valve Section Disassembly And Assembly

(Cont’d)
Figure 20-40-157
1
P-33925
1

P-35072
Figure 20-40-160

torque.
Figure 20-40-158
1
1
5
P-35074

3
2 Installation: Tighten the bolts to 5 ft.-lb. (6,6 N•m)
1 torque.
P-35073
158].


(Cont’d)
Figure 20-40-161
1
P-35076
4
3
2 Remove the spool (Item 1) [Figure 20-40-163].
1 The spool and valve block are not serviced separately.
P-35075

Remove the spool cover (Item 1), spring retainer (Item 2), scratch the spool surface. Do not interchange
spring (Item 3) and spring seat (Item 4) [Figure 20-40- spools and valve blocks.
161].
Figure 20-40-164
Figure 20-40-162
1 1
P-35077
P-33925 Remove the relief valve plug (Item 1) [Figure 20-40-

164].
Installation: Make sure the lip (Item 1) [Figure 20-40- Installation: Tighten the relief valve to 18 ft.-lb. (24 N•m)
162] on the spring seat fits over the spool. torque.


(Cont’d)
Figure 20-40-165
1
P-33913
2
1 main relief valve.
P-35078
Figure 20-40-168

[Figure 20-40-165]. 1
2
Figure 20-40-166 1
P-33915

[Figure 20-40-168].
1
P-35079
Remove the main relief valve (Item 1) [Figure 20-40- Inspect all parts for wear or damage. Replace any worn
166]. or damaged parts.
Installation: Tighten the valve to 31 ft.-lb. (42 N•m) Always install new seals and O-rings. Lubricate all seals
torque. and O-rings with clean hydraulic fluid before installation.

Blade Valve Section Disassembly And Assembly
Clean the outside of the blade valve before disassembly.
IMPORTANT
parts clean. Always use caps and plugs on hoses, 1
damage the system.
P-35082
I-2003-0888
Figure 20-40-169 Remove the O-rings (Item 1) [Figure 20-40-170] from

the blade valve section.
Figure 20-40-171
P-35081
Remove the blade valve section (Item 1) [Figure 20-40- P-35083

Remove the load check valve (Item 1) [Figure 20-40-

171].


(Cont’d)
Figure 20-40-172
1
P-35085
Remove the cover (Item 1) [Figure 20-40-174].
P-33922 Figure 20-40-175

load check valve.
Figure 20-40-173
P-35086
1

P-35084 torque.

torque.


(Cont’d)
Figure 20-40-176
2 1
2 1
P-35120
Remove the washer (Item 1) and O-ring (Item 2) [Figure

20-40-178] from the spool.
P-35087
Figure 20-40-179
Remove the spool retainer (Item 1) and seal (Item 2)

[Figure 20-40-176].
3
Figure 20-40-177
2
1
P-35121
2
Remove the spool assembly (Item 1), washer (Item 2)

and O-ring (Item 3) [Figure 20-40-179].
P-33906
Installation: Make sure the lip (Item 1) on the seal fits NOTE: When the spool is removed, use care not to
inside the lip (Item 2) [Figure 20-40-177] on the retainer. scratch the spool surface. Do not interchange


(Cont’d)
Figure 20-40-180
Cut
2.0” 1
0.5625”
P-35122

1.500”
0.750” B-14674 Installation: Tighten the plug to 18 ft.-lb. (24 N•m)
torque.
To remove the spring assembly from the spool a holding Figure 20-40-183
fixture will have to be made from a 0.750 in. thick x 1.500
in. wide x 2.0 in. long (19 mm thick x 38 mm wide x 51
mm long) piece of hardwood. Drill a 0.5625 in. (14 mm) 1
lengthwise [Figure 20-40-180]. 1
Figure 20-40-181
2
P-33891
2
1 Remove the O-rings (Item 1) and backup ring (Item 2)
P-33886
Using the wood blocks clamp the spool (Item 1) in a vise

and remove the spring assembly (Item 2) [Figure 20-40-
181].

damaged.
Installation: Tighten the spring assembly to 7 ft.-lb. (9,8

N•m) torque.


(Cont’d)
1
Figure 20-40-184
1 P-33932

plug.
P-35124
Remove the relief valve plug (Item 1) [Figure 20-40- Inspect all parts for wear or damage. Replace any worn
184]. or damaged parts.
Installation: Tighten the plug to 18 ft.-lb. (24 N•m) Always install new seals and O-rings. Lubricate all seals
torque. and O-rings with clean hydraulic fluid before installation.
Figure 20-40-185
2
1
P-35125

[Figure 20-40-185].

Slew Valve Section Disassembly And Assembly

1
Clean the outside of the slew valve before disassembly.
IMPORTANT
damage the system.
P-35127
I-2003-0888
Figure 20-40-187 Remove the load check valve (Item 1) [Figure 20-40-
188].
Figure 20-40-189
P-35126
Remove the slew valve section (Item 1) [Figure 20-40- P-33922


load check valve.


(Cont’d)
Figure 20-40-190
1
1 P-33925

P-35128
Figure 20-40-193

torque.
6
Figure 20-40-191
5 5
4
3
2
1
P-35131
4 Remove the bolts (Item 1), spool cover (Item 2), spring
3
2 retainer (Item 3), spring (Item 4) and spring seat (Item 5)
1 [Figure 20-40-193].

torque.
spring (Item 3) and spring retainer (Item 4) [Figure 20-
40-191].

Slew Valve Section Disassembly And Assembly 1

(Cont’d)
Figure 20-40-194 1
2
P-33891

1 [Figure 20-40-196] from the plug.
P-35132
Figure 20-40-197

Figure 20-40-195
P-35135

torque.
1
P-35133

torque.


(Cont’d)
1
Figure 20-40-198
2
1
P-35043

[Figure 20-40-200] from the fitting.
P-33872

plug.
Figure 20-40-199
1
P-35136
Installation: Tighten the fitting to 31 ft.-lb. (42 N•m)

torque.

Assembly

or damaged parts.

1
IMPORTANT P-35082

clean the work area before disassembly and keep all Install the O-rings (Item 1) [Figure 20-40-202] on the
parts clean. Always use caps and plugs on hoses, blade valve section.
damage the system. Figure 20-40-203
I-2003-0888
Figure 20-40-201
P-35081
1
Install the blade valve section (Item 1) [Figure 20-40-

P-35126
203] on the tie rods.
Install the slew valve section (Item 1) [Figure 20-40-201]

on the tie rods.

Assembly (Cont’d)
Figure 20-40-204
P-35059
1
Install the O-rings (Item 1) [Figure 20-40-206] on the left

P-35070 side of the auxiliary valve section.
Figure 20-40-207
Install the O-rings (Item 1) [Figure 20-40-204] on the
boost valve section.
Figure 20-40-205
P-35058
1

P-35069 right side of the auxiliary valve section.
Install the boost valve section (Item 1) [Figure 20-40-


Assembly (Cont’d)
Figure 20-40-208
1
P-35055
Install the bucket valve section (Item 1) [Figure 20-40-

1
P-35057 210] on the tie rods.
Figure 20-40-211
Install the auxiliary valve section (Item 1) [Figure 20-40-
Figure 20-40-209
P-35046
1
Install the O-rings (Item 1) [Figure 20-40-211] on the arm
P-35056 valve section.

bucket valve section.

Assembly (Cont’d)
Figure 20-40-212
P-33920
1 Install the O-rings (Item 1) [Figure 20-40-214] on the left

P-35045 side if the boom valve section.
Figure 20-40-215
Install the arm valve section (Item 1) [Figure 20-40-212]
on the tie rods.
Figure 20-40-213
P-33919
1 Install the O-rings (Item 1) [Figure 20-40-215] on the

P-33933 right side of the boom valve section.
Install the left travel section (Item 1) [Figure 20-40-213]

on the tie rods.

Assembly (Cont’d)
Figure 20-40-216
1 P-33894
1 Install the boom swing valve section (Item 1) [Figure 20-

P-33918 40-218] on the tie rods.
Figure 20-40-219
Install the boom valve section (Item 1) [Figure 20-40-
Figure 20-40-217
1
P-33870
1
Install the right travel section (Item 1) [Figure 20-40-219]
P-33895 on the tie rods.

boom swing valve section.

Assembly (Cont’d)
Figure 20-40-220
1 1
P-33865
Install the fittings [Figure 20-40-221].

P-33869
Install the control valve assembly on the mount (Item 1)
[Figure 20-40-221].
Install the washers and nuts (Item 1) [Figure 20-40-220]
on the ends of the tie rods, finger tight.
Be sure the valve assembly does not rock on a flat

surface.
Tighten the tie rod nuts (Item 1) [Figure 20-40-220] to 10

ft.-lb. (13 N•m) torque.
The valve assembly must not have any spacing between

the valve section and the spools must be free when
pushed in and released.
Tighten the tie rod nuts to 25 ft.-lb. (36 N•m) torque.
The spools must not stick, if the spools do stick, loosen

the tie rod nuts and tighten per above information.
Recheck the control valve assembly for level settings.

Assembly (Cont’d)
Figure 20-40-222
P-33866
Figure 20-40-223
1
1
P-33867
Install the bolts (Item 1) [Figure 20-40-222] & [Figure

20-40-223] on the control valve assembly. Tighten the
bolts to 18 - 19 ft.-lb. (24 - 26 N•m) torque.

HYDRAULIC PUMP Pump outlet 2 (Item 2) [Figure 20-50-1] & [Figure 20-50-
2] provides hydraulic fluid flow to the left hand travel, arm
Description and bucket valve sections.
Pump outlet 3 (gear pump) (Item 3) [Figure 20-50-1] &

[Figure 20-50-2] provides hydraulic fluid flow to the
upperstructure slew, blade and boost valve sections.
IMPORTANT Hydraulic flow from pump outlet 2 (Item 2) [Figure 20-50-
When repairing hydrostatic and hydraulic systems, 1] & [Figure 20-50-2] and 3 (Item 3) [Figure 20-50-1] &
clean the work area before disassembly and keep all [Figure 20-50-2] are combined for the auxiliary hydraulic
parts clean. Always use caps and plugs on hoses, flow.
damage the system.
I-2003-0888
Figure 20-50-1
1
2
P-50555
Figure 20-50-2
P-22092
Pump outlet 1 (Item 1) [Figure 20-50-1] & [Figure 20-50-

2] provides hydraulic fluid to the right hand travel, boom
swing and boom valve sections.

HYDRAULIC PUMP (CONT’D) Engage the following hydraulic functions, and continue to
engage the functions.
Torque Adjustment
Engage the auxiliary hydraulics.
Prior to making any torque adjustment, all piston and Extend the bucket cylinder.
gear pump tests must be completed and are to rated Extend the arm cylinder.
specifications. (See the following pages for pump tests.) Extend the boom cylinder.
Extend the boom swing cylinder.
Prior to making any torque adjustment, make sure the no Engage the upperstructure slew.
load engine RPM is correct. (See Engine on Page SPEC-
10-4.) With all the above hydraulic functions engaged, the
engine speed must maintain 2400 RPM.
Figure 20-50-3
Loosen the nut (Item 2) [Figure 20-50-3] and turn the
adjustment screw clockwise to increase pump torque.
counterclockwise to decrease pump torque.
Tighten the nut and retest the pump.
Increase or decrease pump torque until correct engine

2 RPM is maintained.
1
P-50437
The adjustment screw (Item 1) [Figure 20-50-3] is used

to match the maximum hydraulic horsepower of the
pump to the maximum rated engine horsepower.
Remove any auxiliary hydraulic attachments from the

excavator.
Engage the slew lock.
Start the engine and move the speed control to the high
idle position.

HYDRAULIC PUMP (CONT’D) Figure 20-50-6
Testing The Piston Pump
All pump testing is done with the hydraulic oil at operating

temperature and with the engine high idle speed. (See
Engine on Page SPEC-10-4.)
1
The following tool will be needed for the hydraulic pump
test:
MEL10003 - Hydraulic Tester
Stop the engine. 2
Open the tailgate. P-50556
Figure 20-50-4
Connect the inlet side (Item 1) [Figure 20-50-6] of the
tester to the pump.
1
Connect the outlet side of the tester to the hose (Item 2)
[Figure 20-50-6] that was removed from the pump.
P-50555
Figure 20-50-5
P-22092
Remove the outlet hose (Item 1) [Figure 20-50-4] &

[Figure 20-50-5] from the hydraulic pump being tested.

HYDRAULIC PUMP (CONT’D) NOTE: The high pressure flow must be at least 80% of
free flow.
Testing The Piston Pump (Cont’d) HIGH PRESSURE FLOW (GPM)
%= x100
Figure 20-50-7 FREE FLOW (GPM)
If the high pressure flow is less than 80% of free flow,

remove the hydraulic pump for repair or replacement.
P-22253
NOTE: Open the flow control knob (Item 1) [Figure 20-

50-7] fully to prevent pump damage. This is a
direct pump test. There is no relief valve in the
system.
Start the engine and run at low RPM. Make sure the
tester is connected correctly. If no flow is indicated at the
tester, the hoses are connected wrong.
Increase the engine speed to full RPM. Warm the

hydraulic fluid to 150° F (66° C) by turning the restrictor
valve until the gauge reads about 1000 PSI (69 bar). Do
not exceed system pressure.
After the temperature is correct, open the restrictor valve

fully.
Record the pump free flow GPM (L/min.).
Pump flow on a new piston pump is 10.1 gpm (38.2 L/

min.).
Close the flow control knob (Item 1) [Figure 20-50-7]

slowly to 100 PSI below the relief valve setting (2650 PSI
[180 bar]).
Record the pump high pressure flow GPM (L/min.).

Testing The Gear Pump
All pump testing is done with the hydraulic oil at operating 1

temperature and with the engine at high idle speed. (See
Engine on Page SPEC-10-4.)
Figure 20-50-8
P-50557
1
Connect the inlet side (Item 1) [Figure 20-50-10] of the

tester to the pump.
Connect the outlet side of the tester to the hose (Item 2)

[Figure 20-50-10] that was removed from the pump.
P-50555
Figure 20-50-11
Figure 20-50-9
P-22253
P-22092
NOTE: Open the flow control knob (Item 1) [Figure 20-
50-11] fully to prevent pump damage. This is a
Remove the outlet hose (Item 1) [Figure 20-50-8] & direct pump test. There is no relief valve in the
[Figure 20-50-9] from the gear pump. system.
Start the engine and run at low RPM. Make sure the
tester is connected correctly. If no flow is indicated at the
tester, the hoses are connected wrong.


fully.

HYDRAULIC PUMP (CONT’D)
Testing The Gear Pump (Cont’d)
Record the pump free flow GPM (L/min.).
Pump flow on a new gear pump is 7.03 GPM (26,6 L/

min.).
Figure 20-50-12
P-22253
Close the flow control knob (Item 1) [Figure 20-50-12]

slowly to 100 PSI (6,9 bar) below the relief valve setting
(2500 PSI [172 bar]).
Record the pump high pressure flow GPM (L/min.).
NOTE: The high pressure flow must be at least 80% of

free flow.
HIGH PRESSURE FLOW (GPM)
%= x100
FREE FLOW (GPM)
If the high pressure flow is less than 80% of free flow,

remove the hydraulic pump for repair or replacement.

Testing Auxiliary Hydraulic Flow
The auxiliary hydraulic flow is the combined flow of pump

outlet 2 and pump outlet 3.
All testing is done with the hydraulic oil at operating

temperature and the engine at high idle speed setting.
(See Engine on Page SPEC-10-4.)
The following tool will be needed for the auxiliary

hydraulic flow test:
1
MEL10003-Hydraulic Tester.
P-22253
Stop the engine.
Figure 20-50-13 NOTE: Open the flow control knob (Item 1) [Figure 20-
50-14] fully.
2
Start the engine, and run at low RPM. Engage the
auxiliary hydraulic circuit.
NOTE: When engaging the auxiliary hydraulic circuit,

make sure the female coupler is pressure and
1 the male coupler is return.
Make sure the tester is connected correctly. If no flow is

indicated at the tester, the hoses are connected wrong.

P-50408
Connect the inlet side of the tester to the female coupler
(Item 1). Connect the out side of the tester to the male
fully.
coupler (Item 2) [Figure 20-50-13].
Record the auxiliary hydraulic free flow GPM (L/min.).

HYDRAULIC PUMP (CONT’D) Mark and remove the three hoses (Item 1) [Figure 20-
50-16].
Figure 20-50-17
Figure 20-50-15
1
P-22628
Remove the hydraulic reservoir to pump hose (Item 1)

P-50394 [Figure 20-50-17].
Remove the clamp (Item 1) [Figure 20-50-15] and

tailpipe.
IMPORTANT
damage the system.
I-2003-0888
Figure 20-50-16
P-22627

Figure 20-50-18
P-22626
Open the bleed valve (Item 1) [Figure 20-50-20] on the

P-22630 hydraulic pump. Close the valve after a steady stream of
hydraulic fluid free of any air drains from the valve.
Remove the hydraulic filter to pump hose (Item 1) Tighten the bleed valve.
[Figure 20-50-18].
Coupler Removal And Installation
Figure 20-50-19
Figure 20-50-21
0.180-0.200”
P-22629 (4,6-5,1 mm)
MS-1117
Remove the two bolts (Item 1) [Figure 20-50-19].

Remove the bolt (Item 1) [Figure 20-50-21] from the
Installation: Tighten the bolts to 55 - 60 ft.-lb. (75 - 85 coupler.
N•m) torque.
Slide the coupler off of the pump shaft.
Pump Installation: Whenever the hydraulic system has
been drained and refilled, the hydraulic pump must be When installing the coupler, maintain 0.19 in. (4,8 mm)
purged of air. gap from the pump mount flange to the coupler.
Tighten the bolt (Item 1) [Figure 20-50-21] to 36 - 44 ft.-

lb. (49 - 60 N•m) torque.

Hydraulic Pump Start Up
NOTE: This procedure is to prevent a dry start up of

the hydraulic pump.
Figure 20-50-22
STARTER
SOLENOID
INLET
HOSE P-59355
Figure 20-50-25
S TERMINAL
P-31281
Disconnect the pump inlet hose connection at the filter

head. Fill the pump inlet and hose completely with
hydraulic fluid. Reconnect the hose [Figure 20-50-22].
Figure 20-50-23 BATTERY TERMINAL
MOMENTARY SWITCH
P-61040
Connect the starter bypass tool to the starter solenoid

battery terminal and S terminal. Crank the engine for 15
seconds, then stop for at least 30 seconds. Again, crank
the engine for 15 seconds. Remove the starter bypass
tool [Figure 20-50-24] & [Figure 20-50-25].
Start the excavator from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
STARTER BYPASS TOOL
P-59354 hydraulics.
After operating the engine at low idle, operate the

To crank the engine without starting, the machine key hydraulic systems several times or until air is purged from
switch can be bypassed. Obtain a starter bypass tool the system. Avoid running over the relief valve setting
from a local source which can be used as a universal at the end of cylinder stroke.
connection to remotely crank the engine without starting
[Figure 20-50-23]. With the excavator parked on a level surface and lift arms
down, check and fill the hydraulic reservoir as required.
The starter bypass tool consists of two wires, each with a Check for hydraulic leaks.
clamp. The momentary switch, when depressed, will
allow current to pass through the circuit.

Gear Pump Parts Identification
1. End Plate
1
2. Guide
3. O-Ring 2
4. Seal 3
5. Spacer
4
6. Bearing
7. Gear 5
8. Housing
9. Bolt
4
6
4
3 6
5
3
8
3
9
MS-1236S

Piston Pump Parts Identification
1. Bolt
2. O-Ring 2
10 2
3. Piston 3
4
4. Coned Disc Spring
5. Spacer 5
6. Shim 11 6
7. Sleeve 12 9
8. Parallel Pin 7 2
9. Fitting
11 8
10. Swash Plate 12
11. Guide Seat
12. Guides
13. Bearing
14. Housing
15. Seal 16 14
17 6
16. Washer 16
17. Snap Ring 13
17
18. Spring
19. Cylinder Block 18
20. Pins 16
21. Retainer 19
22. Retainer Plate
23. Pistons 20 2 15
24. Shaft 21
25. Spring Seat 22
26. Plug 23
27. Face Plate
28. Port Plate
29. Gasket
30. Adjusting Plate 24
31. Nut
32. Adjusting Screw 1
1 17
33. Spring Guide
31 27
32 2 26
3 2
30
6 28
29
13
33
18
25
MS2048A

Disassembly
Clean the outside of the hydraulic pump before

disassembly.
Figure 20-50-26
P-22724
1 Remove the three fittings (Item 1) [Figure 20-50-28].
Figure 20-50-29
P-22722
1
Remove the two bolts (Item 1) and the fitting (Item 2)
[Figure 20-50-26].
Figure 20-50-27
2
1
P-58900
Remove the bolt (Item 1) and coupler (Item 2) [Figure

20-50-29].
P-22723

fitting.

Gear Pump Disassembly 1

2 2
1 1
IMPORTANT
parts clean. Always use caps and plugs on hoses, 2 2
damage the system.
I-2003-0888
P-50395
Clean the outside of the pump before disassembly.

Remove the O-rings (Item 1) and four bolts (Item 2)
Mark the outside of the pump for ease of assembly. [Figure 20-50-31].
Figure 20-50-30 Figure 20-50-32
2
2
P-22913 P-50396
NOTE: Do not turn the adjusting screw (Item 1) Turn the pump over and remove the end plate (Item 1)
[Figure 20-50-30] unless necessary. The [Figure 20-50-32].
pressure setting may be changed causing
damage to the hydraulic system.
Remove the bolts (Item 2) [Figure 20-50-30] and remove

the gear pump.

Gear Pump Disassembly (Cont’d)
Figure 20-50-33
1
1
P-50399

P-50397 guide.
Figure 20-50-36
Remove the O-rings (Item 1) and seal (Item 2) [Figure
20-50-33] from the pump housing.
Figure 20-50-34
1
P-50400
Remove the spacer (Item 1) [Figure 20-50-36].

P-50398
Remove the guides (Item 1) and O-rings from the

spacers [Figure 20-50-34].

Gear Pump Disassembly (Cont’d)
Figure 20-50-37 1
P-50403
Remove the spacers (Item 1) [Figure 20-50-39].

P-50401
Figure 20-50-40
Turn the pump and push in on the shaft (Item 1) [Figure

20-50-37].
Figure 20-50-38 1
1
2 2
P-22922
Remove the bearings (Item 1) and seals (Item 2) [Figure

20-50-40] from the gears.
P-50402
Remove the bearing/gear assembly (Item 1) [Figure 20-

50-38].

Gear Pump Assembly

or damaged parts.

Figure 20-50-41
P-50406
1
Stand the bearing/gear assembly up [Figure 20-50-43].
Figure 20-50-44
P-50405 2
Install the seal (Item 1) [Figure 20-50-41] (both sets.)
Figure 20-50-42 3
1
1 P-50403
1
Apply assembly lube to the spacers and install the

spacers (Item 1) [Figure 20-50-44] into the pump.
NOTE: The cut out area (Item 2) on the spacer is

installed toward the outlet port (Item 3)
[Figure 20-50-44].
1 1
P-50404
Install the bearings (Item 1) [Figure 20-50-42] on the

gears.

Gear Pump Assembly (Cont’d)
Figure 20-50-45
P-50399

P-50407 guides.
Figure 20-50-48
Install the housing over the bearing/gear assembly
[Figure 20-50-45].
Figure 20-50-46 1
2
P-50398
Install the guide/O-ring assembly (Item 1) [Figure 20-50-

P-50400 48] into the spacers.
NOTE: The flanges on the guides must face out.

Turn the pump over and install the spacer (Item 1)
[Figure 20-50-46].
NOTE: The cut out area (Item 2) on the spacer is

installed toward the outlet port (Item 3)
[Figure 20-50-46].

Gear Pump Assembly (Cont’d)

2
1 1
Figure 20-50-49
2
2
1
1 1
1
P-50395
2
Turn the pump over and install the four bolts (Item 1)
P-50397 [Figure 20-50-51].
Tighten the bolts to 41 - 47 ft.-lb. (57 - 63 N•m) torque.

Install the O-rings (Item 1) and the seal (Item 2) [Figure
20-50-49] in the pump housing. Install the O-rings (Item 2) [Figure 20-50-51].
Figure 20-50-50
P-50396
Install the end plate (Item 1) [Figure 20-50-50].

Piston Pump Disassembly
Clean the outside of the pump before disassembly.

1
Figure 20-50-52
2
P-65734
1
Remove the face plate (Item 1) [Figure 20-50-54] from

the pump housing.
P-22875
Remove the O-ring (Item 1) and coupler (Item 2) [Figure

20-50-52] from the face plate.
Figure 20-50-53
1
1
1 1
P-65733
Mark and remove the four bolts (Item 1) [Figure 20-50-

53]. Note the length and location of each bolt for correct
assembly.

Piston Pump Disassembly (Cont’d)
Figure 20-50-55
1
P-65736
Remove the gasket (Item 1) [Figure 20-50-57].

P-65735
Figure 20-50-58
Remove the port plate (Item 1), piston (Item 2) and

needle bearing (Item 3) [Figure 20-50-55] from the face
1
plate.
Figure 20-50-56
1
2
2
P-65737
Remove the springs (Item 1) and spring guide (Item 2)

[Figure 20-50-58].
P-58907
Remove the O-ring (Item 1) and two shims (Item 2)

[Figure 20-50-56] from the piston.

Figure 20-50-59
P-65740
Remove the rotating group (Item 1) [Figure 20-50-61].

P-65738
NOTE: The following procedure shown is to
disassemble the rotating group for inspection
Remove the spring seat (Item 1) [Figure 20-50-59]. only. The rotating group parts cannot be
ordered separately and must be ordered as an
Figure 20-50-60 assembly.
NOTE: Check for scratches or damage on the sliding

surfaces.
Figure 20-50-62
P-65739 1
Remove the snap ring (Item 1) [Figure 20-50-60].

P-58919
Remove the retainer plate (Item 1) and pistons (Item 2)

[Figure 20-50-62] from the cylinder block.

Figure 20-50-63
P-65742
Place tape around the shaft splines as shown to protect

P-58928 the seal and remove the shaft (Item 1) [Figure 20-50-65]
from the pump housing.
Remove the retainer (Item 1) [Figure 20-50-63]. Figure 20-50-66
Figure 20-50-64
1
1
1
1
P-58922
P-58920
Remove the snap ring (Item 1) [Figure 20-50-66] from
the shaft.
Remove and inspect the pins (Item 1) [Figure 20-50-64]
for wear or damage. NOTE: Inspect the shaft for damage or wear. Replace
shaft if damaged or worn.

Figure 20-50-67
1
1
P-65744
Remove the guides (Item 1) [Figure 20-50-69] from the

P-65743 pump housing.
NOTE: Mark the location of each guide for correct

Remove the swash plate (Item 1) [Figure 20-50-67]. assembly.
Figure 20-50-68 Figure 20-50-70
1
2 1
P-58925 P-61015
Remove the brass guide seat (Item 1) and steel guide Remove the seal (Item 1) and bearing (Item 2) [Figure
seat (Item 2) [Figure 20-50-68] from the swash plate. 20-50-70].
NOTE: Mark the location of each guide for correct

assembly.

Figure 20-50-71 2 5
1 3 4
P-58924
Remove the three coned disc springs (Item 1), spacer

P-65747 (Item 2), shims (Item 3), parallel pin (Item 4) and sleeve
(Item 5) [Figure 20-50-73].
Remove the piston (Item 1) [Figure 20-50-72].
Figure 20-50-72
P-58914
Remove the two O-rings (Item 1) [Figure 20-50-72].

Piston Pump Assembly
Clean all parts in solvent and dry with compressed air. Do

not use compressed air to dry the bearings.

or damaged parts. 1

1
Apply a thin coat of hydraulic fluid to all components
before assembly.
P-58914
Figure 20-50-74
Install the two O-rings (Item 1) [Figure 20-50-76].
2 5 Figure 20-50-77
1 3 4
P-58924
Assemble the three coned disc springs (Item 1), spacer

(Item 2), shims (Item 3), parallel pin (Item 4) and sleeve P-65747
(Item 5) [Figure 20-50-74] and install in the housing.
Figure 20-50-75 Install the piston (Item 1) [Figure 20-50-77].
2
MS2049
The three coned disc springs (Item 1) must face the

piston (Item 2) [Figure 20-50-75] as shown.

Piston Pump Assembly (Cont’d)
Figure 20-50-78
2
1
1
P-58925
2
Install the brass guide seat (Item 1) and steel guide seat
P-61015 (Item 2) [Figure 20-50-80] in the pump housing.
Figure 20-50-81
Install the bearing (Item 1) and seal (Item 2) [Figure 20-
50-78] in the pump housing.
Figure 20-50-79
1
P-65743
Install the swash plate (Item 1) [Figure 20-50-81] in the

P-65744 pump housing.
Install the guides (Item 1) [Figure 20-50-79] in the

locations noted during disassembly.
NOTE: Apply assembly lube to the shim for ease of

assembly.


1
Figure 20-50-82
1
1
P-58920
Install the pins (Item 1) [Figure 20-50-84].

P-58922
Figure 20-50-85
Install the snapring (Item 1) [Figure 20-50-82] on the

shaft.
Figure 20-50-83
1
P-58928
Install the retainer (Item 1) [Figure 20-50-85] on the pins.
P-65742
Place tape around the shaft splines as shown to protect

the seal and install the shaft (Item 1) [Figure 20-50-83] in
the pump housing.

Figure 20-50-86
P-65754
Install the snap ring (Item 1) [Figure 20-50-88].

P-58919
Figure 20-50-89
Install the retainer and piston assembly (Item 1) in the

cylinder block (Item 2) [Figure 20-50-86].
NOTE: It is NOT important that the pistons are

installed in their original positions. 1
Figure 20-50-87
P-65755
Install the spring seat (Item 1) [Figure 20-50-89].
P-65753
Lay the pump housing on its side and install the rotary
group (Item 1) [Figure 20-50-87].


1
Figure 20-50-90
2
P-58907
Install the O-ring (Item 1) and two shims (Item 2) [Figure

P-65737 20-50-92] on the piston.
Figure 20-50-93
Install the spring guide (Item 1) and spring (Item 2)
[Figure 20-50-90].
Figure 20-50-91 2
3
1
P-65735
Install the piston (Item 1) and needle bearing (Item 2)

P-65736 [Figure 20-50-93].
Apply assembly grease on the port plate (Item 3)

Install the gasket (Item 1) [Figure 20-50-91]. [Figure 20-50-93] and install.

Figure 20-50-94
2
1
1
P-22875
Install the O-ring (Item 1) and coupler (Item 2) [Figure

P-65734 20-50-96] on the face plate.
Install the face plate (Item 1) [Figure 20-50-94] on the

pump housing.
Figure 20-50-95
1 1
1
1
P-65733
Install the four bolts (Item 1) [Figure 20-50-95] in the

location noted during disassembly and tighten the bolts
to 41 - 51 ft.-lb. (55 - 69 N•m) torque.

Figure 20-50-97 1 1
P-22913
Install the two bolts (Item 1) [Figure 20-50-99]. Tighten

P-22914 the bolts to 41 - 51 ft.-lb. (55 - 69 N•m) torque.
Figure 20-50-100
Figure 20-50-98
1 1
P-58900
P-22875
Install the coupler (Item 1) [Figure 20-50-100] on the

Align the splines on the gear pump shaft (Item 1) [Figure pump. (See Coupler Removal And Installation on Page
20-50-97] with the splines in the coupler (Item 1) [Figure 20-50-9.)
20-50-98] and install the gear pump on the piston pump.

Figure 20-50-101
P-22722
1
Install the fitting (Item 1) and bolts (Item 2) [Figure 20-
P-22724 50-103].

Install the fittings (Item 1) [Figure 20-50-101].
Figure 20-50-102
P-22723
Install the O-ring (Item 1) [Figure 20-50-102] in the

fitting.

MANIFOLD ASSEMBLY/ ACCUMULATOR
Description
The manifold body contains three valves, the pressure

IMPORTANT
reducing valve, main relief valve and build up valve.
The manifold supplies 428 PSI (29,5 bar) 406 - 450 PSI clean the work area before disassembly and keep all
(28 - 31 bar) to the joysticks to activate the control valve parts clean. Always use caps and plugs on hoses,
spools. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
The accumulator is connected to the manifold body.
The accumulator provides short term reserve pressure Mark the hoses for correct installation.
for joystick function with the engine off and the key in the
ON position.

WARNING
move both control levers to relieve hydraulic pressure. Hydraulic fluid escaping under pressure can have
Drain the hydraulic reservoir. (See Replacing The penetrating the skin. This can cause serious injury
Hydraulic Oil on Page 10-100-2.) and possible death if proper medical treatment by a
Remove the right side cover. (See Removal And immediately.
Installation on Page 40-200-1.) W-2145-0290
Figure 20-60-1
Figure 20-60-2
2
1
P-55420
P-35756
For models equipped with a windshield washer, lift up on

the windshield washer fluid reservoir (Item 1) and remove
the reservoir from the bracket (Item 2) [Figure 20-60-1].
Reposition the reservoir away from the manifold
assembly.
Remove the battery. (See Removing And Installing The

Battery on Page 50-20-2.)

MANIFOLD ASSEMBLY/ ACCUMULATOR (CONT’D) Figure 20-60-5
Figure 20-60-3
1
1 P-35753
Disconnect the five electrical connectors (Item 1) [Figure

P-35755 20-60-5].
Figure 20-60-6
Figure 20-60-4
1
1
P-35403
P-35754 Remove the hose (Item 1) [Figure 20-60-6].

Figure 20-60-7
1
1
P-22727
Remove the hose (Item 1) [Figure 20-60-9] from the oil

P-35404 cooler.
NOTE: The hose will be removed with the manifold.

Figure 20-60-10
Figure 20-60-8
2
1 1
1
P-35520
P-35405
Remove the bolts (Item 1) from the battery tray (Item 2)

Remove the hose (Item 1) [Figure 20-60-8]. [Figure 20-60-10].
Remove the battery tray.

Figure 20-60-11
1
1
2
P-22519
Push the manifold toward the excavator and remove the

P-55568 wire harness (Item 1) from the two clamps (Item 2)
[Figure 20-60-13].
Remove the bolt (Item 1) [Figure 20-60-11]. Figure 20-60-14
Figure 20-60-12
1 P-35758
P-35759
Move the manifold forward and remove the manifold from
the excavator [Figure 20-60-14].

MANIFOLD ASSEMBLY/ACCUMULATOR (CONT’D)
1. Nut
2. O-Ring
3. Back-up Ring
4. Auxiliary Coil
(w/Blue Tie Strap)
5. System Bypass Coil
(w/ Brown Tie Strap)
6. 2-Speed Coil
(w/Yellow Tie Strap)
7. Joystick Lockout Coil 1 1
(w/Green Tie Strap)
8. Auxiliary Coil 2
2
(w/Red Tie Strap)
9. Solenoid 1
4 1
10. Cap 5
11. Spring 2 2
12. Check Ball
10 2 8
13. Seat
14. Accumulator 2 6 1
15. Housing 9
16. Main Relief Valve 11 9 2
2
17. Pressure Reducing Valve 12
18. Plug 9
13 2
19. Glid Ring 9
2 7
20. Fitting 2 18
2
18
3 2 2
2
2 3 11 2 9
2
12 2 3
2 3
13
2 2 3
3
2
2 3
2 2 3
18
2 2 3
15
2
13 2
12
11
2
10 19
3
2
2 2 18 2
2 14
2
3 2
16
2 3 18 20
17 MS1402

MANIFOLD ASSEMBLY/ACCUMULATOR (CONT’D) Figure 20-60-17
Disassembly
Clean the outside of the manifold assembly before

disassembly.
Figure 20-60-15
3 2
2 1
P-35710
1
Remove the accumulator (Item 1) [Figure 20-60-17].
Figure 20-60-18
P-35521
Remove the bolts (Item 1), clamps (Item 2) and mount

(Item 3) [Figure 20-60-15] from the manifold.
Figure 20-60-16
P-22367

accumulator.
2 1 P-35522
Remove the hose (Item 1) and fitting (Item 2) [Figure 20-

60-16].

Figure 20-60-19 1
P-35526
1
Remove the pressure reducing valve (Item 1) [Figure 20-
P-35524 60-21].
Figure 20-60-22
Remove the diagnostic coupler (Item 1) and five fittings
(Item 2) [Figure 20-60-19].
Figure 20-60-20
1
1
1
2
2
1
P-35527
Remove the O-rings (Item 1) and back-up rings (Item 2)

P-35525 [Figure 20-60-22] from the pressure reducing valve.

diagnostic coupler and fittings.

2
Figure 20-60-23
1
1
P-35529
Remove the two diagnostic ports (Item 1) and two fittings

P-35528 (Item 2) [Figure 20-60-25].
Figure 20-60-26
Figure 20-60-24
2
1
3 P-35525
1
4
P-22370 Remove the O-ring (Item 1) [Figure 20-60-26] from the

diagnostic ports and fittings.
Remove the O-ring (Item 1) and back-up rings (Item 2)

[Figure 20-60-24] from the main relief valve.
Remove the ring (Item 3) and O-ring (Item 4) [Figure 20-

60-24] from the main relief valve.
NOTE: Later model excavators may be equipped with

a different main relief valve. Record the
location of O-rings, back-up rings, seals or
glid rings during disassembly for proper
assembly.

Figure 20-60-27
1
1
P-35537

P-35530 plugs.
Figure 20-60-30
Remove the build up valve (Item 1) [Figure 20-60-27].
NOTE: See Build Up Valve Disassembly. (See

Disassembly And Assembly on Page 20-160-
3.)
1
Figure 20-60-28
P-35538
Remove the nuts (Item 1) [Figure 20-60-30] from the

solenoids.
1
P-35536

1
Figure 20-60-31
P-35541
Remove the solenoids (Item 1) [Figure 20-60-33].

P-35539
Figure 20-60-34
Remove the O-ring (Item 1) [Figure 20-60-31] from both

nuts.
Figure 20-60-32 1
2
2
1 2
1
1
P-35550
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-60-34] from both solenoids.
P-35540
Remove the coil with the red tie strap (Item 1) [Figure
20-60-32] from the solenoid.
Remove the coil with the blue tie strap (Item 2) [Figure

Figure 20-60-35 1
1
P-35544
1
1
P-35542 coil.
Figure 20-60-38
Remove the nut (Item 1) [Figure 20-60-35] from the
solenoids.
Figure 20-60-36
P-35546
1
Remove the solenoid (Item 1) and spring (Item 2) [Figure
P-35543 20-60-38].
Remove the coil with the brown tie strap (Item 1) [Figure

Figure 20-60-39 1
1
P-35544
Remove the two O-rings (Item 1) [Figure 20-60-41] from

P-35547 the coils.
Figure 20-60-42
solenoid.
Figure 20-60-40
1
P-35549
2
1
Remove the solenoids (Item 1) [Figure 20-60-42].
P-35548
Remove the coil with the yellow tie strap (Item 1) [Figure
Remove the coil with the green tie strap (Item 2) [Figure

Figure 20-60-43 1
2
4
5
1
2
2
P-35552
1
1
Remove the O-ring (Item 1), spring (Item 2), check ball
P-35550 (Item 3), seat (Item 4) and O-ring (Item 5) [Figure 20-60-
45] from the five check valve ports.
Remove the O-rings (Item 1) and back-up rings (Item 2) Figure 20-60-46
Figure 20-60-44
P-35553
1
P-35551 Remove the port adapter (Item 1) [Figure 20-60-46].
Remove the check valves (Item 1) [Figure 20-60-44].

1
Figure 20-60-47
1
2
2 1
P-35557
Remove the O-rings (Item 1) and back-up ring (Item 2)

P-35555 [Figure 20-60-49] from the port adapter.
Figure 20-60-50
Remove the fitting (Item 1) and spool (Item 2) [Figure
20-60-47] from the port adapter.
Figure 20-60-48
P-35558

P-35556

fitting.

Figure 20-60-51
1
1
2
4
5
P-35533
3

P-35559 fittings.
Figure 20-60-54
Remove the O-ring (Item 1), spring (Item 2), check ball
(Item 3), seat (Item 4) and O-ring (Item 5) [Figure 20-60-
51] from the port.
Figure 20-60-52
1 1
P-35561
P-35560
Remove the fittings (Item 1) [Figure 20-60-52].

Figure 20-60-55
P-35537

plugs.

Assembly

1
or damaged parts.

Figure 20-60-56
P-35533
Install the O-ring (Item 1) [Figure 20-60-58] on the four

1 fittings.
Figure 20-60-59
P-35537
Install the O-ring (Item 1) [Figure 20-60-56] on the plugs.

1 1
Figure 20-60-57
P-35560
Install the fittings (Item 1) [Figure 20-60-59].
P-35561
Install the plugs (Item 1) [Figure 20-60-57]. Tighten the

plugs to 18 - 20 ft.-lb. (24,4 - 27,1 N•m) torque.

Assembly (Cont’d)
1
Figure 20-60-60
6 1
2
5
4
2
1
P-35557
3
Install the O-rings (Item 1) and back-up ring (Item 2)

P-35559 [Figure 20-60-62] on the port adapter.
Figure 20-60-63
Figure 20-60-61
1
P-35556
P-35558
Install the O-ring (Item 1) [Figure 20-60-63] on the fitting.

Install the O-ring (Item 1), seat (Item 2), check ball (Item
3), spring (Item 4), O-ring (Item 5) and plug (Item 6)
[Figure 20-60-60] in the port (Item 1) [Figure 20-60-61]
in the manifold housing.

Assembly (Cont’d)
6
Figure 20-60-64 5
4
2
1
1 2
P-35552
Figure 20-60-67
P-35555
1
Install the spool (Item 1) and fitting (Item 2) [Figure 20-
60-64] in the port adapter.
Figure 20-60-65
1
P-35551
3), spring (Item 4), O-ring (Item 5) and plug (Item 6)
[Figure 20-60-66] in the check valve ports (Item 1)
[Figure 20-60-67].
P-35553
Tighten the plugs to 19 - 22 ft.-lb. (25,1 - 29,8 N•m)
torque.
Install the port adapter (Item 1) [Figure 20-60-65].

Assembly (Cont’d)
Figure 20-60-68 1
1
1
2
2
P-35544
1
1
Install the O-rings (Item 1) [Figure 20-60-70] on the coils.
P-35550
Figure 20-60-71
Install the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-60-68] on the solenoids.
Figure 20-60-69
1
2
P-35548
Install the coil with the green tie strap (Item 1) [Figure
1 20-60-71] on the solenoid.
P-35549
Install the coil with the yellow tie strap (Item 2) [Figure
20-60-71] on the solenoid.
Install the solenoids (Item 1) [Figure 20-60-69].

Assembly (Cont’d)
Figure 20-60-72 1
1
P-35544
Install the O-rings (Item 1) [Figure 20-60-74] on the coil.

P-35547
Figure 20-60-75
Install the O-ring (Item 1) [Figure 20-60-72] on the

solenoid.
Figure 20-60-73
1 P-35543
2 Install the coil with the brown tie strap (Item 1) [Figure
P-35546
Install the spring (Item 1) and solenoid (Item 2) in the port

(Item 3) [Figure 20-60-73]. Tighten the solenoid to 19 -
22 ft.-lb. (25,1 - 29,8 N•m) torque.

Assembly (Cont’d)
1
Figure 20-60-76
P-35541
1
Install the solenoids (Item 1) [Figure 20-60-78].
P-35542
Tighten the solenoids to 19 - 22 ft.-lb. (25,1 - 29,8 N•m)
torque.
Install the nut (Item 1) [Figure 20-60-76] on the
solenoids. Figure 20-60-79
Tighten the nuts to 3 - 5 ft.-lb. (4,1 - 6,1 N•m) torque.

1
2
NOTE: Overtightening the coil nuts (Item 1) [Figure
20-60-76] may cause spool or coil failure.
Figure 20-60-77
1
2
2
P-35540
Install the coil with the red tie strap (Item 1) [Figure 20-
60-79] on the solenoid.
1
1
Install the coil with the blue tie strap (Item 2) [Figure 20-
P-35550 60-79] on the solenoid.


Assembly (Cont’d)
Figure 20-60-80
P-35537

P-35539
Figure 20-60-83
Install the O-ring (Item 1) [Figure 20-60-80] on the two

nuts. 1
Figure 20-60-81
P-35536
Install the plugs (Item 1) [Figure 20-60-83].
P-35538
Install the nut (Item 1) [Figure 20-60-81] on the solenoid.
Tighten the nuts to 3 - 5 ft.-lb. (4,1 - 6,1 N•m) torque.
NOTE: Overtightening the coil nuts may cause spool

or coil failure.

Assembly (Cont’d) 2
Figure 20-60-84 1
P-35529
Install the diagnostic couplers (Item 1) and fittings (Item

P-35530 2) [Figure 20-60-86].
Figure 20-60-87
Install the build up valve (Item 1) [Figure 20-60-84].
Figure 20-60-85
2
1
3
1
4
P-22370
P-35525 Install the O-ring (Item 1) and back-up ring (Item 2)

[Figure 20-60-87] on the main relief valve.
Install the O-ring (Item 1) [Figure 20-60-85] on the two Install the O-ring (Item 3) and ring (Item 4) [Figure 20-
diagnostic couplers and two fittings. 60-87] on the main relief valve.
NOTE: Later model excavators may have a different

main relief valve. Check the proper location of
O-rings, back-up rings, glid rings and seals
recorded earlier.

Assembly (Cont’d)
1
Figure 20-60-88
P-35526
1
Install the pressure reducing valve (Item 1) [Figure 20-
P-35528 60-90].
Tighten the pressure reducing valve to 19 - 22 ft.-lb. (25,1

Install the main relief valve (Item 1) [Figure 20-60-88]. - 29,8 N•m) torque.
Tighten the main relief valve to 30 - 35 ft.-lb. (40,7 - 47,5 Figure 20-60-91
N•m) torque.
Figure 20-60-89
1 1
2
2
1 P-35525
1
P-35527 Install the O-ring (Item 1) [Figure 20-60-91] on the

diagnostic coupler and five fittings.

[Figure 20-60-89] on the pressure reducing valve.

Assembly (Cont’d)
Figure 20-60-92
1
1
P-35710
Install the accumulator (Item 1) [Figure 20-60-94].

P-35524
Tighten the accumulator to 22 - 24 ft.-lb. (29 - 33 N•m)
torque.
Install the diagnostic coupler (Item 1) and fittings (Item 2)
[Figure 20-60-92]. Figure 20-60-95
Figure 20-60-93
P-35712
P-22367

accumulator.

Assembly (Cont’d)
Figure 20-60-96
1
2
P-35522
Install the fitting (Item 1) and hose (Item 2) [Figure 20-

60-96] on the manifold block.
Figure 20-60-97
2
1
2
3
3
P-35521
Install the mount (Item 1), clamps (Item 2) and bolts (Item
3) [Figure 20-60-97] on the manifold block.

MANIFOLD ASSEMBLY
1. Nut
2. O-Ring
3. Backup Ring
4. Auxiliary Coil
(w/Blue Tie Strap)
5. System Bypass Coil
(w/ Brown Tie Strap)
6. 2-Speed Coil
(w/Yellow Tie Strap)
7. Joystick Lockout coil 1 1
(w/Green Tie Strap)
8. Auxiliary coil 2
2
(w/Red Tie Strap)
9. Solenoid 1
4 1
10. Cap 5
11. Spring 2 2
12. Check Ball
10 2 8
13. Seat
14. Accumulator 2 6 1
15. Housing 9
16. Main Relief Valve 11 9 2
2
17. Pressure Reducing Valve 12
18. Plug 9
13 2
19. Glide Ring 9
2 7
20. Fitting 2 18
2
18
3 2 2
2
2 3 11 2 9
2
12 2 3
2 3
13
2 2 3
3
2
2 3
2 2 3
18
2 2 3
2
13 2
12
11
2
10 19
3
2
2 2 18 2
2 14
2
3 2
16
2 3 18 20
16 MS1402

MANIFOLD ASSEMBLY (CONT’D) Figure 20-61-3
Disassembly
Clean the outside of the manifold assembly before

disassembly.
Mark the outside of the manifold assembly for ease of

assembly.
Figure 20-61-1
1
3 2 P-35710
2
Remove the accumulator (Item 1) [Figure 20-61-3].
1
Figure 20-61-4
P-35521
Remove the three bolts (Item 1), clamps (Item 2) and

mount plate (Item 3) [Figure 20-61-1] from the manifold.
1
Figure 20-61-2
P-22367

accumulator.
2 1 P-35522
Remove the hose (Item 1) and fitting (Item 2) [Figure 20-

61-2].

Figure 20-61-5 1
P-35526
1
Remove the pressure reducing valve (Item 1) [Figure 20-
P-35524 61-7].
Figure 20-61-8
Remove the diagnostic port (Item 1) and five fittings (Item
2) [Figure 20-61-5].
Figure 20-61-6
1
1
1
2
2
1
P-35527
Remove the O-rings (Item 1) and backup rings (Item 2)

P-35525 [Figure 20-61-8] from the pressure reducing valve.

diagnostic port and fittings.

2
Figure 20-61-9
1
1
P-35529
Remove the two diagnostic ports (Item 1) and two fittings

P-35528 (Item 2) [Figure 20-61-11].
Figure 20-61-12
Figure 20-61-10
2
1
3 P-35525
1
4
P-22370 Remove the O-ring (Item 1) [Figure 20-61-12] from the

diagnostic ports and fittings.
Remove the O-ring (Item 1) and backup rings (Item 2)

[Figure 20-61-10] from the main relief valve.
Remove the glid ring (Item 3) and O-ring (Item 4) [Figure

20-61-10] from the main relief valve.

Figure 20-61-13
1
1
P-35537

P-35530 plugs.
Figure 20-61-16
Remove the build up valve (Item 1) [Figure 20-61-13].
NOTE: See Buildup Valve Disassembly. (See

Disassembly And Assembly on Page 20-160-
3.)
1
Figure 20-61-14
P-35538
Remove the nuts (Item 1) [Figure 20-61-16] from the two

solenoids.
1
P-35536
Remove the three plugs (Item 1) [Figure 20-61-14].

1
Figure 20-61-17
P-35541
Remove the two solenoids (Item 1) [Figure 20-61-19].

P-35539
Figure 20-61-20
Remove the O-ring (Item 1) [Figure 20-61-17] from both

nuts.
Figure 20-61-18 1
2
2
1 2
1
1
P-35550
Remove the O-rings (Item 1) and backup rings (Item 2)

P-35540
Remove the coil with the red tie strap (Item 1) [Figure
20-61-18] from the left solenoid.
Remove the coil with the blue tie strap (Item 2) [Figure
20-61-18] from the right solenoid.

Figure 20-61-21 1
1
P-35544
1
1
P-35542 coil.
Figure 20-61-24
Remove the nut (Item 1) [Figure 20-61-21] from the
three solenoids.
Figure 20-61-22
P-35546
1
Remove the solenoid (Item 1) and spring (Item 2) [Figure
P-35543 20-61-24].
Remove the coil with the brown tie strap (Item 1) [Figure

Figure 20-61-25 1
1
P-35544
Remove the two O-rings (Item 1) [Figure 20-61-27] from

P-35547 the coils.
Figure 20-61-28
solenoid.
Figure 20-61-26
1
P-35549
2
1
Remove the two solenoids (Item 1) [Figure 20-61-28].
P-35548
Remove the coil with the yellow tie strap (Item 1) [Figure
Remove the coil with the green tie strap (Item 2) [Figure

1
Figure 20-61-29 2
3
5
6
1
2
2
P-35552
1
1
Remove the cap (Item 1). O-ring (Item 2), spring (Item 3),
P-35550 check ball (Item 4), seat (Item 5) and O-ring (Item 6)
[Figure 20-61-31] from the five check valve ports.
Remove the O-rings (Item 1) and backup rings (Item 2) Figure 20-61-32
Figure 20-61-30
P-35553
1
P-35551 Remove the port adapter (Item 1) [Figure 20-61-32].
Loosen the five check valves (Item 1) [Figure 20-61-30].

1
Figure 20-61-33
1
2
2 1
P-35557

P-35555 [Figure 20-61-35] from the port adapter.
Figure 20-61-36
Remove the fitting (Item 1) and spool (Item 2) [Figure
20-61-33] from the port adapter.
Figure 20-61-34
P-35558
Loosen the cap (Item 1) [Figure 20-61-36].

P-35556

fitting.

Figure 20-61-37
1
1
2
3
5
6
P-35533
4

P-35559 fittings.
Figure 20-61-40
Remove the cap (Item 1), O-ring (Item 2), spring (Item 3),
check ball (Item 4), seat (Item 5) and O-ring (Item 6)
[Figure 20-61-37] from the port.
Figure 20-61-38
1 1
P-35561
Remove the two plugs (Item 1) [Figure 20-61-40].
P-35560
Remove the four fittings (Item 1) [Figure 20-61-38].

MANIFOLD ASSEMBLY (CONT’D)
Figure 20-61-41
P-35537

plugs.

Assembly

1
or damaged parts.

Figure 20-61-42
P-35533
Install the O-ring (Item 1) [Figure 20-61-44] on the four

1 fittings.
Figure 20-61-45
P-35537

1 1
Figure 20-61-43
P-35560
Install the four fittings (Item 1) [Figure 20-61-45].
P-35561
Install the two plugs (Item 1) [Figure 20-61-43]. Tighten

the plugs to 18 - 20 ft.-lb. (24,4 - 27,1 N•m) torque.

Assembly (Cont’d)
Figure 20-61-46 1
1
6 2
5
4
2
1
P-35557
3
Install the O-rings (Item 1) and backup ring (Item 2)

P-35559 [Figure 20-61-48] on the port adapter.
Figure 20-61-49
Figure 20-61-47
1
P-35556
P-35558

3), spring (Item 4), O-ring (Item 5) and cap (Item 6)
[Figure 20-61-46] in the port (Item 1) [Figure 20-61-47]
in the manifold housing.

Assembly (Cont’d)
6
Figure 20-61-50 5
4
2
1
1 2
P-35552
Figure 20-61-53
P-35555
1
Install the spool (Item 1) and fitting (Item 2) [Figure 20-
61-50] in the port adapter.
Figure 20-61-51
1
P-35551
3), spring (Item 4), O-ring (Item 5) and cap (Item 6)
[Figure 20-61-52] in the five check valve ports (Item 1)
[Figure 20-61-53].
P-35553
Tighten the caps to 19 - 22 ft.-lb. (25,1- 29,8 N•m) torque.
Install the port adapter (Item 1) [Figure 20-61-51].

Assembly (Cont’d)
Figure 20-61-54 1
1
1
2
2
P-35544
1
1
Install the two O-rings (Item 1) [Figure 20-61-56] on the
P-35550 coils.
Figure 20-61-57
Install the O-rings (Item 1) and backup rings (Item 2)
Figure 20-61-55
1
2
P-35548
1 Install the coil with the green tie strap (Item 1) [Figure
P-35549 20-61-57] on the left solenoid.
Install the coil with the yellow tie strap (Item 2) [Figure
Install the solenoids (Item 1) [Figure 20-61-55]. 20-61-57] on the right solenoid.

Assembly (Cont’d)
Figure 20-61-58 1
1
P-35544
Install the O-rings (Item 1) [Figure 20-61-60] on the coil.

P-35547
Figure 20-61-61

solenoid.
Figure 20-61-59
1 P-35543
2 Install the coil with the brown tie strap (Item 1) [Figure
P-35546
Install the spring (Item 1) and solenoid (Item 2) in the port

(Item 3) [Figure 20-61-59]. Tighten the solenoid to 19 -
22 ft.-lb. (25,1- 29,8 N•m) torque.

Assembly (Cont’d)
1
Figure 20-61-62
P-35541
1
Install the two solenoids (Item 1) [Figure 20-61-64].
P-35542
Tighten the solenoids to 19 - 22 ft.-lb. (25,1- 29,8 N•m)
torque.
Install the nut (Item 1) [Figure 20-61-62] on the three
solenoids. Figure 20-61-65
Hand tighten the nuts.

1
2
Figure 20-61-63
1
2
2
P-35540
Install the coil with the red tie strap (Item 1) [Figure 20-
61-65] on the left solenoid.
1
1
Install the coil with the blue tie strap (Item 2) [Figure 20-
P-35550 61-65] on the right solenoid.


Assembly (Cont’d)
Figure 20-61-66
P-35537

P-35539
Figure 20-61-69
Install the O-ring (Item 1) [Figure 20-61-66] on the two

nuts. 1
Figure 20-61-67
P-35536
Install the three plugs (Item 1) [Figure 20-61-69].
P-35538
Install the nuts (Item 1) [Figure 20-61-67] on the

solenoid.
Tighten the nuts to 3 - 5 ft.-lb. (4,1- 6,1 N•m) torque.


Assembly (Cont’d) 2
Figure 20-61-70 1
P-35529
Install the two diagnostic ports (Item 1) and two fittings

P-35530 (Item 2) [Figure 20-61-72].
Figure 20-61-73
Install the build up valve (Item 1) [Figure 20-61-70].
Figure 20-61-71
2
1
3
1
4
P-22370
P-35525 Install the O-ring (Item 1) and backup rings (Item 2)

[Figure 20-61-73] on the main relief valve.
Install the O-ring (Item 1) [Figure 20-61-71] on the two Install the O-ring (Item 3) and glid ring (Item 4) [Figure
diagnostic ports and two fittings. 20-61-73] on the main relief valve.

Assembly (Cont’d)
1
Figure 20-61-74
P-35526
1
Install the pressure reducing valve (Item 1) [Figure 20-
P-35528 61-76].
Tighten the pressure reducing valve to 19 - 22 ft.-lb.

Install the main relief valve (Item 1) [Figure 20-61-74]. (25,1- 29,8 N•m) torque.
Tighten the main relief valve to 30 - 35 ft.-lb. (40,7 - 47,5 Figure 20-61-77
N•m) torque.
Figure 20-61-75
1 1
2
2
1 P-35525
1
P-35527 Install the O-ring (Item 1) [Figure 20-61-77] on the

diagnostic port and five fittings.

[Figure 20-61-75] on the pressure reducing valve.

Assembly (Cont’d)
Figure 20-61-78
1
1
P-35710
Install the accumulator (Item 1) [Figure 20-61-80].

P-35524
Tighten the accumulator to 22 - 24 ft.-lb. (29 - 33 N•m)
torque.
Install the diagnostic port (Item 1) and five fittings (Item 2)
[Figure 20-61-78]. Figure 20-61-81
Figure 20-61-79
P-35712
P-22367

accumulator.

MANIFOLD ASSEMBLY (CONT’D)
Assembly (Cont’d)
Figure 20-61-82
1
2
P-35522
Install the fitting (Item 1) and hose (Item 2) [Figure 20-

61-82] on the manifold block.
Figure 20-61-83
2
1
2
3
P-35521
Install the mount plate (Item 1), two clamps (Item 2) and
three bolts (Item 3) [Figure 20-61-83] on the manifold
block.

TRAVEL MOTOR Figure 20-70-2
Lift and block the side of the track frame where the final
drive will be removed.
Release the track tension and remove the track. (See

TRACKS on Page 30-20-1.)
Figure 20-70-1 1
P-56030
Remove the hoses (Item 1) [Figure 20-70-2] from the

1 travel motor.
1
Figure 20-70-3
1
P11248
Remove the bolts (Item 1) [Figure 20-70-1] from the

track frame cover.
Installation: Tighten the bolts to 20 - 25 ft.-lb. (27 - 34

N•m) torque.
Remove the cover.
P-56031
IMPORTANT
When repairing hydrostatic and hydraulic systems, travel motor.
parts clean. Always use caps and plugs on hoses, Installation: Apply thread lock (Loctite® 242) to the bolts
tubelines and ports to keep dirt out. Dirt can quickly and tighten to 74 - 81 ft.-lb. (100 - 110 N•m) torque.
damage the system.
I-2003-0888
Remove the travel motor from the track frame.
Mark the hoses for correct installation.

TRAVEL MOTOR (CONT'D)
1. Snap Ring 41
2. Plug 40
3. O-Ring 44 38 39 43
4. Cover 42
36
5. Bushing 42 40
6. Drive Shaft 35 33
32
7. Snap Ring 31 28
30
8. Planetary Carrier 41
9. Sun Gear 43 37
10. Snap Ring 34
11. Anti-Rotation Washer
27
12. Bearing 29 26
13. Planetary Gear 24
14. Thrust Washer
15. Planetary Gear
16. Ring Gear 25
17. Snap Ring 25
18. Shims
19. Bearings 23
20. Spacer 19
21. Snap Ring 22
22. O-Ring 20
19
23. Seal Ring 18
24. Snap Ring 17
25. Snap Ring 16
26. Bearing
27. Drive Shaft
28. Hub 15
29. Seal 21 10
30. Alignment Pin
31. Swash Plate
32. Rotating Block
33. Motor Plate
34. Alignment Pin 14
35. Bearing 13 10
36. O-Ring 11
37. Alignment Pin 10
38. Motor Cover
39. Spool
40. Washer 12
6 4
41. Spring 3
42. O-Ring 9 1
43. Plug 7
44. Bolt 8
5
2
B-14711

TRAVEL MOTOR (CONT’D) Figure 20-70-5
Disassembly
IMPORTANT
damage the system.
I-2003-0888
B-14729
The following tool will need to be ordered from OTC Tool
to reassemble the travel motor:
Remove the internal snap ring from the travel motor case
MEL1519 for torque ring and seal ring assembly. [Figure 20-70-5].
1
1
B-14497 B-14730
Remove the drain plugs (Item 1) [Figure 20-70-4] from To remove the cover, install two threaded pins in the
the cover. drain holes and lift the cover off [Figure 20-70-6].
Drain the oil into a container. Air pressure may also be used to remove the cover.

Figure 20-70-7
B-14732
Remove the planetary carrier [Figure 20-70-9].

B-14731
Figure 20-70-10
Screw the adapter in a drain hole and apply 8 - 11 psi

[Figure 20-70-7].
1
NOTE: Do not use excess pressure or seal damage
2
may result.
4
Figure 20-70-8
3
1
5
B-14733
Remove the snap rings (Item 1), anti-rotation washers

(Item 2), gears (Item 3), bearings (Item 4) and the bottom
thrust washers (Item 5) [Figure 20-70-10] from the
planetary carrier assembly.
B-14772A

cover.

Figure 20-70-11
1
2
B-14736
Remove the snap rings (Item 1) and the gears/bearings

B-14734 (Item 2) [Figure 20-70-13].
Figure 20-70-14
Remove the drive shaft (Item 1) [Figure 20-70-11] from
the carrier.
Figure 20-70-12 1
2 2
1 B-14737
Remove the external snap ring (Item 1) and the shim(s)

B-14735 (Item 2) [Figure 20-70-14].
Before the ring gear can be pulled from the hub, a plate
Remove the sun gear (Item 1) from the planetary carrier, must be placed on the three pins of the planetary carrier.
by removing the snap ring (Item 2) and pushing the sun
gear (Item 1) [Figure 20-70-12] out of the carrier. The plate will provide support for the three jaw puller.

Figure 20-70-15
0.250 in.
(6,35 mm)
5.500 in.
(140 mm)
B-14739
Remove the ball bearing from the ring gear as shown

B-14725 [Figure 20-70-17].
NOTE: Do not damage the top surface of the bearing

Obtain the plate [Figure 20-70-15] locally. as it is lapped (polished) to mate with the front
seal ring.
The dimensions of the plate are as follows:
Figure 20-70-18
Diameter 5.500 in. (140 mm)
Thickness 0.250 in. (6.35 mm)
Figure 20-70-16 1
B-14740

ring gear.
B-14738
Using a three jaw puller, separate the hub and the ring
gear assembly [Figure 20-70-16].

Figure 20-70-19
B-14839
Remove the front seal ring from the motor hub [Figure
B-14741 20-70-21].
Figure 20-70-22
Remove the internal snap ring (Item 1) and spacer (Item
2) [Figure 20-70-19].
5
Figure 20-70-20
4
1
2
3
4
3 2
1
B-14744
Remove the plugs (Item 1), O-rings (Item 2), springs

B-14742 (Item 3), and washers (Item 4) [Figure 20-70-22] from
both ends of the spool.
Remove the second bearing from the ring gear [Figure Remove the spool (Item 5) [Figure 20-70-22].
20-70-20].

Figure 20-70-23
B-14745
Remove the bolts and motor cover [Figure 20-70-25].

B-14492
Figure 20-70-26
To disassemble the spool, insert a hardened pin through

the hole in the spool and use a vise with protective jaws 1
to hold the spool [Figure 20-70-23].
NOTE: Do not use any type of tool to grip the spool or

damage to the spool will result. 2
Remove the end plug from both ends of the spool

[Figure 20-70-23].
Figure 20-70-24
2
B-14677
Remove the valve plate (Item 1) and dowel pin (Item 2)

2 [Figure 20-70-26]
1
3
3
1
B-14491
Remove the spring (Item 1), poppet (Item 2), and check
ball (Item 3) [Figure 20-70-24] from both ends of the
spool.

Figure 20-70-27 1
B-14747
Remove the internal snap ring (Item 1) [Figure 20-70-29]

B-14633 retaining the bearing/drive shaft to the hub.
Figure 20-70-30
Remove the O-Ring (Item 1), bearing (Item 2) and the
two alignment pins (Item 3). Remove the bearing (Item 2)
[Figure 20-70-27] with a bearing puller.
Figure 20-70-28 1
B-14748
Push the drive shaft (Item 1) [Figure 20-70-30] from the

bottom to remove the shaft from the hub.
B-14746
Invert the hub, and the rotating block will slide out
[Figure 20-70-28]

TRAVEL MOTOR (CONT’D)
Figure 20-70-31
2
3
B-14751
Remove the snap ring (Item 1), bearing (Item 2) and the
snap ring (Item 3) [Figure 20-70-31] from the drive shaft.
Figure 20-70-32
3
1
B-14728
Remove the swash plate (Item 1), seal (Item 2) and

alignment pin (Item 3) [Figure 20-70-32].

Assembly

1
Inspect all parts and replace any that are damaged. If
any of the planetary gears are damaged, replace all the
planetary gears and the sun gear from the planetary
assembly that is damaged. 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.
The following tools will be needed to assemble the travel

motor: B-14753
MEL 1519 - Seal Installation Tool

Apply oil to the inside diameter of the oil seal and install
Figure 20-70-33 the oil seal (Item 1) [Figure 20-70-34] in the hub.
Figure 20-70-35
2
1
B-14752
B-14754
Install the snap ring (Item 1), bearing (Item 2) and snap
ring (Item 3) [Figure 20-70-33] on the drive shaft.
Install the drive shaft/bearing assembly (Item 1) [Figure
20-70-35] in the hub.
NOTE: Make sure the bearing is seated in the hub.

Assembly (Cont’d)
Figure 20-70-36
1
B-14757
Apply oil to the piston faces and install the rotating block
B-14755 (Item 1) [Figure 20-70-38] in the motor hub.
Figure 20-70-37
1
3
3
B-14756
Invert the hub and install the alignment pin (Item 1) and
swash plate (Item 2) [Figure 20-70-37].
Install the two alignment pins (Item 3) [Figure 20-70-37]

in the motor hub.

Assembly (Cont’d)
Figure 20-70-39
2
0.098 - 0.110”
(2,5 - 2,8 mm)
B-14759
1
Install the alignment pin (Item 1) [Figure 20-70-41] on

B-14777 the motor cover.
Install the valve plate (Item 2) on the motor cover, with

Figure 20-70-40 the alignment notch in the valve plate, sliding over the
alignment pin (Item 1) [Figure 20-70-41].
Figure 20-70-42
1
2
B-14758
Press the bearing (Item 1) [Figure 20-70-39] & [Figure

B-14774
20-70-40] in the motor cover.
The bearing (Item 1) [Figure 20-70-39] must extend from Lubricate the bearing with oil and install the motor cover
the face of the motor cover 0.098 - 0.110 in. (2,5 - 2,8 on the hub with the screws [Figure 20-70-42].
mm).
Tighten the bolts in a crisscross manner to 18 - 22 ft.-lb.
Install the O-ring (Item 2) [Figure 20-70-40] on the motor (25 - 30 N•m) torque.
cover.

Assembly (Cont’d)
1
Figure 20-70-43
2
4 5
2 4
3
2
2 5 3
4 4
5 3 5
1
B-14775
1 Apply oil to and install the spool (Item 1) [Figure 20-70-

3 B-14491 45] in the motor cover.
Install the washers (Item 2) and the springs (Item 3) on

Install the check ball (Item 1), poppet (Item 2) and the both ends of the spool (Item 1) [Figure 20-70-45].
spring (Item 3) [Figure 20-70-43] in both ends of the
spool. Install the O-rings (Item 4) on the plugs (Item 5) [Figure
20-70-45].
Install the new O-rings (Item 4) on the plugs (Item 5)
[Figure 20-70-43]. Install the plugs (Item 5) [Figure 20-70-45] on the motor
cover.
Figure 20-70-44
To install the bearings, a bearing installation tool will be
needed.
This tool is placed on the top of the bearing inner and

outer race and a press is used to seat the bearings.
B-14492
To assemble the spool, insert a hardened pin through the

hole in the spool and use a vise with protective jaws to
hold the spool [Figure 20-70-44].
NOTE: Do not use any type of tool to grip the spool or

damage to the spool will result.
Install the plug in both ends of the spool [Figure 20-70-

44].
Tighten the plugs to 18 - 22 ft.-lb. (25 - 30 N•m) torque.

TRAVEL MOTOR (CONT’D) NOTE: If either the top or bottom bearing has been
replaced, measure the thickness of the old
Assembly (Cont’d) and new bearing. If the difference is greater
than ± 0.002 in. (0,05 mm) add or subtract
Figure 20-70-46 shims to match the new bearing thickness to
0.250” the old bearing thickness.
(6,35 mm)
If shims are needed, order the appropriate shim(s) from
Bobcat Parts:
P/N 6669119 0.0079 in. (0,2 mm)

P/N 6669120 0.0118 in. (0,3 mm)
P/N 6669121 0.0157 in. (0,4 mm)
P/N 6669122 0.0354 in. (0,9 mm)
6.6875”
(170 mm) P/N 6669123 0.0374 in. (0,95 mm)
Figure 20-70-48
B-14725
Obtain the tool locally [Figure 20-70-46]. 2
The dimensions are as follows: 1
Diameter 6.6875 in. (170 mm)

Thickness 0.250 in. (6,35 mm)
Figure 20-70-47
B-14760
Install the spacer (Item 1) and internal snap ring (Item 2)

[Figure 20-70-48].
1
B-14726
Lubricate the outer edge of the bearing and press the

bearing (Item 1) [Figure 20-70-47] in the housing, using
the bearing installation tool.

Assembly (Cont’d)
Figure 20-70-49
B-14726
Lubricate the outer edge of the second bearing and press

B-14761 the bearing in the housing (Item 1) [Figure 20-70-51].
Figure 20-70-52
Invert the ring gear, and using a brass drift, seat the
bearing against the spacer [Figure 20-70-49].
2
Figure 20-70-50
B-14496
Install the O-ring (Item 1) on the seal ring (Item 2)

B-14762 [Figure 20-70-52].
NOTE: Inspect the seal ring for burrs before installing

Install the O-ring (Item 1) [Figure 20-70-50]. the O-ring. Install the O-ring making sure it is
not twisted. To remove any twists, gently pull
NOTE: Make sure the O-ring is correctly installed in a section of the O-ring and let it snap back.
the housing groove so it is not damaged when
the second bearing is installed. The O-ring, seal ring and motor assembly must be clean
and free of any dust, oil film or foreign matter.

Assembly (Cont’d)
Figure 20-70-53
0.300 in. 0.300 in.
(7,62 mm) (7,62 mm)
B-14494
After the seal ring is installed, check the stand out height
B-14764 [Figure 20-70-55] in four places, 90° apart.
The stand out height is 0.300 ± 0.020 in. (7,62 ± 0,5 mm).
Install the seal seating tool (MEL1519) on the seal ring
and O-ring assembly [Figure 20-70-53]. NOTE: If the seal ring does not meet the height
specifications inspect the O-ring for twists or
The O-ring and seal ring assembly has to be lubricated obvious bulges. Remove and reinstall the seal
with alcohol so the O-ring will slip past the housing ring if the O-ring is twisted or bulged.
retaining ring and seal uniformly in the motor housing
radius [Figure 20-70-53]. Apply a light film of oil to the seal ring and lapped face of
the bearing.
Dip the O-ring and seal ring assembly in a pan of alcohol.
NOTE: Do not get any oil on the rubber O-ring.
Figure 20-70-54
Figure 20-70-56
B-14493
B-14765
Shake off the excess alcohol and install the seal ring
assembly on the motor [Figure 20-70-54]. Press the reduction unit and motor assembly in the
bearings [Figure 20-70-56]. The inner bearing may move
Use firm even pressure on the installation tool deeper into the housing as the motor assembly is
(MEL1519) to pop the O-ring into the motor housing. pressed in the housing. If this happens, tap the inner
bearing down to its original position using a brass drift.

Assembly (Cont’d)
2
Figure 20-70-57
2
1
1
B-14768
Install the sun gear (Item 1) [Figure 20-70-59] into the

B-14766 outer planetary carrier.
Install the snap ring (Item 2) on the sun gear (Item 1)

Install the shim(s) (Item 1) and snap ring (Item 2) [Figure [Figure 20-70-59].
20-70-57] in the motor reduction unit.
Figure 20-70-60
The shim(s) (Item 1) [Figure 20-70-57] are used to
remove any end play between the ring gear and
reduction unit.
The snap ring (Item 2) must be snug against the shim(s)

(Item 1) [Figure 20-70-57] and fully seated in the snap 1
ring groove.
Figure 20-70-58
2
1 B-14769
Install the drive shaft (Item 1) [Figure 20-70-60].
B-14767
Install the planetary gears/bearings (Item 1) and the snap

rings (Item 2) [Figure 20-70-58].
NOTE: The second stage planetary gears/bearings

must be installed with the bearing race flare
facing down to match the shoulder on the
pins.

Assembly (Cont’d)
2
Figure 20-70-61
5
1
4
1 B-14676
Inspect the cover bushing (Item 1) [Figure 20-70-63] for

B-14770 wear.
If the bushing (Item 1) [Figure 20-70-63] needs to be

Install the thrust washers (Item 1), planetary gears (Item replaced, drill a hole in the center of the bushing using a
2), bearings (Item 3), anti-rotation washers (Item 4) and number 3 drill bit.
the snap rings (Item 5) [Figure 20-70-61].
Thread the hole with a 0.250 x 28 in. NF tap.
NOTE: Install the snap rings (Item 5) [Figure 20-70-61]
so the opening of the snap ring is towards the Install a 0.250 x 28 in. bolt (Item 2) [Figure 20-70-63] in
outside. the bushing and pull the bushing out of the cover.
Figure 20-70-62 Install the new bushing in the cover with the bevel down.
The clearance between the cover bushing and the sun

gear must be 0.008 - 0.031 in. (0,2 - 0,8 mm).
Figure 20-70-64
B-14771
Install the planetary assembly in the hub [Figure 20-70-

62].
B-14778
Place a 0.500 in. (13 mm) long piece of 0.0625 in. (1,5
mm) solder (Item 1) [Figure 20-70-64] on the end of the
drive shaft.
Seat the cover in the hub.

Assembly (Cont’d)
Remove the cover and measure the solder.

1
If the clearance between the sun gear and cover bushing
does not meet specifications, order the appropriate
bushing shim from Bobcat Parts.
Shim Thickness MEL Part Number

0.020 in. (0,5 mm) 6669597
0.030 in. (0,76 mm) 6669598
0.050 in. (1,27 mm) 6669699
B-14773
Remove the bushing.
Install the correct shim under the bushing and install the Install the snap ring (Item 1) [Figure 20-70-66].
bushing.
Figure 20-70-67
NOTE: Make sure there are no burrs on the bushing
face from bushing removal.
Repeat the procedure for checking clearance between

the sun gear and cover bushing.
1
Figure 20-70-65
1 2
2
B-14498
Add 0.55 quarts (0,5 L) of gear lube 80W90 to the top

plug hole (Item 1) until the gear lube is at the bottom of
the plug hole (Item 2) [Figure 20-70-67].
B-14772 Install and tighten the two plugs.
Install the O-ring (Item 1) [Figure 20-70-65] on the cover.
Install the cover (Item 2) [Figure 20-70-65] on the hub.

SWIVEL JOINT Figure 20-80-1
Description
The swivel joint is a rotary hydraulic swivel which diverts 1

hydraulic oil, under pressure, to the travel motors and the
blade cylinder.
WARNING
P-55417
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s Remove the hoses (Item 1) [Figure 20-80-1] from the top
Handbook and signs (decals) on machine. Follow of the swivel joint.
making repairs, adjustments or servicing. Check for Figure 20-80-2
W-2003-0807
110-1.) or (See Removal And Installation (Cab Equipped
Excavators) on Page 40-110-2.)
1
IMPORTANT
P-55547
parts clean. Always use caps and plugs on hoses, Remove the nut and swivel joint stop bolt (Item 1)
tubelines and ports to keep dirt out. Dirt can quickly [Figure 20-80-2].
damage the system.
I-2003-0888 Installation: Apply thread lock adhesive (Loctite® 242)
to the swivel joint stop bolt and install the nut and the bolt
Mark the hoses for ease of installation. in the swivel joint. Tighten the nut completely on the bolt
threads. Tighten the bolt to 110 - 125 ft.-lb. (150 - 175
N•m) torque.

SWIVEL JOINT (CONT’D) Figure 20-80-4
Removal And Installation (Cont’d) 1
Figure 20-80-3
2
1 1
1
1
P-55415
Remove the hoses from the lower end of the swivel joint
P-55414 [Figure 20-80-4].
Remove the four bolts (Item 1) [Figure 20-80-4].

Support the swivel joint with a jack.
Remove the access plate (Item 2) [Figure 20-80-3] from
the bottom of the undercarriage. Rotate the swivel joint 90° to allow clearance between
the swivel joint and the mount brackets.
Installation: Apply thread lock adhesive (Loctite® 242)

to the bolts. Tighten the bolts to 48 - 55 ft.-lb. (65 - 75
N•m) torque.
Lower the swivel joint through the bottom of the

undercarriage.

SWIVEL JOINT (CONT’D)
1. Bolt
2. Rotor
3. Plug
4. Crown Seal
5. O-Ring
6. Glid Ring
7. Body
8. O-Ring
9. Cover
10. Bolt
1
7
3
8
4
6 9
10
D-2250

Disassembly
Clean the outside of the swivel joint before disassembly.
Figure 20-80-5
P-5873
Remove the O-ring from the O-ring groove [Figure 20-

80-7].
P-5871 Figure 20-80-8
Remove the six bolts from the cover [Figure 20-80-5].
Figure 20-80-6
P-5874
Clamp the swivel joint, base end down in a vise, and

drive the rotor out of the body with a soft faced hammer
P-5872 [Figure 20-80-8].
Remove all the O-rings and glid rings from the rotor.
Remove the cover [Figure 20-80-6].
NOTE: Use care not to scratch the rotor surface as
damage to the finished surface could cause
internal leakage.

Assembly

or damaged parts.

Figure 20-80-9
P-5877
Install the crown seal O-ring [Figure 20-80-11].
Figure 20-80-12
P-5875
Install the O-rings on the rotor [Figure 20-80-9].
Heat the glid rings and crown seal in hydraulic oil for
three minutes at 130° F (54° C).
Figure 20-80-10 P-5878
Stretch the heated crown seal to 4.500 in. (114,3 mm)

[Figure 20-80-12].
P-5876
Stretch the heated rings to 4.0 in. (101,6 mm) and install
on the rotor [Figure 20-80-10].

Assembly (Cont’d)
Figure 20-80-13
P-5882
Seat the rotor using a soft faced hammer [Figure 20-80-

P-5879 15].
Figure 20-80-16
Work the crown seal on the rotor and down to the top
groove [Figure 20-80-13].
Figure 20-80-14
P-5883
Install the O-ring in the groove on the bottom of the body

P-5880 [Figure 20-80-16].
Press the wiper seal in the body [Figure 20-80-14]
Lubricate the inside of the body and the rotor with

hydraulic oil or light grease.
Slide the rotor in the body.

Assembly (Cont’d)
Figure 20-80-17
P-5886
Check the breakaway torque of the swivel joint [Figure

P-5884 20-80-19].
The breakaway torque of the swivel joint is 50 - 90 ft.-lb.

Install the cover on the body [Figure 20-80-17]. (68 - 122 N•m).
Figure 20-80-18
P-5885
Apply thread lock adhesive (Loctite® 242) to the bolt

threads, and install the cover bolts. Tighten the bolts to
18 ft.-lb. (24 N•m) torque [Figure 20-80-18].

SWING MOTOR Figure 20-90-3

2
Remove the floormat and floor plate. (See Removal And
110-1 or See Removal And Installation (Cab Equipped
Remove the battery. (See Removing And Installing The 1

Battery on Page 50-20-2.)
Figure 20-90-1
P-55419
Remove the bolts (Item 1) from the right floor plate (Item
2) [Figure 20-90-3]. Remove the right floor plate.
1
IMPORTANT
P-55427
damage the system.
I-2003-0888
Remove the bolt (Item 1) [Figure 20-90-1].
1 1 1
2
P-55418 P-55488
Remove the nut (Item 1) from the ball joint on the right Remove the three hoses (Item 1) [Figure 20-90-4].
pedal linkage (Item 2) [Figure 20-90-2]. Remove the
linkage from the pedal.

SWING MOTOR (CONT’D) Figure 20-90-7
Figure 20-90-5 1
P-55989
1
Install a hoist (Item 1) [Figure 20-90-7] on the boom.

P-55489
Raise the hoist until the boom/bucket is off the ground.
Remove the hoses (Item 1) [Figure 20-90-5]. Figure 20-90-8
Figure 20-90-6
P-55491
P-55490
Rotate the upperstructure until the swing motor is in the
position shown [Figure 20-90-8].
Remove the four bolts (Item 1) [Figure 20-90-6].
Lower the boom/bucket to the ground.
Installation: Apply thread lock adhesive (Loctite® 242)
to the bolt threads. Tighten the bolts to 90 - 100 ft.-lb.
(125 - 135 N•m) torque.

SWING MOTOR (CONT’D)
Figure 20-90-9
P-55492
Raise and tilt the motor (Item 1) [Figure 20-90-9] toward

the left side of the excavator.
Remove the swing motor.
Figure 20-90-10
P-55493

1. Seal
2. Housing
3. Drive Shaft
4. O-Ring
5. O-Ring
6. Geroler®
7. Plate
8. Drive
9. Valve
10. Valve Plate
11. Spring
12. Crossport Relief Valve
7
13. Housing
14. Valve 5
15. Bolt 6
16. Plug
5
17. Poppet
4
2 3
4
1
14
12 15
13
5
14
11
1
10 12
17
1 4 16
11
8 9
MS1847S

Disassembly
Figure 20-90-11
1
2
1
1
P-42252
1

P-42250 [Figure 20-90-13].
Mark the housing for ease of assembly.

Remove the crossport relief valves (Item 1) [Figure 20-
90-11]. Figure 20-90-14
Figure 20-90-12
1 1
1 1
P-42254
P-42251
Remove the ring (Item 1) [Figure 20-90-12].

1
Figure 20-90-15
P-42256
Remove the O-rings (Item 1) [Figure 20-90-17].

P-42255
Figure 20-90-18
Remove the valve housing (Item 1) [Figure 20-90-15].
Figure 20-90-16
2
2
1
P-42258
Remove the inner seal (Item 1) and outer seal (Item 2)

P-42257 [Figure 20-90-18].
Lift the housing straight up. If done carefully the springs

(Item 1) and balance ring sub-assembly (Item 2) [Figure
20-90-16] will remain on the valve for easy removal.
Remove the springs and balance ring.

Figure 20-90-19
1
P-42261
Remove the valve drive (Item 1) [Figure 20-90-21].

P-42259
Figure 20-90-22
Remove the valve (Item 1) and valve plate (Item 2)

[Figure 20-90-19].
1
Figure 20-90-20
P-42262

Geroler®.
P-42260
Turn the valve plate over and remove the O-ring (Item 1)
[Figure 20-90-20].

Figure 20-90-23
1
P-42265

P-42263 housing.
Figure 20-90-26
Remove the Geroler® (Item 1) [Figure 20-90-23].
Figure 20-90-24
1
P-42266
P-42264 Remove the drive shaft (Item 1) [Figure 20-90-26].
Turn the Geroler® over and remove the O-ring (Item 1)

[Figure 20-90-24].

Figure 20-90-27
2
1 2
P-42267
Use a tap to remove all the old thread adhesive from the
bolt hole threads (Item 2) [Figure 20-90-27].

Assembly
Check the components for damage or wear. 1
Always use new O-rings and seals.
Apply clean hydraulic oil to the components during

installation.
Figure 20-90-28
1
Figure 20-90-31
P-42267
Install the O-ring (Item 1) [Figure 20-90-28]. 1

Figure 20-90-29
P-42264
1
Geroler®.
P-42266
Install the drive shaft (Item 1) [Figure 20-90-29].

Assembly (Cont’d)
Figure 20-90-32
1
2
P-42261
Install the valve drive (Item 1) [Figure 20-90-34] in the

P-42263 Geroler®.

Turn the Geroler® over and install the Geroler® (Item 1)
[Figure 20-90-32] on the housing. Figure 20-90-35
Timing the hydraulic motor:
The timing parts include: 1

1.Geroler®
2.Valve drive
3.Valve plate
4.Valve
Figure 20-90-33
2 1
P-42260
Install the O-ring (Item 1) [Figure 20-90-35] on the valve

4 plate.
P-42268
Align the case drain hole (Item 1) and the pressure relief
hole (Item 2) [Figure 20-90-33] in the Geroler® with the
case drain hole and pressure relief hole in the housing.
Locate the largest opening in the Geroler® (Item 3), and

mark the location on the outside edge of the Geroler®
(Item 4) [Figure 20-90-33].

SWING MOTOR (CONT’D) Rotate the valve clockwise until the spline teeth engage
in the valve.
Assembly (Cont’d)
Figure 20-90-38
Figure 20-90-36
1
2
P-42272
P-42269
Apply clean grease on the three balance ring assembly

Align the case drain hole (Item 1) in the valve plate (Item springs (Item 1) [Figure 20-90-38] and install the springs
2) [Figure 20-90-36] with the case drain hole in the in the holes located inside of the valve housing.
Geroler®. Install the valve plate (seal side toward
Geroler®) on the Geroler®. Figure 20-90-39
NOTE: Locate the slot opening (Item 3) [Figure 20-90-

36] in the valve plate which is in line with the 1
largest opening (marked earlier) in the
Geroler®.
Figure 20-90-37
P-42273
2
valve housing.
P-42270
Install the valve (Item 1) [Figure 20-90-37].
Locate any one of the side openings of the valve (Item 2)

[Figure 20-90-37] that goes through to the face of the
valve.
Line up this side opening with the open slot of the valve
plate that is in line with the largest opening of the
Geroler® (marked earlier).

Assembly (Cont’d)
Figure 20-90-40
Outer Outer
Seal Seal
Balance Plate
P-42275
Figure 20-90-43
Pin Inner Seal B-3046
Pin B-8732
‘
Install the inner and outer face seals on the balance ring
[Figure 20-90-40].
1
NOTE: Install the face seals as shown in [Figure 20-
90-40], or the motor will not operate properly.
Any damage to these seals will affect the
operation of the motor.
Figure 20-90-41
P-42255
1 Insert a small screw driver (Item 1) [Figure 20-90-42]

through the port in the housing. Apply pressure to side of
the balance ring assembly until the valve housing is in
place. Align the case drain hole in the housing with the
case drain hole in the valve plate. Install the valve
housing (Item 1) [Figure 20-90-43] against the valve
plate and remove the screwdriver.
NOTE: Check that the O-rings on the motor sections

P-42274 are in place before the bolts are installed. If
the O-rings are out of position the swing
motor will leak between the sections.
Align the balance ring assembly pins with the two holes
in the valve housing, and install the balance ring sub-
assembly (Item 1) [Figure 20-90-41] in the valve
housing.

Assembly (Cont’d)
Figure 20-90-44
1
1
3 2 1
P-42252
2 4
Install the O-rings (Item 1) and backup ring (Item 2)

P-42253 [Figure 20-90-46] on both crossport relief valves.
Figure 20-90-47
Install the four bolts. Tighten the bolts in sequence (Item
1 through Item 4) [Figure 20-90-44] to 63 ft.-lb. (86 N•m)
of torque.
Follow these procedures:
NOTE: This motor requires Loctite® in threaded holes 1

of the mounting flange.
Figure 20-90-45
P-42251
Install the ring (Item 1) [Figure 20-90-47].
P-8418
Adequate Loctite® penetration and sealing depends

highly on cleanliness and dryness of the threads. Use a
non-petroleum base solvent to clean excess oil from
threads of the flange after disassembly. Apply two to
three drops of Loctite® 290 at the top of the threaded
holes [Figure 20-90-45].
NOTE: Allow the Loctite® five minutes for thread

penetration before installing the motor on the
swing motor carrier.

Assembly (Cont’d)
Figure 20-90-48
P-42250
Install the relief valves (Item 1) [Figure 20-90-48].
Figure 20-90-49
P-42278
Clamp the motor in a press. Turn the shaft in a clockwise

direction. If the motor is correctly timed, there will be
suction at the top port (Item 1) [Figure 20-90-49].

SWING MOTOR DRIVE CARRIER Figure 20-91-2
Remove the swing motor. (See Removal And Installation

on Page 20-90-1.) 1
Figure 20-91-1 1
P-23199
Install two of the short mount bolts (Item 1) [Figure 20-

1 91-2] in the threaded holes in the carrier. Tighten the
bolts to push the carrier off of the two alignment pins. The
pins may stay in either the carrier or the upperstructure.
1
P-23198
Mark and remove the eight bolts (Item 1) [Figure 20-91-

1].
NOTE: It is necessary to mark the bolts as the bolts

are two different lengths. The bolts must be
installed in the original positions.
Installation: Apply Loctite® 242 to the bolt threads and

tighten the bolts to 78 - 85 ft.-lb. (105 - 115 N•m) torque.

SWING MOTOR DRIVE CARRIER (CONT’D)
1. Snap Ring
1
2. Spacer
3. Bearing
4. Bearing Cup 2
5. Housing
6. Dowel Pin 3
7. O-Ring
8. Spacer
9. Seal 4
10. Snap Ring
11. Plug
12. Shaft
6
6
4
10
11
12
PE-1154

SWING MOTOR DRIVE CARRIER (CONT’D) Figure 20-91-4
Disassembly
Clean the outside of the carrier before disassembly.
IMPORTANT
parts clean. Always use caps and plugs on hoses, 1
damage the system. P-23266
I-2003-0888
Remove the snap ring (Item 1) [Figure 20-91-4] from the

Drain the lubrication oil from the assembly. Tip the carrier bottom of the carrier.
over, allowing the oil to drain through the top bearing.
Figure 20-91-5
Figure 20-91-3
P-23267
P-23265
Support the motor carrier on two support blocks and

Remove the snap ring (Item 1) and the spacer (Item 2) press the drive shaft out the bottom of the carrier to
[Figure 20-91-3] from the top of the drive shaft. remove the top bearing and bottom seal [Figure 20-91-
5].
Remove the drain plug (Item 3) [Figure 20-91-3] from the
bottom of the drive shaft.

Figure 20-91-6
P-23268
Using a hammer and brass punch, remove the bearing

P-6372 cups from the top and bottom of the carrier [Figure 20-
91-8].
Remove the bottom bearing and spacer by supporting Clean all parts in solvent and dry with compressed air.
the spacer and pressing the shaft through it [Figure 20-
91-6]. After cleaning, inspect the following components for
damage and wear:
Figure 20-91-7
Bearings and Bearing Cups
Drive Shaft
Housing
Washer
Spacer
Snap Rings
P-6373
Remove the O-ring located inside the spacer [Figure 20-

91-7].

Assembly
Figure 20-91-9
P-6376
Press the spacer (Item 1) and a new bearing (Item 2)

P-23269 [Figure 20-91-11] on to the drive shaft.
Install the drive shaft with the spacer and the new
Apply a light film of grease to the outside of the new bearing installed, through the bottom of the carrier.
bearing cups, and press the top and bottom cups into the
carrier [Figure 20-91-9]. Figure 20-91-12
Figure 20-91-10
P-23270
P-6373
Press a new bearing on the top of the drive shaft [Figure
20-91-12].
Oil and install a new O-ring inside the spacer [Figure 20-
91-10].

Assembly (Cont’d)
Figure 20-91-13
P-23271
1
Clamp the carrier in a vise that has padded jaws. Thread

P-23265 a bolt in the threaded hole in the carrier flange. Setup a
dial indicator so the end play of the drive shaft can be
checked, by placing a pry bar under the head of the
Install the washer (Item 1) and the snap ring (Item 2) installed bolt and across the end of the drive shaft
[Figure 20-91-13] on the drive shaft. [Figure 20-91-15].
Oil and install a new O-ring on the drain plug. End play should not be more than 0.009 in. (.229 mm)
and the shaft should rotate smoothly.
Figure 20-91-14
If the end play is greater than 0.009 in. (.229 mm) the
carrier assembly has to be disassembled and the
following components checked;
Snap Ring 0.078 ± 0.002 in. (1.98 ± 0.05 mm)

1
Washer 0.78 ± 0.001 in. (4.52 ± 0.03 mm)
Spacer 0.042 ± 0.002 in. (12.0 ± 0.05 mm)
Figure 20-91-16
P-23272
Apply thread adhesive (Loctite® 242) on the plug threads

and install the plug (Item 1) [Figure 20-91-14] in the
bottom of the drive shaft.
3.3189” ± 0.0015”
(84,30 ± 0,038mm)
B-14413
Length of drive shaft from top of snap ring groove to top

of splined section 3.3189 in. ± 0.0015 in. (84.3 ± 0.038
mm) [Figure 20-91-16].

Assembly (Cont’d)
Figure 20-91-17
P-6381
0.765” ± 0.0015”
(19,44 ± 0,038mm) A seal installation tool can be made locally [Figure 20-
B-14412 91-19].
Dimensions of the seal installation tool:

Housing top bearing cup seat to bottom bearing cup seat
0.765 in. ± 0.0015 in. (19,44 ± 0,038 mm) [Figure 20-91- I.D. 3.250 in. (82,55 mm)
16].
O.D. 4.0 in. (101,6 mm)
Height 5.0 in. (127 mm)
Figure 20-91-18
Figure 20-91-20
1
P-23273
P-23266
Install the seal in the bottom of the carrier [Figure 20-91-
18].
Install the bottom snap ring (Item 1) [Figure 20-91-20].
After the drive assembly has been installed in the

excavator, fill the carrier with enough hydraulic fluid to
cover the top bearing, before installing the swing motor.

CONTROL PATTERN SELECTOR VALVE
Remove the right console cover. (See Console Cover

Remove the right console base. (See Console Base

Mark all hydraulic hoses for proper installation.
Figure 20-100-1
1
P-24200
Remove the eight hydraulic hose from the control pattern

selector valve (Item 1) [Figure 20-100-1].
Cap and plug the hoses and fittings.
Figure 20-100-2
P-24201
Remove the valve from the excavator.

CONTROL PATTERN SELECTOR VALVE (CONT’D)
1. Handle
2. Roll Pin
3. Snap Ring
4. Spool
5. O-Ring
6. Valve Block
7. Washer
3
7
6
3 2
4
2
2
5
TS-1353

CONTROL PATTERN SELECTOR VALVE (CONT’D) Figure 20-100-5
Disassembly
Clean the outside of the selector valve before

disassembly.
Clamp the valve in a vise equipped with padded jaws.

1
Figure 20-100-3
P-11961
Pull the spool (Item 1) [Figure 20-100-5] out of the valve.

1
Figure 20-100-6
P-11959
1 1
Figure 20-100-4
P-11962

spool.
P-11960
Remove the washer (Item 1) [Figure 20-100-4].

CONTROL PATTERN SELECTOR VALVE (CONT’D) Figure 20-100-9
Assembly

or damaged parts.

and O-rings with clean hydraulic fluid before installation. 1
Figure 20-100-7
P-11960
1 1
Install the washer (Item 1) [Figure 20-100-9] on the end
of the spool.
Figure 20-100-10
P-11962

spool.
Figure 20-100-8
1
P-11959
Install the snap ring (Item 1) [Figure 20-100-10] on the

1 spool.
P-11961
Apply oil to and install the spool (Item 1) [Figure 20-100-

8] in the valve body.

RIGHT CONTROL LEVER (JOYSTICK) Figure 20-110-3
Testing
The following tools will be needed to do the procedure:
MEL1355 - Hydraulic Test Kit 1
Stop the engine.
Figure 20-110-1
P-50560

from the control valve.
Figure 20-110-4
P-49411
Open the right side access cover (Item 1) [Figure 20-

110-1].
Figure 20-110-2
1 P-50561
From the test kit Install a 1000 PSI (6896 kPa) gauge
(Item 1) [Figure 20-110-4] on the pilot line.
Start the excavator, and warm the hydraulic oil to

operating temperature of 150° F (66° C).
Engage the circuit to be tested. Record the operating

P-50558 pressure.
The operating pressure should be approximately 428 SPI

At the control valve assembly find the pilot line (Item 1) (29.5 Bar) with an acceptable range of 406 - 450 PSI (28
[Figure 20-110-2] of the control lever (joystick) that is to - 31 Bar).
be checked (Boom, Arm, Boom Swing, Bucket.)
If the operating pressure is correct, check the valve
section spool for proper operation. If the operating
pressure is incorrect, remove the pressure reducing
valve, clean, install and retest. (See Testing And
Adjusting The Pressure Reducing Valve on Page 20-33-
1.) If the pressure is still incorrect replace the pressure
reducing valve.

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-110-7
Handle Removal And Installation
Figure 20-110-5
P-50874
Remove the screw (Item 1) [Figure 20-110-7] from the

P-50876 cup holder.
Figure 20-110-8
Remove the cover (Item 1) [Figure 20-110-5] from the
arm rest.
Figure 20-110-6
P-50873
1
Remove the nut (Item 1) [Figure 20-110-8] from the key
P-50875 switch. Allow the keyswitch to drop inside the console.
Lift the console cover up and over the joystick.

Remove the two bolts (Item 1) [Figure 20-110-6] from
the arm rest.
Remove the arm rest.

Handle Removal And Installation (Cont’d)
Figure 20-110-9
P-21732
Turn the controller to allow it to pass through the console

P-50872 cover [Figure 20-110-11].
Figure 20-110-12
Installation: Install the keyswitch and nut (Item 1)
[Figure 20-110-9] before installing the controller.
Figure 20-110-10
1 1
P-52068
Disconnect the wire harness (Item 1) [Figure 20-110-12].

P-21730
Disconnect the accessory outlet electrical connector

(Item 1) [Figure 20-110-10].
Depress the four tabs (Item 2) [Figure 20-110-10] and

remove the controller.

Figure 20-110-13
P-21668
Installation: The wires [Figure 20-110-15] must be

P-21666 installed in the proper locations in the wire connector,
listed below.
Remove the lock (Item 1) [Figure 20-110-13] from the A Green

joystick electrical connector.
B Brown
Figure 20-110-14 C Pink
D Black
E White
1
2 Check each wire to be certain the tab locks into position.
Figure 20-110-16
P-21671A
With a small piece of wire, depress the wire terminal tabs 1

(Item 1) [Figure 20-110-14].
Carefully remove the individual wires from the back of the 2

electrical connector. P-52069
Installation: Use a small piece of wire and re-bend the

tab (Item 2) [Figure 20-110-14] on each wire before Pull the boot (Item 1) [Figure 20-110-16] up.
installing in the electrical connector.
Installation: The top of the boot is molded to fit over the
flange of the joystick. It has tabs that fit between the
handle and joystick flange (Item 2) [Figure 20-110-16].
Install the boot properly before installing the console
cover.

Figure 20-110-17
2
1
1
P-32521
Pull the boot (Item 1) [Figure 20-110-19] down.

P-52070
Installation: The top of the boot is molded to fit over the
flange of the joystick. It has tabs that fit between the
Lift the grommet (Item 1) [Figure 20-110-17] from the handle and joystick flange (Item 2) [Figure 20-110-19].
mount plate. Install the boot properly before installing the console
cover.
Figure 20-110-18
Figure 20-110-20
1
1
P-33820
P-32521
Remove the wire and grommet (Item 1) [Figure 20-110-

18]. Loosen the nut (Item 1) [Figure 20-110-20].
Remove the handle.

Joystick Assembly, Removal And Installation
Figure 20-110-21
P-50874
Remove the screw (Item 1) [Figure 20-110-23] from the

P-50876 cup holder.
Figure 20-110-24
arm rest.
Lift up on the rear of the cover and slide the cover ahead
to remove it.
Figure 20-110-22
1
1
P-50873
Remove the nut from the key switch (Item 1) [Figure 20-
110-24] (if equipped). Allow the switch to drop inside the
console.
1
P-50875 Lift the console up and over the joystick.

arm rest.


(Cont’d)
Figure 20-110-25
P-21732
1
Turn the controller to allow it to pass through the console
cover [Figure 20-110-27].
P-50872
Remove the console cover.
Installation: Install the keyswitch and nut (Item 1) Figure 20-110-28

[Figure 20-110-25] before installing the controller.
Figure 20-110-26
P-33821
P-21730 Mark the hoses for proper installation. Remove the six
hoses (Item 1) [Figure 20-110-28] from the housing.
Disconnect the accessory outlet electrical connector

(Item 1) [Figure 20-110-26].
Remove the controller from the console cover by IMPORTANT

pressing the mounting tabs (Item 2) [Figure 20-110-26].
damage the system.
I-2003-0888

RIGHT CONTROL LEVER (JOYSTICK) (CONT’D)

(Cont’d)
Figure 20-110-29
1
3
3
2
P-52070
Pull the boot (Item 1) [Figure 20-110-29] up.
Installation: The bottom of the boot is molded to fit over

the flange of the joystick. It has tabs that fit between the
joystick flange (Item 2) [Figure 20-110-29] and the
mounting plate. Position the boot properly before
installing the console cover.

housing.
Figure 20-110-30
P-52068
Disconnect wire harness (Item 1) [Figure 20-110-30].
Remove the joystick assembly.

1. Handle
2. Dust Boot
3. Coupler
4. Control Plate
5. U-Joint 1
6. Grommet
7. Plate
8. Plunger
9. Spool
10. Spring
11. Housing
12. Wire Harness
13. Lock 2
14. Connector
4
6
10
11
12
13
14
MS1352

Disassembly
2
Clean the outside of the control lever before
disassembly.
Remove the handle. (See Handle Removal And

Installation on Page 20-110-2.)
Figure 20-110-31
P-32576
1
Loosen the nut (Item 1) and remove the connector (Item

2 2) [Figure 20-110-33].
Figure 20-110-34
1
P-32560
2
Remove the boot (Item 1) from the control lever (joystick)
(Item 2) [Figure 20-110-31].
Figure 20-110-32
3
3
P-32574
2
1 Mark the coupler (Item 1), control plate (Item 2), and
plate (Item 3) (Item 1) [Figure 20-110-34] for correct
installation.
P-32568
Mark the coupler (Item 1), nut (Item 2), and connector
(Item 3) [Figure 20-110-32] for correct assembly.

1
Figure 20-110-35
2
1
P-32578
Mark the plate and housing for correct installation.

P-32574 Remove the U-Joint (Item 1) [Figure 20-110-37].
NOTE: The plate (Item 2) [Figure 20-110-37] is spring

Remove the coupler (Item 1) from the control plate (Item loaded and will come up as the U-Joint is
2) [Figure 20-110-35]. removed.
Figure 20-110-36 Figure 20-110-38
1 1
P-32577 P-32582
Remove the control plate (Item 1) from the U-Joint (Item Remove the plate (Item 1) [Figure 20-110-38].
2) [Figure 20-110-36].
NOTE: Use care while removing the plate. The
plungers (Item 2) [Figure 20-110-38] are spring
loaded.

1
Figure 20-110-39
P-32588
Remove the spool assemblies (Item 1) [Figure 20-110-

P-32583 41].
Figure 20-110-42
Remove the plunger assemblies (Item 1) [Figure 20-110-
39].
1
Figure 20-110-40 2
1
2 3
P-32591
Compress the spring (Item 1) and remove the seat (Item

P-32587 2) [Figure 20-110-42].
Remove the O-ring (Item 1) and plunger (Item 2) from the

bushing (Item 3) [Figure 20-110-40].
NOTE: Mark the spool assemblies for installation in

their original location.

1
1
Figure 20-110-43
3
2
1
P-32579

P-32590
Figure 20-110-46
Remove the spring (Item 1) and shim (Item 2) from the

spool (Item 3) [Figure 20-110-43]. 1
Figure 20-110-44
P-32593
Remove the end cap (Item 1) [Figure 20-110-46].
P-32592
Remove the springs (Item 1) [Figure 20-110-44] from the

housing.
Clamp the housing in a vise. Use care not to damage the

housing.

Figure 20-110-47
2
1
P-32594
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

110-47].

Assembly

1 1
or damaged parts.

Figure 20-110-48
P-32580
1
2
Install the bolts (Item 1) [Figure 20-110-50].
Turn the housing over.
Figure 20-110-51
1
P-32594
Clamp the housing in a vise equipped with padded jaws.

Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
110-48].
Figure 20-110-49
1
P-32592
Install the springs (Item 1) [Figure 20-110-51].
P-32593
Install the end cap (Item 1) [Figure 20-110-49].

RIGHT CONTROL LEVER (JOYSTICK) (CONT'D) Figure 20-110-54
Assembly (Cont'd)
1
Figure 20-110-52
1
2
P-32588
Install the spool assemblies (Item 1) [Figure 20-110-54]

P-32590 into the housing.
Figure 20-110-55
Install the shim (Item 1) and spring (Item 2) on the spool
(Item 3) [Figure 20-110-52].
Figure 20-110-53 1
2
1
P-32586
Install the plunger (Item 1) into the bushing (Item 2)

P-32591 [Figure 20-110-55].
Compress the spring (Item 1) and install the spring seat

(Item 2) [Figure 20-110-53].

Assembly (Cont'd)
Figure 20-110-56 1
P-32582
Install the plate (Item 1) [Figure 20-110-58].

P-32584
NOTE: Spring pressure can dislodge the plunger
assemblies until the plate is secured in place.
bushing. Figure 20-110-59
Figure 20-110-57
3
1 1
P-32578
P-32583
Press down on the plate (Item 1) keeping the plunger
assemblies (Item 2) fully seated and install the U-joint
Install the plunger assemblies (Item 1) [Figure 20-110- (Item 3) [Figure 20-110-59].
57] into the housing.

Assembly (Cont'd)
1
Figure 20-110-60 3
1
2
P-32573
2
Install the connector (Item 1) [Figure 20-110-62].

P-32577
Align the connector with the coupler (Item 2) and tighten
the nut (Item 3) [Figure 20-110-62].
Install the control plate (Item 1) until the plate makes light
contact with all four plungers (Item 2) [Figure 20-110- Figure 20-110-63
60].
1
Figure 20-110-61
2
2
3
P-32560
P-32574 Install the tabs of the boot (Item 1) in between the joystick
flange and mounting plate (Item 2) [Figure 20-110-63].
Align the coupler (Item 1) with the control plate (Item 2) Install the handle. (See Handle Removal And Installation
and plate (Item 3) [Figure 20-110-61]. Tighten the on Page 20-110-2.)
coupler.

LEFT CONTROL LEVER (JOYSTICK) Figure 20-111-3
Testing
The following tools will be needed to do the procedure:
MEL1355 - Hydraulic Test Kit 1
Stop the engine.
Figure 20-111-1
1
P-50560

from the control valve.
Figure 20-111-4
P-49411
1
Open the right side cover (Item 1) [Figure 20-111-1].
Figure 20-111-2
P-50561
1
From the test kit install a 1000 PSI (6896 kPa) gauge
(Item 1) [Figure 20-111-4] on the pilot line. Start the
excavator, and warm the hydraulic oil to a minimum
temperature of 150° F (66° C).
Engage the circuit to be tested. Record the operating

P-50558 pressure.
The operating pressure should be approximately 428 PSI

At the control valve assembly (Item 1) [Figure 20-111-2], (2951 kPa) with an acceptable range of 406 - 450 psi
find the pilot line of the control lever (joystick) that is to be (2799 - 3103 kPa).
checked (Boom, Arm, Slew, Bucket.)
If the operating pressure is correct, check the valve
section spool for proper operation. If the operating
pressure is incorrect, remove the pressure reducing
valve, clean, install and retest. (See Testing And
Adjusting The Pressure Reducing Valve on Page 20-33-
1.) If the pressure is still incorrect replace the pressure
reducing valve.

LEFT CONTROL LEVER (JOYSTICK) (CONT’D) Figure 20-111-7
Handle Removal And Installation
Figure 20-111-5
1 1
P-21737
1
Remove the two mount bolts (Item 1) [Figure 20-111-7]
P-21734 from the arm rest.

Remove the seven mounting bolts (Item 1) [Figure 20-
111-5] from the lower half of the operator console. Raise the upper half of the console cover.
Remove the lower half of the console. Figure 20-111-8
Lower the console.
Figure 20-111-6
1
1
P-21738
Disconnect the electrical connector (Item 1) [Figure 20-

P-21736 111-8].
NOTE: These connectors are keyed so they can be

Remove the cover (Item 1) [Figure 20-111-6] from the plugged in only one way.
arm rest.

Figure 20-111-9
1
2
P-32914
1
Using a small piece of wire, depress the wire terminal
P-33832 tabs (Item 1) [Figure 20-111-11].
Carefully remove the individual wires from the back of the

Disconnect the joystick wire connector (Item 1) [Figure electrical connector.
20-111-9] from the wire harness.
Remove the control handle (joystick) assembly from the
Figure 20-111-10 excavator.
1 Installation: Use a small piece of wire and rebend the

tab on each wire before installing it in the electrical
connector.
Figure 20-111-12
P-32915
Remove the lock (Item 1) [Figure 20-111-10] from the

joystick electrical connector. 1
P-32916
Installation: The wires [Figure 20-111-12] must be

installed in the proper locations in the wire connector,
listed below.
C Red
D Black
Check each wire to be certain the tab (Item 1) [Figure

20-111-12] locks into position.

Figure 20-111-13
1 1
3
P-32521
2
Remove the boot (Item 1) [Figure 20-111-15] from the
3
P-32513 joystick handle.
Installation: Align the top of the dust boot (Item 1) with

Raise the boot (Item 1) and pull the grommet (Item 2) up the groove (Item 2) [Figure 20-111-15].
through the mount plate (Item 3) [Figure 20-111-13].
Hold the boot down and loosen the nut (Item 3) [Figure
Figure 20-111-14 20-111-15].
Remove the handle.
P-32517
Remove the grommet and wire (Item 1) [Figure 20-111-

14] from the mount plate.

Joystick Assembly Removal And Installation
Figure 20-111-16
1 1
P-21737
1
Remove the two mount bolts (Item 1) [Figure 20-111-18]
P-21734 from the arm rest.

Remove the seven mounting bolts (Item 1) [Figure 20-
111-16] from the lower half of the operator console. Raise the upper half of the console cover.
Remove the lower half of the console. Figure 20-111-19
Lower the console.
Figure 20-111-17
1
1
P-21738

P-21736 111-19].

Remove the cover (Item 1) [Figure 20-111-17] from the plugged in only one way.
arm rest.

Joystick Assembly Removal And Installation (Cont’d)
Figure 20-111-20 1
2
3
P-32513
1
Raise the boot (Item 1) up from the mounting plate (Item
P-33832 2) [Figure 20-111-22].
Remove the four bolts (Item 3) [Figure 20-111-22] from

Disconnect the electrical connector (Item 1) [Figure 20- the control lever (joystick) mounting bolt.
111-20].
Remove the control lever (joystick).
Figure 20-111-21
P-33834
Mark and remove the hoses [Figure 20-111-21].

LEFT CONTROL LEVER (JOYSTICK) (CONT’D)
1. Handle
2. Dust Boot
3. Coupler
4. Control Plate
5. U-Joint
6. Grommet 1
7. Plate
8. Plunger
9. Spool
10. Spring
11. Housing
12. Wire Harness
13. Lock 2
14. Pin
15. Connector
3
4
6
10
11
12
13
14
15
MS1354

Disassembly
Remove the left handle. (See Handle Removal And 2

Clean the outside of the control lever before

disassembly.
Figure 20-111-23
1 P-32576
Loosen the nut (Item 1) and remove the connector (Item

2 2) [Figure 20-111-25].
Figure 20-111-26
1
P-32560 2
Remove the boot (Item 1) from the control lever (joystick)

(Item 2) [Figure 20-111-23].
Figure 20-111-24
3 2
P-32574
1
Mark the coupler (Item 1), control plate (Item 2), and
plunger (Item 3) [Figure 20-111-26] for correct
installation.
P-32568
Mark the coupler (Item 1), nut (Item 2), and connector
(Item 3) [Figure 20-111-24] for correct assembly.

1
Figure 20-111-27
1 1
P-32578
Mark the plate and housing for correct installation.

P-32574 Remove the U-joint (Item 1) [Figure 20-111-29].
NOTE: The plate (Item 2) [Figure 20-111-29] is spring

Remove the coupler (Item 1) from the control plate (Item loaded and will come up as the U-joint is
2) [Figure 20-111-27]. removed.
Figure 20-111-28 Figure 20-111-30
2
1 1
P-32577 P-32582
Remove the control plate (Item 1) from the U-joint (Item Remove the plate (Item 1) [Figure 20-111-30].
2) [Figure 20-111-28].
NOTE: Use care while removing the plate. The
plungers (Item 2) [Figure 20-111-30] are spring
loaded.

1
Figure 20-111-31
P-32588
Remove the four spool assemblies (Item 1) [Figure 20-

P-32583 111-33].
Figure 20-111-34
Remove the four plunger assemblies (Item 1) [Figure 20-
111-31].
1
Figure 20-111-32
3
1
2
3
4 2
P-32591
Compress the spring (Item 1) until the end of the spool

P-32587 (Item 2) can be aligned with the offset hole (Item 3) in the
washer (Item 4) [Figure 20-111-34].
Remove the O-ring (Item 1) and plunger (Item 2) from the

NOTE: Mark the spool assemblies for installation in

their original location.

1
Figure 20-111-35
1
P-32592
Remove the four springs (Item 1) [Figure 20-111-37]

P-32589 from the housing.
Figure 20-111-38
Remove the washer (Item 1) from the spool (Item 2)
[Figure 20-111-35].
1
Figure 20-111-36 1
1
1
P-32579
Clamp the housing in a vise [Figure 20-111-38]. Use

P-32590 care not to damage the housing.

Remove the spring (Item 1) and shim (Item 2) from the
spool (Item 3) [Figure 20-111-36].

LEFT CONTROL LEVER (JOYSTICK) (CONT’D)
Figure 20-111-39
P-32593
Remove the end cap (Item 1) [Figure 20-111-39]
Figure 20-111-40
P-32594
Remove the O-ring (Item 1) and seal (Item 2) [Figure 20-

111-40].

Assembly
1

or damaged parts.

Figure 20-111-41
P-32593
1 2
Install the end cap (Item 1) [Figure 20-111-42].
Figure 20-111-43
1
1
P-32594
Clamp the housing in a vise. Install the O-ring (Item 1)

and seal (Item 2) [Figure 20-111-41].
NOTE: Use care not to damage the housing.
P-32580
Install the two bolts (Item 1) [Figure 20-111-43].
Turn the housing over.

Assembly (Cont’d)
Figure 20-111-44
2
1
P-32589
Figure 20-111-47
P-32592
Install the four springs (Item 1) [Figure 20-111-44]. 1
Figure 20-111-45
3
2
1
2
3
P-32591
Install the washer (Item 1) [Figure 20-111-46] & [Figure

20-111-47] by compressing the spring (Item 2) [Figure
20-111-47] and pushing the end of the spool into the
P-32590 offset hole (Item 3) [Figure 20-111-46].
Center the end of the spool (Item 2) [Figure 20-111-46]

Install the shim (Item 1) and spring (Item 2) on the spool in the washer (Item 3) [Figure 20-111-47].
(Item 3) [Figure 20-111-45].

Assembly (Cont’d)
1
Figure 20-111-48
P-32584

P-32588 bushing.
Figure 20-111-51
Install the four spool assemblies (Item 1) [Figure 20-111-
48] into the housing.
1
Figure 20-111-49
1
2
P-32583
Install the four plunger assemblies (Item 1) [Figure 20-

P-32586 111-51] into the housing.
Install the plunger (Item 1) into the bushing (Item 2)

[Figure 20-111-49].

Assembly (Cont’d)
1
Figure 20-111-52
P-32577
Install the control plate (Item 1) until the plate makes light
P-32582 contact with all four plungers (Item 2) [Figure 20-111-54].
Figure 20-111-55
NOTE: Spring pressure can dislodge the plunger
assemblies until the plate (Item 1) [Figure 20- 1
111-52] is secured in place.
Install the plate (Item 1) [Figure 20-111-52].

2
Figure 20-111-53
3
1
P-32574
2
Align the coupler (Item 1) with the control plate (Item 2)

and plunger (Item 3) [Figure 20-111-55]. Tighten the
coupler.
P-32578
Press down on the plate (Item 1) to seat the four plunger

assemblies (Item 2). Install the U-joint (Item 3) [Figure
20-111-53].

Assembly (Cont’d)
1
Figure 20-111-56
1 3
P-32560
Figure 20-111-58
P-32573
Install the connector [Figure 20-111-56].
Align the connector with the coupler (Item 2) and tighten 1

the nut (Item 3) [Figure 20-111-56].
P-32571
Install the boot (Item 1) [Figure 20-111-57] & [Figure 20-

111-58] in the groove (Item 2) [Figure 20-111-57] &
[Figure 20-111-58].
Install the left handle. (See Handle Removal And


HYDRAULIC FILTER MOUNT Figure 20-120-2
1
IMPORTANT
damage the system.
I-2003-0888
P-22924
Open the tailgate. Remove the wire (Item 2) [Figure 20-120-2] from the
sending unit.
Figure 20-120-1
Figure 20-120-3
1
1
P-22926
P-22927

Remove the oil cooler to filter hose (Item 1) [Figure 20-
Loosen the hose clamp (Item 2) [Figure 20-120-1] and 120-3].
remove the hose.

HYDRAULIC FILTER (CONT’D)
Figure 20-120-4
P-55984
Remove the filter and filter mount.

HYDRAULIC RESERVOIR Figure 20-130-2
IMPORTANT
1
damage the system.
I-2003-0888
P-56285
Open the tailgate.
Drain the reservoir. (See Replacing The Hydraulic Oil on Remove the pump supply line (Item 1) [Figure 20-130-
Page 10-100-2.) 2].
Remove the muffler. (See Removal And Installation on Figure 20-130-3

Page 60-20-1.)
Figure 20-130-1
1
P-56286

P-56284

HYDRAULIC RESERVOIR (CONT’D)
Figure 20-130-4
P-56287
Figure 20-130-5
2 1
P-56288
Remove the mount (Item 1) [Figure 20-130-5].
Remove reservoir (Item 2) [Figure 20-130-5].

OIL COOLER Figure 20-140-2
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
1
damage the system.
I-2003-0888
P-22727
Remove the three hoses (Item 1) [Figure 20-140-2]
Figure 20-140-1 from the front of the cooler.
NOTE: If the excavator is not equipped with the direct

to tank valve there will be two hoses on the
front of the cooler.
Figure 20-140-3
P-55985

rear of the cooler.
P-22728
Remove the front bottom bolt (Item 1) [Figure 20-140-3].

OIL COOLER (CONT’D) Figure 20-140-6
Figure 20-140-4
P-55987
Remove the two bolts (Item 1) [Figure 20-140-6] and

P-56637 reposition the filter mount to provide clearance to remove
the cooler.
Remove the front top bolt (Item 1) [Figure 20-140-4]. Remove the cooler.
Figure 20-140-5
P-55992
Remove the rear top and bottom bolts (Item 1) [Figure

20-140-5], and lower the cooler to the excavator frame.

DIRECT TO TANK VALVE Figure 20-150-2
IMPORTANT
damage the system.
I-2003-0888
P-22623

Hydraulic Oil on Page 10-100-2.) Remove the lower hose (Item 1) [Figure 20-150-2].
Open the right side cover. Figure 20-150-3
Figure 20-150-1
1 P-22624
1
P-22622
Remove the two mount bolts (Item 1) [Figure 20-150-3].
Remove the two hoses (Item 1) [Figure 20-150-1]. Remove the valve.

DIRECT TO TANK VALVE (CONT’D) To prevent cutting the new seal on the sharp edges, wrap
the spool in three or four layers of glossy paper. Leave
Disassembly And Assembly the front seal groove exposed.
Figure 20-150-4 Install the new seal over the paper and into the front seal
groove.
Put clean grease on the new seal. Remove the paper

and install the spool in the body.
With a rotating action, push the spool until the front seal
is in the body and the rear seal groove is exposed.
1 2
Install the rear seal in the groove.
Put clean grease on the rear seal.
Install the rear snap ring and pull the spool toward the
front until it stops.
P-22625
Install the front snap ring.
Remove the two nuts and bolts (Item 1). Remove the
mount (Item 2) [Figure 20-150-4] from the valve.
Figure 20-150-5
B-13660
Remove the snap rings (Item 1) [Figure 20-150-5].
Push the spool in until the rear seal (Item 2) [Figure 20-
150-5] is exposed. Remove the rear seal.
Remove the spool from the valve body. Remove the front
seal (Item 3) [Figure 20-150-5] from the spool.

BUILD UP VALVE
Description
The build up valve provides hydraulic pressure to charge

the accumulator when the engine is at low idle.
IMPORTANT
damage the system.
I-2003-0888
Figure 20-160-1
P-23563
The build up valve (Item 1) [Figure 20-160-1] is located

on the manifold assembly.
Either the valve (Item 1) or valve body (Item 2) [Figure

20-160-1] may be removed for O-ring and back-up ring
replacement.
Valve Removal: Remove the valve (Item 1) [Figure 20-

160-1].
Valve Body Removal: Remove the hose (Item 3) [Figure

20-160-1] from the valve.
Loosen the manifold mount bolts and reposition the

manifold for clearance.
Remove the valve body (Item 2) [Figure 20-160-1].

BUILD UP VALVE (CONT’D)
1. Valve
2. O-Ring
3. Back-Up Ring
4. Valve Body
MS2135

BUILD UP VALVE (CONT’D)
Disassembly And Assembly
Clamp the valve in a vise with padded jaws.
Figure 20-160-2
P-12118
Remove the valve (Item 1) [Figure 20-160-2].
Figure 20-160-3
P-12119
Remove the O-rings (Item 1) and back up ring (Item 2)

[Figure 20-160-3].
Apply oil to and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-160-3].
Install the valve (Item 1) [Figure 20-160-2] in the valve

body.

CASE DRAIN FILTER Figure 20-170-3
IMPORTANT 1

damage the system.
I-2003-0888
P-55987
Figure 20-170-1 Remove the bolts (Item 1) [Figure 20-170-3].
Remove the filter.
P-55988
Figure 20-170-2
P-22924

rear of the case drain filter.

SLEW LOCK VALVE Figure 20-220-2
Description
The slew lock valve uses two pilot operated check valves
to restrict hydraulic flow between the control valve and
the slew motor.
When the joystick is moved to swing the upperstructure, 1

hydraulic pressure opens the slew lock check valves and
allows hydraulic flow to the swing motor to rotate the
upperstructure. When the joystick is in neutral, the check
valves close, restricting hydraulic flow to the swing motor.

P-92785
Lower the boom / bucket and blade to the ground.
With the engine OFF, turn the key to the ON position and Remove the hoses (Item 1) [Figure 20-220-2].
move the joysticks to relieve hydraulic pressure.
Figure 20-220-3
IMPORTANT
damage the system.
I-2003-0888
Mark all hoses for ease of assembly.

P-93045
Figure 20-220-1
Remove the nuts (Item 1) [Figure 20-220-3]. Remove
the valve.
1
P-96219

SLEW LOCK VALVE (CONT’D)
1. Plug
2. O-Ring
3. Seat
4. Spring
5. Ball
6. Valve
7. Spool
1
1
2
2
3
4
5
5 1
4
7
2
1
4
NA-1334S


IMPORTANT
Inspect all parts for wear or damage. Replace any worn When repairing hydrostatic and hydraulic systems,
or damaged parts. clean the work area before disassembly and keep all
Always install new back-up rings and O-rings with clean tubelines and ports to keep dirt out. Dirt can quickly
hydraulic fluid before installation. damage the system.
I-2003-0888
Mark the locations and orientation of the six fittings.

Figure 20-220-6
Remove the six fittings from the manifold.
1
Figure 20-220-4
S10542
1
S10540
plug.
Remove the plug (Item 1) [Figure 20-220-4]. Figure 20-220-7

torque.
Figure 20-220-5
2 1
1
S10543
S10541
torque.
Remove the spring (Item 1) and spool (Item 2) [Figure

20-220-5]

SLEW LOCK VALVE (CONT’D) Figure 20-220-10
Disassembly And Assembly (Cont’d)
Figure 20-220-8
S10546
Remove the spring (Item 1) and ball (Item 2) [Figure 20-

S10544 220-10].
Figure 20-220-11
plug.
Figure 20-220-9 1
S10547

S10545 plug.

torque.

SLEW LOCK VALVE (CONT’D) Figure 20-220-14
Figure 20-220-12 1
S10547

S10548 plug.
Figure 20-220-15

torque. 1
Figure 20-220-13
S10550
2
1
S10549 torque.
Remove the spring (Item 1) and ball (Item 2) [Figure 20-

220-13].

Figure 20-220-16
2
1
S10551
Remove the shuttle seat (Item 1) and ball (Item 2)

[Figure 20-220-16].
Figure 20-220-17
S10547

plug.

UNDERCARRIAGE
BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
SWING CIRCLE GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2
Swing Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1
TRACK DAMAGE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 UNDERCARRIAGE

Abrasion Of Embedded Metals . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2
Abrasion Of The Track Roller Side . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Cracks And Cuts On The Lug Side Rubber . . . . . . . . . . . . . . . . 30-40-8
Cracks On The Lug Side Rubber Due To Fatigue . . . . . . . . . . . 30-40-6
Cuts On The Edges Of Track Roller Side . . . . . . . . . . . . . . . . 30-40-10
Cuts On The Lug Side Rubber. . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Cutting Of Steel Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Lug Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-7
Separation Of Embedded Metals. . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Separation Of Embedded Metals Due To Corrosion . . . . . . . . . 30-40-4
TRACK FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511315 &
Below, A9KO11108 & Below And A9K111109 & Below) . . . . . . 30-30-3
Recoil Spring Cylinder Disassembly And Assembly (S/N AAC511316 &
Above, A9K011109 & Above And A9K111110 & Above) . . . . . . 30-30-5
Recoil Spring Cylinder Parts Identification (S/N AAC511316 & Above,
A9K011109 & Above And A9K111110 & Above) . . . . . . . . . . . . 30-30-4
TRACK IDLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
TRACK ROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Rubber Track Removal And Installation. . . . . . . . . . . . . . . . . . . 30-20-4
Steel Track Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-20-6
Track Lug Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE
SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS

MAY VARY.

BLADE
Lower the blade and bucket to the ground.
Remove the blade cylinder. (See Removal And

Figure 30-10-1
P-22607

washer from the blade arm pivot pins (both sides).
Figure 30-10-2
P-22608
Remove the blade arm pivot pins (Item 1) [Figure 30-10-

2] (both sides).
Remove the blade.

TRACKS Adjustment
Track Lug Height NOTE:The wear of the pins and bushings on the
undercarriage vary with the working conditions and
Rubber Track the different types of soil conditions. It is necessary
to inspect track tension to maintain the correct
The lug height of a new rubber track (Bridgestone or tension. (See SERVICE SCHEDULE on Page 10-50-1)
Spencer) is 0.984 in. (25,0 mm). for the correct service interval.
Straight Edge
1
B-14489 P-49460
To find the percentage of wear on an excavator track, Raise the side of the machine (approximately 4 in. [102
measure the height of the lug by placing a straight edge mm]) using the boom and arm [Figure 30-20-2].
across the top of three lugs and measure the distance
from the base of the track to the bottom of the straight Raise the blade fully and install jackstands under the
edge [Figure 30-20-1]. blade and track frame (Item 1) [Figure 30-20-2]. Raise
the boom until all machine weight is on the jackstands.
Divide this measurement by the new track height and
multiply by 100. This will give the percentage of track lug Stop the engine.
left.
Example: lug height 0.787 in. (20,0 mm)

0.787
x 100 = 80
WARNING
0.984
AVOID INJURY
80% of the track lug is remaining with 20% wear on the Keep fingers and hands out of pinch points when
track lugs. checking the track tension.
W-2142-0903

TRACKS (CONT’D) Steel Track Clearance
Adjustment (Cont’d) Figure 30-20-5
Rubber Track Clearance
Figure 30-20-3
0.490-0.690 P-11662
(12,4-17,5 mm)
Figure 30-20-6
P-49187
Track Frame
Figure 30-20-4
0.380-0.590” Track Frame

(9,7-14,7 mm)
0.770-1.270”
(19,6-32,3 mm) Track
Track
Roller B-15022
Measure the steel track clearance at the center of the

Track B-14067 track, between the contact surface of the roller and the
contact surface of the track [Figure 30-20-5] & [Figure
30-20-6]. Do Not get fingers into pinch points between
Measure the clearance at the middle track roller [Figure the track and the track roller.
30-20-3]. Do Not get fingers into pinch points between
the track and the track roller. Use a bolt or a dowel of the Steel Track Clearance 0.770 - 1.270 in.
appropriate size to check the gap between the contact (19,6 - 32,3 mm)
edge of the roller and the top edge of the track guide lug
[Figure 30-20-3] & [Figure 30-20-4]
Rubber Track Clearance 0.380 - 0.590 in.

(9,7 - 14,7 mm)

TRACKS (CONT’D) Figure 30-20-9
Adjustment (Cont’d)
2
Figure 30-20-7
1
1 1
N-18490
Use tool MEl1560 (Item 1) to loosen the bleed fitting

P-49116 (Item 2) [Figure 30-20-9] to release tension from the
track.
If the track tension is not correct loosen the two bolts on NOTE: Do not loosen the grease fitting (Item 1)
the cover (Item 1) [Figure 30-20-7]. Pivot the cover [Figure 30-20-8].
downward.
Repeat the procedure for the other side.
Figure 30-20-8
1
2
P-42471
Add grease to the fitting (Item 1) [Figure 30-20-8] until

the track tension is correct.

TRACKS (CONT’D)
Rubber Track Removal And Installation

WARNING
Lift and block both sides of the machine as follows:
Put jackstands under the blade and rear corners of
Raise the blade fully. the undercarriage before working under the machine.
Failure to block up the machine may allow it to move
Figure 30-20-10 or fall and result in injury or death.
W-2218-1195
Stop the engine.
Figure 30-20-12
1
P-22621
1
Use the boom and arm to lift the blade end of the
machine up about 3.0 in. (75 mm) and install jackstands
(Item 1) [Figure 30-20-10] under the blade.
P-11365
Raise the boom.
Loosen the two bolts (Item 1) [Figure 30-20-12] on the
Figure 30-20-11
cover. Pivot the cover downwards.
Figure 30-20-13
1
2
3
P-2839
Swing the upperstructure 180° and use the boom and N-18490 P-11363
arm to slowly lift the opposite end of the undercarriage

and install jackstands under the undercarriage [Figure
Use tool MEL1560 (Item 1) to loosen the bleed fitting
30-20-11].
(Item 2) [Figure 30-20-13] (a maximum of 1-1/2 turns) to
release the tension from the grease spring.
Raise the boom until the weight of the machine is
supported by the jackstands.
NOTE: Do not loosen the grease fitting (Item 3)
[Figure 30-20-13].

Rubber Track Removal And Installation (Cont’d)
Start the engine.
Slowly turn the track in the forward direction.
Figure 30-20-14
P-22619
Insert a pry bar between the track and the idler wheel and
pry out on the track until the track slides off the idler
wheel [Figure 30-20-16].
Remove the track.

P-22617
To install the rubber track:
Insert a steel rod or pipe (Approximately 1.250 in. [30 Put the track over the rear drive sprocket lugs.
mm] diameter) between the track and the idler wheel
[Figure 30-20-14]. Put the front of the track onto the front idler wheel.
Figure 30-20-15 See Adjustment for adding grease to the grease spring
and for checking track tension (See Adjustment on Page
30-20-1.)
P-22618
Insert a second steel rod or pipe, at a distance of two

lugs, between the track and the idler wheel [Figure 30-
20-15]. Continue to turn the track until the first pipe
contacts the track frame.
Stop the engine.

TRACKS (CONT’D) To remove the track by removing a connecting pin:
Steel Track Removal And Installation Figure 30-20-18
With the excavator raised and the bleed fitting loosened,

start the excavator (See Adjustment on Page 30-20-1.).
Slowly turn the track. This will force more grease out of
the grease spring. Stepped Diameter
This Area
Stop the engine.
WARNING
Keep fingers and hands out of pinch points when CD-13032
removing the track.
W-2173-0195
There is no master link or master connecting pin with this
track. The connecting pins have a stepped diameter
The track can be removed either as a complete assembly
[Figure 30-20-18]. The smaller diameter is a slip fit into
or by removing a connecting pin and separating the track.
the track connecting links and the larger diameter is a
press fit.
Figure 30-20-17
To remove a connecting pin, hold a heavy steel block on
the connecting link near the pin being removed. Use a
hammer and a punch to drive out the connecting pin.
WARNING
CD-9482 • Engine is running.
W-2019-0907
To remove the track as a compete assembly, install a pry
bar between the track and the front idler wheel and pry
out on the track [Figure 30-20-17].
Installation: Put the track over the drive sprocket lugs.

Then position the front of the track over the front idler
wheel.
See Adjustment for adding grease to the grease spring

30-20-1.)

Steel Track Removal And Installation (Cont’d)
Figure 30-20-19
Forward
B-13788
With the help of a second person, start the excavator.

B-13786 Make sure that the slew lock lever is in the locked
position. Use the travel lever (on which side the track is
being installed) to slowly turn the drive motor in the
Installation: Put the steel track under the track frame so forward direction. Hold the end of the track upwards as
the front end of the track extends approximately three the drive motor slowly moves the track forward. Guide
links in front of the idler wheel [Figure 30-20-19]. the end of the track over the top of the guide block and up
to the front idler wheel [Figure 30-20-21].
Figure 30-20-20
Stop the engine.
WARNING
Sprocket Drive motor must be operated slowly to avoid any
sudden movements that could cause injury or death.
W-2174-0195
B-13787
Pull the opposite end of the track up and forward and

position the end links of the steel track onto the sprocket
[Figure 30-20-20].

TRACKS (CONT’D)
Steel Track Removal And Installation (Cont’d)
Position the two ends of the track together and use a drift
pin to hold the links together.
Figure 30-20-22
B-13789
Insert the connecting link pin (Item 1) [Figure 30-20-22]

into the track link hole. Tap the end of the pin until the
press fit diameter contacts the connecting link hole.
Hold a heavy steel block on the back side of the track

connecting link and use a hammer to drive the
connecting link pin into the track link until the head of the
pin is flush with the track link.
See Adjustment for adding grease to the grease spring

30-20-1.)

TRACK FRAME Figure 30-30-2
Use the following procedure to remove the different parts

from the track frame.
Remove the track. (See Rubber Track Removal And

Installation on Page 30-20-4 or See Steel Track Removal
And Installation on Page 30-20-6.)
Figure 30-30-1
P-8557
Remove the recoil spring (Item 1) [Figure 30-30-2].
Figure 30-30-3
P-8556
Slide the front track idler out of the track frame [Figure
30-30-1].
DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY (Item 1) [Figure 30-30-2].
P-8559
WARNING Remove the drive sprocket bolts (Item 1) [Figure 30-30-

3].
Installation: Put thread lock adhesive (Loctite® 242) on

the bolts. Tighten the bolts to 80 ft.-lb. (108 N•m) torque.
Remove the drive sprocket from the travel motor.
P-62574

• Spring loaded components under pressure can
cause serious injury or death.
• Do not disassemble the coil spring assembly.
W-2617-1004

TRACK FRAME (CONT’D) Figure 30-30-6
Figure 30-30-4
P-8562
Remove the track roller (Item 1) [Figure 30-30-6].

P-8560
Figure 30-30-7
Remove the guide block bolts (Item 1) [Figure 30-30-4].
Remove the guide block.
Figure 30-30-5
TS-1348A
1 1
Remove the four guide plates (two per side) (Item 1)
[Figure 30-30-7] from the track frame (steel tracks only).
P-8561
Loosen the nuts (Item 1) [Figure 30-30-5] on the track

roller on both sides of the track frame.
Installation: Tighten the nuts to 125 - 140 ft.-lb. (170 -

190 N•m) torque.

Recoil Spring Cylinder Disassembly And Assembly

(S/N AAC511315 & Below, A9KO11108 & Below And
A9K111109 & Below)

3
WARNING 1
2
P-11644
Remove the seal (Item 1) back-up ring (Item 2) and O-

ring (Item 3) [Figure 30-30-9] from the cylinder.
Installation: Apply oil to the O-ring, back-up ring and

P-62574
seal before installation.

W-2617-1004
Figure 30-30-8
2 1
P-8558
Remove the cylinder (Item 1) [Figure 30-30-8] from the

shaft.

TRACK FRAME (CONT’D)
Recoil Spring Cylinder Parts Identification (S/N AAC511316 & Above, A9K011109 & Above And A9K111110 &
Above)
1. Coil Spring Assembly

2. O-Ring
3. Spacer (Steel Track Only)
4. Shaft
5. Wiper Seal
6. Wear Ring 3
7. Back-up Ring
8. Tube 2
9. Bleed Fitting
10. Grease Fitting
11. Bolt 1
9
8 10
11
2
7
6
5
*6
4 *2
*7
*5
* Early Models
PE-3895S


(S/N AAC511316 & Above, A9K011109 & Above And
A9K111110 & Above)

1
WARNING
P-91104
Installation: Apply oil to the O-ring before installation.

P-62574
Figure 30-30-12

W-2617-1004
Figure 30-30-10
1 2
P-91105
Remove the shaft (Item 1) from the tube (Item 2) [Figure

30-30-12].
2 1
P-91102
Remove the cylinder (Item 1) from the coil spring

assembly (Item 2) [Figure 30-30-10].

TRACK FRAME (CONT’D)

(S/N AAC511316 & Above, A9K011109 & Above And
A9K111110 & Above) (Cont’d)
Early Models
Figure 30-30-13
2
3
P-91096
Remove the wiper seal (Item 1), back-up ring (Item 2)

and O-ring (Item 3) and wear ring (Item 4) [Figure 30-30-
13].
Installation: Apply oil to the O-ring, back-up ring, and

Later Models
Figure 30-30-14
1
2
3
4
P-95076
Remove the wiper seal (Item 1), wear ring (Item 2), back-
up ring (Item 3) and O- ring (Item 4) [Figure 30-30-14].
Installation: Apply oil to the O-ring, back-up ring, and


TRACK DAMAGE IDENTIFICATION Causes Of The Damage:
Cutting Of Steel Cords When applied to rubber tracks under the following
circumstances, tension in excess of the breaking strength
The following pages show photos and illustrations of of the embedded steel cords causes steel cords to be
track damage and the probable cause of the damage. It cut:
is intended to be used for identifying the reason for track
Figure 30-40-3
damage and how to avoid future track damage.
Figure 30-40-1
PI-13035
P-3864 When the rubber track is detracting, the idler or sprocket

rides on the projections of the embedded metal [Figure
30-40-3].
Figure 30-40-2
When the rubber track is detracted, projections of rubber
tracks get stuck between the frame of the undercarriage.
The rubber track is clogged with stones or foreign

obstacles.
Furthermore, when moisture invades through a cut on

the lug side rubber surface, the embedded steel cords
will corrode. The deterioration of the design strength may
lead to the breaking off of the steel cords.
Steel Cords Prevention:
The following preventions should be taken to minimize

PI-13034
the risk of this damage:
Damage: Periodical checking on site of the recommended track

tension. (See Adjustment on Page 30-20-1.)
Embedded steel cords are cut off [Figure 30-40-1] &
[Figure 30-40-2]. Avoiding quick turns on bumpy and rocky fields.
Replacement: Drive carefully to avoid having stones and other articles

clog the rubber tracks.
Replacement is required [Figure 30-40-1] & [Figure 30-
40-2]. Driving over sharp objects should be avoided. If this is
impossible, do not make turns while driving over sharp
objects.

TRACK DAMAGE IDENTIFICATION (CONT’D) Causes Of The Damage:
Abrasion Of Embedded Metals When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Figure 30-40-4 inevitable. The following cases sometimes accelerate
their abrasion:
Rubber tracks are driven with an extraordinary heavy

load on them.
Rubber tracks are used on sandy fields.
Prevention:
As long as rubber tracks are used under normal

operating conditions, abnormal abrasion is unlikely to
occur. The level of abrasion should be carefully checked
when the machines are used for dozing which generate a
heavy load for rubber tracks, and when they are operated
P-3865 under a sandy field condition for a long time.
Damage:
In proportion to the service time, embedded metals will

gradually wear away by friction [Figure 30-40-4].
Figure 30-40-5
Abrasion
D D1=0.67D
PI-13037
Replacement:
Replacement is required when the width of the

embedded metals (D1) becomes 67% of their original
width (D) [Figure 30-40-5].

TRACK DAMAGE IDENTIFICATION (CONT’D) Figure 30-40-8
Separation Of Embedded Metals
Figure 30-40-6
Guide
PI-13040
When a rubber track is detracted, it becomes stuck

P-4379 between the guide or the undercarriage frame, causing
the separation of embedded metals [Figure 30-40-8].
Damage: Figure 30-40-9
Extraordinary outer forces applied to embedded metals

cause their separation from the rubber track's body
[Figure 30-40-6].
Replacement:
Even a partial separation of embedded metals requires Abrasion

replacement of the track.
Causes Of The Damage:
Embedded metals are adhered between the steel cords

and the rubber body. The following cases generate
external forces greater than the adhesion strength,
causing separation of the embedded metals:
PI-13041
Figure 30-40-7
Abnormally worn sprockets as shown will pull embedded

metals out [Figure 30-40-9].
Prevention:
Idler
Similar to the prevention against the cutting of the steel
cords:
Rubber
Track Recommended track tension should be periodically
checked. (See Adjustment on Page 30-20-1.)
Quick turns on bumpy and rocky fields should be

avoided.
PI-13039
If abnormal wear of sprockets is observed, they should
be immediately replaced.
When the idler continually rides on the projections of
embedded metals, the embedded metals will eventually
peel off [Figure 30-40-7].

TRACK DAMAGE IDENTIFICATION (CONT’D) Excessively salty fields, like the sea shore.
Separation Of Embedded Metals Due To Corrosion Strong acidic or alkali soil conditions
Figure 30-40-10 Compost spread grounds
On tracks that are out of adjustment, the track rollers,

idlers and sprockets will gradually wear the rubber
surface at track roller side, causing exposure of the
embedded metals. Consequently the embedded metals
will corrode resulting in their separation from the rubber
body.
Prevention:
If rubber tracks are used under such field conditions as

described under (Causes of the damage), they should be
washed with plenty of water. After being completely
dried, they should be stored correctly.
P-4378
When the bonded rubber cover is separated from the
embedded metal projections and the metals in the rubber
Damage: body become loose, it is time to consider replacement of
the rubber track.
Due to corrosion of embedded metals, the adhesion to
the rubber body deteriorates, resulting in complete
separation [Figure 30-40-10].
Replacement:
Even a partial separation of embedded metals requires a

rubber track replacement.
Figure 30-40-11
Embedded Metal
Good
Separation of
Bonded
Rubber Cover
PI-13043
Embedded metals are bonded to the rubber body. The

following operating conditions cause embedded metals
to corrode, causing deterioration of the bonding, and
finally resulting in separation of the embedded metals
from the rubber body [Figure 30-40-11].

TRACK DAMAGE IDENTIFICATIONS (CONT’D) Figure 30-40-13
Cuts On The Lug Side Rubber

Cuts
Figure 30-40-12
PI-13045

P-4377
When rubber tracks drive over projections or sharp
stones in the fields, the concentrated forces applied
Damage: cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface
Cuts on the lug side rubber often occurs as one of the will have an even higher chance to be cut. If the cuts run
most typical failure modes [Figure 30-40-12] through the embedded steel cords, it might result in the
steel cords' breakage due to their corrosion. It is highly
Replacement: recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 30-40-13].
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately repaired Prevention:
with cold vulcanization rubber.
Machine operators are requested to drive with great
attention to the ground's surface especially in terrains of
the following type:
Construction sites
Demolition sites
Paths covered with rocks and wood
Concrete ridges
Stumpy fields
When operating on terrains as mentioned above, high

speed, quick turns and overloading should be avoided.

TRACK DAMAGE IDENTIFICATION (CONT’D) Replacement:
Cracks On The Lug Side Rubber Due To Fatigue When the cracks reach so deep that they expose the
steel cords, track replacement is required.
Figure 30-40-14
Because of wound stress applied to rubber tracks around

the undercarriage parts during operation, the fatigue
especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
even small external cracks. Also when operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.
Prevention:
Rubber tracks are designed with special rubber

compounds to prevent cracks due to fatigue. However,
P-4382 external injuries on the lug side rubber sometimes cause
more chance of cracking. Machine operators should
observe soil conditions when driving, so as not to cause
Figure 30-40-15 external injuries to the lug side rubber. In order to
minimize the occurrence of ozone cracks, attention
should be paid to the following instructions for
maintenance:
Avoid exposing stored tracks to direct sun light.
Avoid exposing stored tracks to direct rain and snow fall.
Store tracks in well ventilated warehouses.
Use the tracks at least once a month.
P-4380
Damage:
Small cracks around the root of the lug as a result from

operation fatigue [Figure 30-40-14] & [Figure 30-40-15].

Lug Abrasion No replacement is required.
Figure 30-40-16 Causes Of The Damage:
Lug abrasion is more or less inevitable. Even if lug

abrasion is proceeding, the rubber track can be used.
However, as the traction performance deteriorates
accordingly, it is highly recommended to replace the
abraded tracks with new ones when the lug height
becomes less than 0.197 in. (5 mm).
Prevention:
In order to prevent the rubber track from abnormal or

premature abrasion, following operating conditions
should be avoided:
P-4381 Making quick and repeated turns on concrete and

asphalt roads
Figure 30-40-17 Driving up and down hilly paths with slippage
Making frequent turns on paths covered with rocks and

wood
Lug Abrasion
PI-13049
Damage:
As its service time proceeds, the lug side inevitably

undergoes abrasion [Figure 30-40-16] & [Figure 30-40-
17].

Cracks And Cuts On The Lug Side Rubber Basically, no replacement is required unless the cuts on
the lug side rubber are discovered all around the edges
Figure 30-40-18 of the embedded metals, as this will result in a complete
cut off.
Figure 30-40-19
Crack at the edge of Cut on lug side

embedded metal rubber
CD-13050
Damage:
PI-13051
Sometimes cracks and cuts on the lug side rubber at the

edges of the embedded metals can be observed [Figure Causes Of The Damage:
30-40-18].
When rubber tracks drive over sharp projections,
intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals
[Figure 30-40-19].
Prevention:
To avoid extensive stress applied to the lug root where

metals are embedded, machine operators are requested
to avoid driving over stumps and ridges.

Abrasion Of The Track Roller Side
Figure 30-40-20
Track Roller
Abrasion
PI-13053

P-4383
The abrasion of the track roller side rubber surface
occurs because of sand and gravel being clogged
Damage: between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against
The rubber surface on which track rollers run is gradually the side of the rubber track to cause the abrasion [Figure
abraded. It will end in the exposure of the embedded 30-40-21].
metals [Figure 30-40-20].
The level of abrasion is highly dependent on terrain
Replacement: conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
It is recommended to replace the rubber track when more stones and gravel. Small stones hardened with mud,
than half of the embedded metals are completely stuck to the track rollers increase the abrasion level. After
exposed. an extended period of abrasion, it will be more likely for
exposed embedded metals to catch moisture through the
inside steel cords, which can cause breakage of steel
cords and separation of the metals from the rubber body.
Prevention:
After operation in wet fields containing many small

stones, wash off the mud that is stuck to the track rollers
completely. When operating on gravel paths and stony
grounds, machines should be driven slowly and the
turning radius should be big enough to prevent stones
and gravel from getting stuck to the track roller side
rubber.

Cuts On The Edges Of Track Roller Side
Figure 30-40-22
PI-13056

P-4384
This damage is caused by objects on the field or by
interference with the machine frame.
Figure 30-40-23
In case of damage by objects on the field:
The edges of rubber track are often deformed largely due

to a bumpy ground surface, stones and other objects,
which cause extensive stress on the edges resulting in
Edge Edge the damage. Especially, when a machine drives over
concrete ridges, this type of damage easily occurs
[Figure 30-40-24].
PI-13055
Damage:
Both edges of a rubber track have no special

reinforcements. It sometimes occurs during operation
that they are cut or torn off [Figure 30-40-22] & [Figure
30-40-23].
Replacement:
In such case, the rubber track does not have to be

replaced.

TRACK DAMAGE IDENTIFICATION (CONT’D)
Cuts On The Edges Of Track Roller Side (Cont’d)
Figure 30-40-25
Cut
Tear
PI-13057
In case of damage by interference with the machine

frame:
If a machine continues operating with rubber tracks being

detracted, the rubber tracks may get caught up in the
machine frame or undercarriage parts resulting in
damage. Furthermore, when a machine travels along
side slopes, the rubber tracks are deformed so much that
they come into contact with the machine frame and
undercarriage parts, which causes cutting, gouging and
rubbing of rubber tracks in the end [Figure 30-40-25].
Prevention:
When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for re-tracking.

TRACK IDLER
1. Roll Pin
2. Block
3. Seal
4. Snap Ring
5. Bearing
6. Shaft 6
7. Idler
3 2
PE1911S

TRACK IDLER (CONT’D) Figure 30-50-3
Disassembly
1
The following tools must be fabricated for this procedure:
Figure 30-50-1
4.500”
0.30” (0,75 mm) (115 mm)
chamfer 3 places
3.500”
(90 mm)
P-47352
Remove any corrosion or paint from both ends of the

2.700” exposed shaft (Item 1) [Figure 30-50-3] that could affect
1.600” (70 mm) Dia. seal removal or damage the new seal during installation.
(40 mm) Dia.
B-14205
Apply penetrating oil to both ends of the exposed shaft to
ease removal of the seal.
1. Driver Tool - [Figure 30-50-1].
Remove the seal (Item 2) [Figure 30-50-3] from both
2. Support Fixture - Tube, 3.0 in. ID x 0.250 in. wall x 6.0 sides of the idler.
in. long (76,2 mm ID x 6,35 mm wall x 152,4 mm long).
Figure 30-50-2
P-52475
Remove the roll pin (Item 1) and block (Item 2) [Figure

30-50-2] from the shaft (both ends.)

Figure 30-50-4
P-29396
Remove the bearing (Item 1) [Figure 30-50-6] from the

P-29393 shaft.
Figure 30-50-7
both sides of the idler.
Figure 30-50-5
P-29395
1
Turn the idler over, and using a bearing driver, remove

P-29394 the second bearing [Figure 30-50-7].
Place the idler on the support fixture (Item 1) [Figure 30-

50-5].
Using a soft faced hammer, tap the shaft (Item 2) [Figure

30-50-5] and bearing out the bottom of the idler.

Assembly
Figure 30-50-8
P-47353
2 Using a bearing driver, install the bearing in the idler

1 1 [Figure 30-50-10].
P-29398 Figure 30-50-11
Inspect the bearings (Item 1) and shaft (Item 2) [Figure

30-50-8] for wear or damage. Replace any worn or
damaged parts.
The bearings are sealed. If the bearings do not roll 1

smoothly, or if the seals are damaged, replace the
bearings.
Figure 30-50-9
P-61215
P-29399
Remove all paint and corrosion from the seal surface

(Item 1) [Figure 30-50-9] on both sides of the idler.

Assembly (Cont’d)
Figure 30-50-12
1
2
1 P-29405

P-29403
Figure 30-50-15
Turn the idler over and place the idler on the support
fixture (Item 1) [Figure 30-50-12].
1
Install the shaft (Item 2) [Figure 30-50-12].
Figure 30-50-13
P-29456
1
Apply assembly lube to the inside diameter (Item 1)

[Figure 30-50-15] of the seal.
Apply a small bead of high temperature silicone sealant

P-29404 around the flange surface (Item 2) [Figure 30-50-15] of
the seal.
Install the bearing (Item 1) [Figure 30-50-13]. Use a

brass drift to seat the bearing.

TRACK IDLER (CONT’D)
Assembly (Cont’d)
Figure 30-50-16
P-61214
Using the driving tool, install the seal (Item 1) [Figure 30-
50-16] on the idler (both ends.)
Figure 30-50-17
P-52475
Install the block (Item 1) and roll pin (Item 2) [Figure 30-
50-17] on the shaft (both ends.)

TRACK ROLLER
1. Nut 8
2. Lock Washer
3. Washer
4. Seal
5. Snap Ring
6. Bearing 6
7. Shaft
8. Roller
5
1
2
3
4
PE1914S

TRACK ROLLER (CONT’D) Figure 30-60-3
Disassembly
The following tools must be fabricated for this procedure:
Figure 30-60-1
1
4.500”
0.30” (0,75 mm) (115 mm)
chamfer 3 places
3.500”
(90 mm)
P-29459

2.700” both sides of the roller.
1.600” (70 mm) Dia.
(40 mm) Dia.
B-14205 Figure 30-60-4
1. Driver Tool - See [Figure 30-60-1].

1
2. Support Fixture - Tubing, 3.0 in. ID x 0.250 in. wide x
6.0 in. long.
Figure 30-60-2
P-46607
Tap the shaft (Item 1) [Figure 30-60-4] and bearings out

1 of the roller.
P-46606
Support the roller in the support fixture (Item 1). Remove

the seal (Item 2) [Figure 30-60-2] from both sides of the
roller.

TRACK ROLLER (CONT’D)
Figure 30-60-5
P-29461
Press the bearings (Item 1) [Figure 30-60-5] off the

shaft.

Assembly
Figure 30-60-6
P-29462
2
1 1 Press the bearings (Item 1) [Figure 30-60-8] on the

shaft.
P-29463 Figure 30-60-9
Inspect the bearings (Item 1) and shaft (Item 2) [Figure 2

30-60-6] for wear or damage.
The bearings are sealed. If the bearings do not roll

smoothly or if the seals are damaged, replace the
bearings.
Replace any worn or damaged parts.

1
Figure 30-60-7
P-29464
Place the roller on the support fixture (Item 1) [Figure 30-

60-9].
1 Tap the shaft and bearing assembly (Item 2) [Figure 30-

60-9] into the roller.
P-29465
Remove all paint and corrosion from the seal surface

(Item 1) [Figure 30-60-7] on both sides of the roller.

Assembly (Cont’d)
Figure 30-60-10
1
P-46606
Using the driving tool, install the seal (Item 1) [Figure 30-
P-29466 60-12] on both sides of the roller.
Install the snap ring (Item 1) [Figure 30-60-10] on both

sides of the roller.
Figure 30-60-11
P-29456
Apply assembly lube to the inside diameter (Item 1)

[Figure 30-60-11] of the seal.
Apply a small bead of high temperature silicone sealant

around the flange surface (Item 2) [Figure 30-60-11] of
the seal.

SWING CIRCLE GEAR
Swing Bearing Removal
Remove the upperstructure. (See Removal on Page 40-

10-1.)
Figure 30-70-1
P-95366
Install a C-clamp (Item 1) [Figure 30-70-1] to prevent the

swing bearing from turning while being removed.
Figure 30-70-2
P-95374
Remove the 16 bolts (Item 1) [Figure 30-70-2] and nuts

that hold the swing bearing to the track frame.
Remove the swing bearing.

SWING CIRCLE GEAR (CONT’D) Figure 30-70-5
Swing Bearing Installation
Figure 30-70-3
OUTER RACE 1
Soft zone is at
the Ball Bearing
filler plug INNER RACE
1 Soft zone is
identified by a
letter “S”
stamped on ring
P-95373
Install the swing bearing mount bolts (Item 1) [Figure 30-

NA1885 70-5] and lock nuts.
Put lubriplate grease or equivalent on the swing bearing

Figure 30-70-4 gear.
P-95373
If reusing the existing swing bearing, use top, side and

edge aligning marks to put the swing bearing in the
correct location. If installing a new swing bearing find the
soft zone area (Item 1) [Figure 30-70-3] & [Figure 30-
70-4].
Install the swing bearing so the inside soft zone is at the

left side of the excavator [Figure 30-70-3] & [Figure 30-
70-4].
NOTE: Do not put the soft zone to the front or rear of

the excavator.

UPPERSTRUCTURE & SWING SECTION
ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1
Arm To Boom Bushing Removal And Installation . . . . . . . . . . . . . 40-160-1
Arm To Bucket And Bucket Link Bushing Removal And Installation40-160-2 SAFETY &
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1 MAINTENANCE
BLADE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Linkage Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-80-4
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-2
Lower Linkage Removal And Installation. . . . . . . . . . . . . . . . . . . . 40-80-6
UPPERSTRUCTURE
DRIVE
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1 & SWING
SYSTEM
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1 SECTION
BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1
Bucket Side Cutting Edge Removal And Installation . . . . . . . . . . 40-170-2
Bucket Teeth Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-170-1
CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1 ELECTRICAL

Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-6 SYSTEM &
Front Window Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-30-7 ANALYSIS
Glass Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-13
Glass Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-12
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1 ENGINE
Right Side Front And Rear Sliding Window Weather Strip Removal And SERVICE
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-11
Right Side Front And Rear Sliding Window Wiper Strip Removal And
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-11
Right Side Front Sliding Window Removal And Installation. . . . . 40-30-10 SPECIFICATIONS
Right Side Rear Sliding Window Removal And Installation . . . . . 40-30-10
CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-171-1
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-70-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
FLOOR MAT AND FLOOR PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1

Removal And Installation (Cab Equipped Excavators) . . . . . . . . 40-110-2
Removal And Installation (Canopy Equipped Excavators) . . . . . 40-110-1
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1


UPPERSTRUCTURE & SWING SECTION (CONT’D)
HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1
LEFT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . 40-60-5
Compression Spring Removal And Installation . . . . . . . . . . . . . . . . 40-60-4
Console Base Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-60-16
Console Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-8
Console Switch Removal And Installation . . . . . . . . . . . . . . . . . . . 40-60-15
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-12
Lock Lever Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . 40-60-7
Lower Console Cover Removal And Installation . . . . . . . . . . . . . . . 40-60-1
Upper Console Cover Removal And Installation . . . . . . . . . . . . . . . 40-60-3
RIGHT CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Console Base Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-50-2
Console Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . 40-50-1
RIGHT PEDAL AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-4
Pedal Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-2
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-210-1

ROPS CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

STANDARD SEAT AND SEAT MOUNT . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

SUSPENSION SEAT AND SEAT MOUNT . . . . . . . . . . . . . . . . . . . . . . 40-41-1

SWING FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1

Boom Swing Bracket Hose Installation . . . . . . . . . . . . . . . . . . . . . 40-140-5
Boom Swing Bracket Removal And Installation . . . . . . . . . . . . . . . 40-140-1
Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-7
Bushing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-6

UPPERSTRUCTURE & SWING SECTION (CONT’D)
TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-1
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-180-2
TRAVEL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-5
UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-4
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
UPPERSTRUCTURE SLEW LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . 40-200-1

X-CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-7
Check Proper Latch Engagement . . . . . . . . . . . . . . . . . . . . . . . . 40-190-13
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-190-3

MAY VARY.

UPPERSTRUCTURE Figure 40-10-2
Removal
1
Figure 40-10-1
P-56040
Fasten chains to the rear of the upperstructure on both

PE1345 sides (Item 1) [Figure 40-10-2] and up to a lifting fixture
above the canopy/cab [Figure 40-10-1]. The lifting fixture
must extend over the sides of the canopy/cab to prevent
Fully extend the cylinders of the bucket, arm, and boom the chains from hitting the ROPS/TOPS.
so that the excavator is in the position as shown [Figure
40-10-1]. Figure 40-10-3
Lower the blade all the way.
Put all the control levers in neutral.

1
The boom must be in full raised position and centered to
the front of the excavator [Figure 40-10-1].
WARNING
• Use a lifting fixture with sufficient capacity for the P-55989
weight of the excavator plus any added
attachments.
• Maintain center of gravity and balance when Install a 1 in. (25 mm) bolt and nut (Grade 5 or 8) through
lifting. the holes at the boom (Item 1) [Figure 40-10-3]. Fasten
• Do not swing boom or upperstructure. Engage a chain from the bolt to the lift fixture [Figure 40-10-1].
the upperstructure slew lock.
• Never lift with operator on machine.
W-2202-0607
325/ 328 Excavator

40-10-1 Service Manual
UPPERSTRUCTURE (CONT’D) Figure 40-10-5
Removal (Cont’d)
Remove the swing motor. (See Removal And Installation

on Page 20-90-1.)
Remove the swing motor drive carrier. (See Removal

Figure 40-10-4
1 P-55417
Mark and remove the hoses [Figure 40-10-5] from the

swivel joint.
Figure 40-10-6
P-56041
1
Mark the upperstructure to the swing bearing and to the

track frame for assembly (Item 1) [Figure 40-10-4].
IMPORTANT
When repairing hydrostatic and hydraulic systems, P-56041

Partially disassemble the upperstructure from the swing
bearing by removing all but four bolts which are spaced
damage the system.
I-2003-0888
at 90° from each other (Item 1) [Figure 40-10-6].
The upperstructure must be rotated to gain access to the

bolts for removal. With the help of a second person,
manually turn the upperstructure to provide clearance for
bolt removal.
NOTE: For disassembly safety a minimum of four

evenly spaced bolts must remain installed, to
be removed later.
Apply a small amount of lifting pressure to the

upperstructure with the lift sling. Remove the four
remaining bolts holding the upperstructure to the swing
bearing.
325/328 Excavator
UPPERSTRUCTURE (CONT’D)
Removal (Cont’d)
Figure 40-10-7
P-56029
Lift the upperstructure off of the swing bearing. Put the

upperstructure on suitable supporting stands or blocks
[Figure 40-10-7].
325/ 328 Excavator

Installation
Figure 40-10-8
FRONT OF MACHINE
OUTER RACE
Soft zone is
at the
INNER RACE Ball Bearing
Soft zone is filler plug 1
identified by a 1
letter “S”
stamped on N-15781
ring
Use a tap (12 mm) in the holes (Item 1) [Figure 40-10-

PI-13677 10] in the upperstructure to remove any dried thread lock
adhesive or burrs.
P-23503 B-13678
Rotate the swing bearing so the outside soft zone (Item Make three alignment pins by using M12 X 110 mm (P/N
1) [Figure 40-10-8] & [Figure 40-10-9] is to the right 7GM-12110) long bolts. Cut the head off of these bolts at
hand side of the excavator. 3.50 in. (90 mm). Taper this end of the bolts [Figure 40-
10-11].
NOTE: The upperstructure can only be installed on
the swing bearing in one position. Match the
mount holes in the swing bearing to the
mount holes in the upperstructure.
325/328 Excavator
Installation (Cont’d)
Figure 40-10-12
1
1
P-53288
1 Install the three tapered head alignment bolts (Item 1)

N-15784 [Figure 40-10-14] through the swing bearing and into the
upperstructure. These bolts should be spaced 120°
apart.
Install the pins (Item 1) [Figure 40-10-12] into the
upperstructure at approximately 120° apart. These will This procedure will correctly align the upperstructure for
act as alignment pins while lowering the upperstructure correct swing motor gear to swing bearing ring gear
onto the swing bearing. clearance.
Install the upperstructure onto the swing bearing using Tighten these three tapered bolts to 60 ft.-lb. (81 N•m)
the alignment marks and the alignment pins. torque.
Figure 40-10-13
B-13693
Make sure the swivel joint is centered into the

upperstructure access hole [Figure 40-10-13].
325/ 328 Excavator

Figure 40-10-15
P-55417
Install the hoses [Figure 40-10-16] on the swivel joint.

N-15787
Remove the chains and lifting fixture.
Remove the three, 3.50 in. (90 mm) alignment pins (Item Install the swing motor drive carrier. (See Removal And
1) [Figure 40-10-15] from the upperstructure. Installation on Page 20-91-1.)
These headless pins can be removed from the bottom. Check the backlash between the gears by moving the
frame back and forth at several points throughout 360° of
Apply thread lock adhesive (Loctite® 242) to the threads frame rotation. There must be some backlash present.
of the bolts. Install the bolts into all holes (except the
three with the alignment bolts installed). Tighten these Install the swing motor. (See Removal And Installation on
bolts to 78 - 85 ft.-lb. (106 - 115 N•m) torque. Page 20-90-1.)
Remove the three alignment bolts. Install the three

remaining bolts. Tight these bolts to 78 - 85 ft.-lb. (106 -
115 N•m) torque.
325/328 Excavator
ROPS CANOPY
Build the service lifting bracket used to remove and install the ROPS canopy. Use the dimensions shown [Figure 40-20-
1] to build the service lifting bracket.
Figure 40-20-1
Material: 2 X 2 - 0.25 in. wall hot rolled steel tubing

0.25 in. hot rolled steel plate
MS1933

ROPS CANOPY (CONT’D) Figure 40-20-3
Figure 40-20-2
1
P-53290
Adjust the lifting bracket to the proper width by moving

P-53289 the bracket (Item 1) [Figure 40-20-3].
Figure 40-20-4
Install the chain hoist (Item 1) in the end hole of the lifting
bracket (Item 2) [Figure 40-20-2].
Install the cab/canopy service lifting bracket on the

canopy [Figure 40-20-2].
NOTE: Use a chain hoist of sufficient capacity.
1
WARNING
Never use the cab/canopy service lifting bracket to 1
lift the excavator. The bracket is not strong enough P-53292
and can fail causing serious injury or death.
W-2384-1000
Remove the bolts and washers (Item 1) [Figure 40-20-4]
from the inside front of the canopy.
Installation: Tighten the bolts to 118 - 133 ft.-lb. (160-

180 N•m) torque.
Remove the canopy.

ROPS CANOPY (CONT’D)
Figure 40-20-5
1 1
P-53291
Remove the bolts and washers (Item 1) [Figure 40-20-5]

from the rear of the canopy.
Installation: Tighten the bolts to 118 - 133 ft.-lb. (160-

180 N•m) torque.
Raise the hoist.
Remove the canopy.

CAB
Build the service lifting bracket used to remove and install the cab. Use the dimensions shown [Figure 40-30-1] to build
the service lifting bracket.
Figure 40-30-1
Material: 2 X 2 - 0.25 in. (51 x 51 - 6,35 mm) wall hot

rolled steel tubing 0.25 in. (6,35 mm) hot rolled steel
plate
MS1933

CAB (CONT’D) Figure 40-30-3
Figure 40-30-2
1
1
2
P-53047
Adjust the lifting bracket to the proper width by moving

P-53048 the bracket (Item 1) [Figure 40-30-3].
The cab may be equipped with either the A/C or heater

Install the chain hoist (Item 1) in the end hole of the lifting duct.
bracket (Item 2) [Figure 40-30-2].
A/C Duct
Install the cab/canopy service lifting bracket on the cab
[Figure 40-30-2]. Figure 40-30-4
NOTE: Use a chain hoist of sufficient capacity. 3
WARNING 2
2
Never use the cab/canopy service lifting bracket to

lift the excavator. The bracket is not strong enough 1
and can fail causing serious injury or death.
W-2384-1000
P-42588
Pull down on the lock (Item 1), remove the screws (Item
2), and remove the A/C duct (Item 3) [Figure 40-30-4].

Figure 40-30-5
1
1
P-52930
2
1 Remove the grommet (Item 1) [Figure 40-30-7] located
P-47438 in the left rear corner of the cab.
Figure 40-30-8
Remove the screws (Item 1). Remove the air manifold
(Item 2) [Figure 40-30-5].
Heater Duct
Figure 40-30-6 1
1
1
P-52931
Remove the wire harness from the cab frame and

disconnect the wire connectors (Item 1) [Figure 40-30-
8].
P-42587
Remove the screws and pull straight up to remove the

heater duct (Item 1) [Figure 40-30-6].

Figure 40-30-9
1
1
P-52928
Open the Operation & Maintenance Manual storage door

P-53070 (Item 1) [Figure 40-30-11].
NOTE: Later models are not equipped with the

Remove the windshield washer hose (Item 1) [Figure 40- storage door.
30-9] from the nozzle.
Figure 40-30-12
Remove the upperstructure light. (See Removal And
Figure 40-30-10
1
1 1
P-52932
Remove the bolts and washers (Item 1) [Figure 40-30-

P-53050 12] from the rear of the cab.
Installation: Tighten the bolts to 118 - 133 ft.-lb. (160 -

Remove the tie strap (Item 1) and disconnect the wire 180 N•m) torque.
harness (Item 2) [Figure 40-30-10].

Figure 40-30-13 1
1
P-53069
Installation: Install the cab mounts (Item 1) [Figure 40-

P-52927 30-15] on the four corners of the cab.
Remove the bolts and washers (Item 1) [Figure 40-30-

13] from the front of the cab.
Installation: Tighten the bolts to 118 - 133 ft.-lb. (160 -

180 N•m) torque.
Figure 40-30-14
P-53051
Guide the wiring harness (Item 1) [Figure 40-30-14]

through the upperstructure as the cab is being removed.

CAB (CONT’D)
Door Removal And Installation
Figure 40-30-16
P-56043
The door can be removed from the cab by slowly

swinging the door back and forth while lifting up on the
door [Figure 40-30-16].
Installation: Align the hinges and swing the door back

and forth until the door weight settles the hinges to full
engagement.

Front Window Removal And Installation
Figure 40-30-17
1
1
P-52936
Remove the nuts (Item 1) [Figure 40-30-19].

P-52934
Figure 40-30-20
Figure 40-30-18 2
2
1
P-52937
Remove the wiper assembly (Item 1) from the pivot

P-52935 mounts (Item 2) [Figure 40-30-20].
Remove the wire harness (Item 1) from the channel (Item

2) [Figure 40-30-18].

Front Window Removal And Installation (Cont’d)
Figure 40-30-21
1 2
1 1
1
P-52941
Remove the seals (Item 1) [Figure 40-30-23].

P-52938
Figure 40-30-24
Remove the nuts and washers (Item 1) [Figure 40-30-

21].
NOTE: Support the wiper motor before removing the

mounting hardware.
1
Figure 40-30-22
3
P-52942
Remove the screw (Item 1) [Figure 40-30-24] holding

the wire harness clamp to the top of the front window.
1
P-52939
Remove the plate (Item 1), washer (Item 2), and wiper
motor (Item 3) [Figure 40-30-22].

Front Window Removal And Installation (Cont’d)
Figure 40-30-25
1
4 3
2
P-52946
1
With the help of a second person holding the front

P-52943 window, remove the retainer (Item 1), spring (Item 2),
roller (Item 3), and handle (Item 4) [Figure 40-30-27]
from both sides of the front window.
Remove the bolt (Item 1) [Figure 40-30-25] holding the
wire harness clamp to the bottom of the front window. Figure 40-30-28
Figure 40-30-26
P-52948
P-52945
Tilt the front window (Item 1) [Figure 40-30-28]. Remove
the front window from the cab frame.
Remove the wire harness (Item 1) from the channel (Item
2) [Figure 40-30-26].

CAB (CONT’D) Right Side Front Sliding Window Removal And
Installation
Right Side Rear Sliding Window Removal And
Installation NOTE: The rear sliding window must be removed
before the front sliding window can be
Close and latch the front and rear sliding windows. removed.
Figure 40-30-29 Unlatch the front sliding window and slide the window
open until it stops.
Figure 40-30-31
P-52949
Use a pick to pull the felt (Item 1) [Figure 40-30-29] from

P-52951
the top window channel.
Unlatch the rear sliding window and slide the window Use a pick to pull the felt (Item 1) [Figure 40-30-31] from
open until it stops. the inside top window channel.
Figure 40-30-30 Figure 40-30-32
P-52950 P-52952
Lift the window up into the top channel and tilt the bottom Lift the window up into the channel and tilt the bottom
edge out [Figure 40-30-30]. Remove the window from edge out [Figure 40-30-32]. Remove the window from
the excavator. the excavator.

CAB (CONT’D) Right Side Front And Rear Sliding Window Wiper
Strip Removal And Installation
Right Side Front And Rear Sliding Window Weather
Strip Removal And Installation Remove the window.
Remove the window. Figure 40-30-35
Figure 40-30-33
1
P-63661
P-63659
Remove the wiper strip (Item 1) [Figure 40-30-35] from
the window channel.
Remove the weather strip (Item 1) [Figure 40-30-33]
from the bottom channel of the window.
Installation: Clean the bottom channel. Apply a bead of

adhesive in the channel.
Figure 40-30-34
2 2
1
P-63660
Install the new weather strip (Item 1). Cut the weather
strip flush with the ends of the window channel (Item 2)
[Figure 40-30-34].

CAB (CONT’D)
Glass Removal
Use the following procedure to remove the glass from the

cab and right side window assembly.
Figure 40-30-36
P-52953
Push a small diameter wire (Item 1) [Figure 40-30-36]

through the adhesive. Pull the wire around the perimeter
of the glass to cut the adhesive.
Remove the glass.
NOTE: The right side window frame is aluminum and

will be destroyed when removed.

CAB (CONT’D) Shake the combo primer for one minute.
Glass Installation Apply the combo primer to the perimeter of the cab and
glass (Item 2) [Figure 40-30-38]. Apply the primer in one
Rear and front lower glass. direction only, using a dauber. Do not dip the dauber in
the primer more than once. Use multiple daubers if
Remove the majority of the old urethane adhesive from needed.
the perimeter of the cab.
Allow the combo primer to dry for five minutes. Dry time
NOTE: Leave a thin film of the old urethane on the cab doubles if the primer is applied in two coats.
frame, fresh urethane will bond to the
remaining film. Cut the tip of the adhesive tube to the desired shape and
size to provide a bead height sufficient to give good
Prime and paint any bare metal or scratches. contact with the glass around the entire perimeter.
Clean the metal surfaces with general purposes adhesive Figure 40-30-39
cleaner. Clean the glass surface with glass cleaner.
Figure 40-30-37 1
1
2
1
1
MS1993
2 Apply a 0.3 x 0.25 in. (7,62 x 6,35 mm) bead of urethane

PE2199S
adhesive (Item 1) [Figure 40-30-39] to the perimeter of
the cab.
Figure 40-30-38
Figure 40-30-40
1
1
MS1992
MS1994
Install the seal (Item 1) on the glass (Item 2) [Figure 40-

30-37] & [Figure 40-30-38]. Install the glass and seal assembly (Item 1) [Figure 40-
30-40]. Press the glass into the cab to make complete
contact with the adhesive. Tape the glass in place.

CAB (CONT’D) Cut the tip of the adhesive tube to the desired shape and
size to provide a bead height sufficient to give good
Glass Installation (Cont’d) contact with the glass around the entire perimeter.
Allow two hours for curing at normal conditions (65° F Figure 40-30-42
(18° C), 75% relative humidity).
Remove the tape after the adhesive is cured. 1

Top, right side and left side glass
Remove the majority of the old urethane adhesive from

the perimeter of the cab.
NOTE: Leave a thin film of the old urethane on the cab

frame, fresh urethane will bond to the 1
remaining film.
Prime and paint any bare metal or scratches.

MS1993
Clean the metal surfaces with general purposes adhesive
cleaner. Clean the glass surface with glass cleaner.
Apply a 0.3 x 0.25 in. (7,62 x 6,35 mm) bead of urethane
Shake the combo primer for one minute. adhesive (Item 1) [Figure 40-30-42] to the perimeter of
the cab.
Figure 40-30-41
Figure 40-30-43
2
1
1
MS1995
2
1 Install the glass (Item 1) [Figure 40-30-43]. Press the
glass into the cab to make complete contact with the
adhesive. Tape the glass in place.
PE2198S
Allow two hours for curing at normal conditions (65° F

(18° C), 75% relative humidity).
Apply combo primer to the perimeter of the cab (Item 1)
and glass (Item 2) [Figure 40-30-41]. Apply the primer in
Remove the tape after the adhesive is cured.
one direction only, using a dauber. Do not dip the dauber
in the primer more than once. Use multiple daubers if
Door and front window glass
needed.
The door and front window glass are not available
Allow the combo primer to dry for five minutes. Dry time
separately. Order and install the door or front window
doubles if the primer is applied in two coats.
frame and glass assembly.

STANDARD SEAT AND SEAT MOUNT
Figure 40-40-1
1
P-23004
Pull the lever (Item 1) [Figure 40-40-1] away from the

seat to release the seat lock. Pull the seat toward the
front of the machine until it is free of the seat tracks.
Remove the seat.
Figure 40-40-2
P-56267
Loosen the bottom bolt (Item 1) [Figure 40-40-2] (both

sides.)
Remove the top bolt (Item 2) [Figure 40-40-2] (both

sides.)
Remove the seat mount.

SUSPENSION SEAT AND SEAT MOUNT Figure 40-41-3
Figure 40-41-1
1 1
P-52286
2
Remove the seat belt mounting bolt (Item 1) [Figure 40-
P-52283 41-3].
Remove the seat belt.

Remove the top bolt (Item 1) [Figure 40-41-1] (both
sides.) Figure 40-41-4
Loosen the bottom bolt (Item 2) [Figure 40-41-1] (both

sides.)
Remove the seat and seat mount from the excavator.

2
Figure 40-41-2 2
1 1
2 2
P-52287
1
Remove the bolts (Item 1) [Figure 40-41-4] from the seat
cables.
Remove the seat mount bolts (Item 2) [Figure 40-41-4].

P-52285
Remove the seat mount from the seat.
Remove the seat belt mounting bolt (Item 1) [Figure 40-

41-2].
Remove the seat belt.

RIGHT CONSOLE Remove the arm rest.
Console Cover Removal And Installation Remove the screw (Item 2) [Figure 40-50-2] from the
cup holder.
Figure 40-50-1
Lift the console cover up and over the joystick lever.
Figure 40-50-3
2
P-49093

P-21730
arm rest.
Lift up on the rear of the cover and slide the cover ahead Disconnect the accessory outlet electrical connector
to remove it. (Item 1) [Figure 40-50-3].
Remove the key and nut from the key switch (Item 2) Remove the controller from the console cover by
[Figure 40-50-1] (if equipped). Allow the switch to drop pressing the mounting tabs (Item 2) [Figure 40-50-3].
inside the console.
Figure 40-50-4
NOTE: The key switch must be removed to remove
and install the console cover.
Figure 40-50-2
P-21732
Turn the instrument panel to allow it to pass through the

P-21729 console cover [Figure 40-50-4].

Remove the two bolts (Item 1) [Figure 40-50-2] from the
arm rest.

RIGHT CONSOLE (CONT’D) Figure 40-50-7
Console Base Removal And Installation
Remove the console cover. (See Console Cover

Figure 40-50-5 2
1 1
P-52221
Remove the screws (Item 1) [Figure 40-50-7].

1
Remove the duct (Item 2) [Figure 40-50-7].
P-42590 Figure 40-50-8
Rotate the lock (Item 1) [Figure 40-50-5].
Figure 40-50-6
2
1
3
1
2
2
P-52223
Push the hose (Item 1) [Figure 40-50-8] inside the

console base.
P-52220
Remove the screws (Item 1) [Figure 40-50-6].
Remove the air conditioning duct (Item 2) [Figure 40-50-

6].
Remove the screw (Item 3) [Figure 40-50-6].

RIGHT CONSOLE (CONT'D) Figure 40-50-11
Console Base Removal And Installation (Cont’d)
Figure 40-50-9
P-56638

P-52225
Figure 40-50-12
Remove the floor mat.
Figure 40-50-10
P-52226
Slide the console base (Item 1) [Figure 40-50-12]

1 forward and remove the base from the excavator.
P-52219

LEFT CONSOLE Remove the cover (Item 1) [Figure 40-60-14] from the
arm rest.
Lower Console Cover Removal And Installation
Figure 40-60-15
Figure 40-60-13
1 1
1
1
P-21737

1 arm rest.
1 Remove the arm rest.
Raise the upper half of the console cover.
P-50877
Remove the seven screws (Item 1) [Figure 40-60-13]

from the lower half of the console cover.
Remove the lower half of the console cover.
Lower the console.
Figure 40-60-14
P-50878

LEFT CONSOLE (CONT'D)
Lower Console Cover Removal And Installation

(Cont'd)
Figure 40-60-16
P-21738

60-16].

plugged in only one way.

Upper Console Cover Removal And Installation
Figure 40-60-17
1
1
1 P-56113
Remove the four console cover screws (Item 1) [Figure

40-60-17].
Figure 40-60-18
P-56114
Lift the console cover and disconnect the harness (Item

1) [Figure 40-60-18] from the potentiometer harness. (If
equipped with heater)
Disconnect the harness (Item 2) [Figure 40-60-18] from

the blower switch. (If equipped with heater)
Remove the console from the excavator.

LEFT CONSOLE (CONT'D) Figure 40-60-21
Compression Spring Removal And Installation
Remove the lower console cover. See Lower Console

Cover Removal And Installation on Page 40-60-1.)
1
Lower the console.
Figure 40-60-19
P-52260
Remove the spring assembly (Item 1) [Figure 40-60-21]

from the console.
1
P-52259
Install a pin (Item 1) [Figure 40-60-19] in the top of the

compression spring rod.
Figure 40-60-20
P-52231
Support the console in the raised position. Remove the

bolt (Item 1) [Figure 40-60-20].

Compression Spring Disassembly And Assembly
Figure 40-60-22
P-52262
1
P-52261
Figure 40-60-25
Figure 40-60-23
1 2
P-52263
Remove the spring (Item 1) from the shaft (Item 2)

P-24008 [Figure 40-60-25].
Apply pressure against the spring, and remove the pin

(Item 1) [Figure 40-60-23] from the shaft.
Release the pressure from the spring.

Compression Spring Disassembly And Assembly

(Cont’d)
Figure 40-60-26
2
3
P-52264
Remove the sleeve (Item 1) and washer (Item 2) from the

shaft (Item 3) [Figure 40-60-26].

LEFT CONSOLE (CONT'D) Remove the spring (Item 1) [Figure 40-60-28].
Lock Lever Removal And Installation Figure 40-60-29
Remove the upper console cover. See Console Removal

And Installation on Page 40-60-8
1
Remove the lower console cover. See Lower Console 2
Cover Removal And Installation on Page 40-60-1
Remove the console base. See Console Base Removal

And Installation on Page 40-60-16
1
Remove the compression spring assembly from the
console. See Compression Spring Disassembly And
Assembly on Page 40-60-5
Figure 40-60-27 P-52267
Remove the tie straps (Item 1) [Figure 40-60-29].
Remove the roll pin (Item 2) [Figure 40-60-29] from the

lock lever pivot pin.
Raise and support the console.
Figure 40-60-30
1
2
P-52265
1
Remove the bolt (Item 1) from the lock lever bearing
(Item 2) [Figure 40-60-27].
Remove the bearing.
Lower the console.
Figure 40-60-28 P-52268
Remove the pivot pin (Item 1) [Figure 40-60-30] from the

lever assembly.
Remove the lock lever.
P-52266

Console Removal And Installation
Remove the seat and seat mount. (See Removal And

Installation on Page 40-40-1 or See Removal And
Installation on Page 40-41-1)
Remove the floormat and floor plate. (See Removal And

110-1 or See Removal And Installation (Cab Equipped 1
1
1
Remove the upper console cover. (See Upper Console
Remove the lower console cover. (See Lower Console

Cover Removal And Installation on Page 40-60-1.) P-52444
Figure 40-60-31
1 right side of the heater unit.
1 Figure 40-60-34
P-52771
1
Remove the bolts (Item 1) and remove the cover (Item 2)

[Figure 40-60-31] from the heater unit.
P-56211
Figure 40-60-32
Remove the bolts (Item 1) [Figure 40-60-34] from the left
side of the heater unit.
P-56210
Mark and remove the heater hoses (Item 1) [Figure 40-

60-32].

LEFT CONSOLE (CONT'D) Remove the six hoses (Item 1) [Figure 40-60-36] from
the joystick.
Console Removal And Installation (Cont’d)
Figure 40-60-37
Figure 40-60-35
P-52773
P-56212
Lower the console. Disconnect the joystick wire harness

Relocate the heater unit as shown [Figure 40-60-35]. (Item 1) [Figure 40-60-37].
Remove the console base. (See Console Base Removal Figure 40-60-38
And Installation on Page 40-60-16)
IMPORTANT
1
damage the system.
I-2003-0888
P-52774
Figure 40-60-36
P-52772

Figure 40-60-39 1
P-52791

P-52775 from the console lockout switch.
Figure 40-60-42
Remove the grommet (Item 1) [Figure 40-60-39].
Figure 40-60-40
1
1
1
P-52777
P-52776 Remove the hose clamp (Item 1) [Figure 40-60-42].
Pull the wire harness out and disconnect the connectors

(Item 1) [Figure 40-60-40].

Figure 40-60-43
1 1
P-52778
Figure 40-60-44
1
1
P-52780
Remove the console (Item 1) [Figure 40-60-45].
P-52779

Figure 40-60-46
P-52783
1
Remove the bolt (Item 1) and bearing (Item 2) [Figure
P-52781 40-60-48].
Figure 40-60-49
Install a pin (Item 1) [Figure 40-60-46] in the shaft.
Figure 40-60-47
1 3 P-52784
P-52782 Remove the roll pin (Item 1) [Figure 40-60-49].
Remove the bolt (Item 1), spring assembly (Item 2), and


1
Figure 40-60-50
2
1
4 P-52787
3
Remove the rollpin (Item 1) [Figure 40-60-52].
P-52785
Figure 40-60-53
Remove the pin (Item 1). Remove the bracket (Item 2)

[Figure 40-60-50].
Installation: Align the hole (Item 3) in the pin with the

hole (Item 4) [Figure 40-60-50] in the bracket.
Figure 40-60-51
4 3
2 1
P-52789
Remove the pin (Item 1) from the bracket (Item 2)

1 [Figure 40-60-53].
Installation: Align the hole (Item 3) in the pin with the

hole (Item 4) [Figure 40-60-53] in the bracket.
P-52786
Remove the spring (Item 1) [Figure 40-60-51].

Figure 40-60-54
P-52790
Remove the bolts (Item 1). Remove the bracket (Item 2)

[Figure 40-60-54].
Figure 40-60-55
P-52788
Remove the dust boot (Item 1) [Figure 40-60-55].

Console Switch Removal And Installation

Cover Removal And Installation on Page 40-60-3)
1
Cover Removal And Installation on Page 40-60-1)
Figure 40-60-56
1 2
2 P-52273
Remove the screws (Item 1) from the switch (Item 2)

1 [Figure 40-60-58].
Remove the console lockout switch.
P-52271
Remove the screws (Item 1) [Figure 40-60-56] from the

magnet side of the console lockout switch.
Remove the magnet (Item 2) [Figure 40-60-56].
Figure 40-60-57
P-52272
Remove the wire harness (Item 1) [Figure 40-60-57]

from the switch.

Console Base Removal And Installation

1
Figure 40-60-59
P-52768
1 Figure 40-60-62
1
P-52230 1
2
console base cover.
Figure 40-60-60
P-52769
Remove the bolt (Item 1) from the bracket (Item 2)

1 [Figure 40-60-62].
Remove the console base mount bracket.
P-52229
Remove the bolt (Item 1) [Figure 40-60-60] from the

console base cover.
Remove the console base cover.

ENGINE SPEED CONTROL Figure 40-70-3
NOTE: The removal and installation procedure for the

engine speed control is the same for both
early and later models. Early model is shown. 2
Remove the right upper console cover. (See Console


1
Figure 40-70-1
P-55640
1
Remove the speed control lever (Item 2) [Figure 40-70-

2 3]
Figure 40-70-4
P-55639 3
2 1
Remove the linkage cable nut (Item 1) [Figure 40-70-1].
Remove the nuts (Item 2) and bracket (Item 3) [Figure

40-70-1].
Figure 40-70-2
P-55641
Remove the washer (Item 1) and spacer (Item 2) from

1 the lever (Item 3) [Figure 40-70-4].
P-56045
Remove the wave washers (Item 1) [Figure 40-70-2].
NOTE: The fuel fill is shown removed for photo clarity.

ENGINE SPEED CONTROL (CONT’D)
Adjustment
Open the engine cover.
Figure 40-70-5
P-72261
Loosen the jam nut (Item 1) and adjust the bolt (Item 2)
[Figure 40-70-5] until the engine runs at 2615 RPM.
Tighten the jam nut (Item 1) [Figure 40-70-5].

BLADE CONTROL Figure 40-80-3
Lever Removal And Installation

Figure 40-80-1
1
P-24241
Remove the blade control lever from the excavator

[Figure 40-80-3].
NOTE: If the two-speed switch needs to be replaced,

P-24238 the complete blade control lever must be
replaced.
Disconnect the two speed wire harness (Item 1) [Figure

40-80-1].
Figure 40-80-2
P-55642
Loosen the bolts (Item 1) [Figure 40-80-2].
325/328 Excavator
BLADE CONTROL (CONT’D) Figure 40-80-6
Linkage Removal And Installation

2
Remove the blade control lever. (See Lever Removal
1
Figure 40-80-4
P-24243
Remove the nut (Item 1) from the mount plate (Item 2)

[Figure 40-80-6].
1
Figure 40-80-7
P-24242
2
NOTE: The console base has been removed for photo 1

clarity.
Figure 40-80-5
3
1
P-24244
Remove the pivot mount (Item 1) bolt (Item 2) and

washers (Item 3) [Figure 40-80-7].
P-24239
Remove the bolt (Item 1) [Figure 40-80-5] from the blade

control pivot mount.
Remove the blade control pivot mount.
325/328 Excavator
BLADE CONTROL (CONT’D)
Linkage Removal And Installation (Cont’d)
Figure 40-80-8
1
N-23856
Remove the washers (Item 1) [Figure 40-80-8] from the

pivot mount.
Figure 40-80-9
1
N-23857
Remove the sleeve (Item 1) [Figure 40-80-9] from the

pivot mount.
Inspect the O-rings (Item 2) [Figure 40-80-9] and replace

parts as needed.
325/328 Excavator
Linkage Bar Removal And Installation

Remove the blade control lever. (See Lever Removal

And Installation on Page 40-80-1.) 2
Figure 40-80-10 1
P-55754
1
Turn the linkage (Item 1) 90°. Remove the cotter pin and
clevis pin (Item 2) [Figure 40-80-12]. Remove the
linkage.
1
Figure 40-80-13
1
P-55745
1
Figure 40-80-11
P-55755
Remove the nut (Item 1) [Figure 40-80-13], bolt, washer

and spacer.
1
P-55753
Remove the nut (Item 1) [Figure 40-80-11] bolt, washers

and spacer.
325/328 Excavator
Linkage Bar Removal And Installation (Cont’d)
Figure 40-80-14
P-24245
Remove the linkage bar (Item 1) [Figure 40-80-14] from

the top.
NOTE: The console base has been removed for photo

clarity.
325/328 Excavator
Lower Linkage Removal And Installation
Remove the right console cover (See Console Cover

Figure 40-80-15
P-55754
1
1
Turn the linkage (Item 1) 90°. Remove the cotter pin and
clevis pin (Item 2) [Figure 40-80-17].
1 Remove the linkage.

P-55745
Figure 40-80-18
Figure 40-80-16
P-55755
Remove the nut (Item 1) [Figure 40-80-18] bolts, washer

P-55753 and spacer.
Remove the nut (Item 1) [Figure 40-80-16] bolts,

washers and spacer.
325/328 Excavator
Lower Linkage Removal And Installation (Cont’d)
Figure 40-80-19
1
2
P-55756
Figure 40-80-20
P-55840
Remove the nuts (Item 1) [Figure 40-80-19] and bolts.
NOTE: Access the bolt (Item 1) [Figure 40-80-20]

through the right console in the cab.
Remove the linkage assembly (Item 2) [Figure 40-80-

19].
325/328 Excavator
325/328 Excavator
RIGHT PEDAL AND LINKAGE
Pedal Removal And Installation
Figure 40-90-21
1 2
P-55418
Remove the nut (Item 1), washers and bolt from the
pedal linkage (Item 2) [Figure 40-90-21].
Remove the linkage.
Figure 40-90-22
P-55428
Remove the right pedal.

RIGHT PEDAL AND LINKAGE (CONT'D) Figure 40-90-25
Pedal Disassembly And Assembly
Figure 40-90-23
1
P-50992
Remove the front pedal (Item 1) [Figure 40-90-25].

P-50990
Figure 40-90-26
Remove the nut and washer (Item 1) [Figure 40-90-23].
Figure 40-90-24
P-50993
3
2
1 Remove the dust cover (Item 1) [Figure 40-90-26].
P-50991
Remove the rear pedal (Item 1) bushing (Item 2) and

wave washer (Item 3) [Figure 40-90-24].

RIGHT PEDAL AND LINKAGE (CONT'D)
Pedal Disassembly And Assembly (Cont'd)
Figure 40-90-27
P-50994

pedal lock.
Remove the pedal lock from the pedal mount.
Figure 40-90-28
P-50995

pedal lock.
NOTE: Do not lubricate the O-rings (Item 1) [Figure 40-

90-27] and [Figure 40-90-28]. The O-rings
provide a friction fit to prevent the lock from
moving freely.

RIGHT PEDAL AND LINKAGE (CONT'D)
Linkage Removal And Installation
Figure 40-90-29
1
P-55745
Figure 40-90-30
P-55757
Remove the nut and bolt (Item 1). Remove the cotter pin
and clevis pin (Item 2). Remove the linkage (Item 3)
[Figure 40-90-30].

TRAVEL CONTROLS Figure 40-100-2

1
Figure 40-100-1
2
1
1 2
P-55549
Mark and remove the cables (Item 1) [Figure 40-100-2]

from the travel levers.
Loosen the nuts (Item 2) [Figure 40-100-2] and remove

the cables from the travel lever mount.
P-55548 Remove the travel lever mount from the excavator.
Remove the bolts and nuts (Item 1) [Figure 40-100-1]

from the front floor panel.
Turn the travel lever mount over.

TRAVEL CONTROLS (CONT’D) Figure 40-100-5
Disassembly of the right travel control is shown. The

procedure is the same for both the left and right travel
control. 1
Figure 40-100-3
P-55550
Remove the wave washer (Item 1) and bushing (Item 2)

[Figure 40-100-5].
1
Figure 40-100-6
P-55556
Remove the nut and washer (Item 1) [Figure 40-100-3]

from the rear pedal.
Installation: Tighten the nut to eliminate side play while

allowing free travel of the pedals.
Figure 40-100-4
1
P-55551
Remove the front pedal (Item 1) [Figure 40-100-6].
P-55555
Remove the rear pedal (Item 1) [Figure 40-100-4].

TRAVEL CONTROLS (CONT’D) Figure 40-100-9
Figure 40-100-7 1
P-55554
1
Figure 40-100-10
P-55552

front pedal.
Figure 40-100-8 1
P-22987
1
Remove the four nuts (Item 1) [Figure 40-100-9] that
attach the pedal stops (Item 1) [Figure 40-100-10] to the
mount plate.
P-55553 Installation: Tighten the nuts to 18 - 19 ft.-lb. (24 - 26

N•m) torque.
Remove the bolt (Item 1) [Figure 40-100-8] and nut. Remove the pedal stops.
Installation: Clean the bolt threads and apply thread

lock adhesive (Loctite® 242). Tighten the bolts to 32 - 35
ft.-lb. (43 - 47 N•m) torque.
Remove the pedal mount.

TRAVEL CONTROLS (CONT’D)
Figure 40-100-11
P-22990
Installation: Adjust the pedal stops to align the hand

levers (Item 1) [Figure 40-100-11] in both forward and
reverse positions.
NOTE: This is the initial adjustment. Final adjustment

must be done after the mount has been
installed and the travel controller linkage has
been connected.
Figure 40-100-12
P-22988
Remove the bolts (Item 1) [Figure 40-100-12] from each

of the pedal stops.

N•m) torque.

TRAVEL CONTROLS (CONT'D) Figure 40-100-15
Adjustment
Neutral
Figure 40-100-13 1
1
P-55852
Turn the nuts (Item 1) [Figure 40-100-15] to adjust the

travel lever length.
Tighten the nuts.

1
1 Repeat the procedure for the opposite travel lever.
P-55852
Loosen the two nuts (Item 1) [Figure 40-100-13] on the

travel linkage.
Figure 40-100-14
2.74”
(69,6 mm)
P-55853
Hold the travel lever (Item 1) [Figure 40-100-14] in the

neutral position.
Neutral position is 2.74 in. (69,6 mm) above the top of the
pedal mount plate [Figure 40-100-13].

Adjustment (Cont'd)
Forward Lever Stop:
Figure 40-100-16
P-55856
1
Slide the pedal stop (Item 1) [Figure 40-100-18] forward

1
until it contacts both levers.
2 Tighten the bolts (Item 2) [Figure 40-100-18] on the
P-55854
pedal stop.
Loosen the bolts (Item 1) on the rear pedal stop (Item 2)

[Figure 40-100-16].
Hold both travel levers in the forward position.
Figure 40-100-17
2.05”
(52,1 mm)
P-55855
Forward position is 2.05 in. (52,1 mm) above the top to

the pedal mount plate [Figure 40-100-17].

Adjustment (Cont'd)
Reverse Lever Stop:
Figure 40-100-19
1 1
P-55857
Slide the front pedal stop (Item 1) [Figure 40-100-21]

until it contacts both levers.
1
P-55854 Tighten the bolts (Item 2) [Figure 40-100-21] on the front
pedal stop.
Loosen the bolts (Item 1) [Figure 40-100-19] on the front

pedal stop.
Hold both travel levers in the reverse position.
Figure 40-100-20
3.36”
(85,3 mm)
P-55857
Reverse position is 3.36 in. (85,3 mm) above the top of

the pedal mount plate [Figure 40-100-20].

FLOOR MAT AND FLOOR PLATE Figure 40-110-3
Removal And Installation (Canopy Equipped

Excavators)
Figure 40-110-1
1
1 1 2 1
P-50548
Remove the floor mat (Item 1) [Figure 40-110-3].
P-50546 Figure 40-110-4
Remove the three bolts (Item 1) [Figure 40-110-1].

1
Remove the retaining plate (Item 2) [Figure 40-110-1].
Figure 40-110-2
1
1
1
1
1 1
1
P-50549
Remove the five mount bolts (Item 1) [Figure 40-110-4]

from the floor plate.
Remove the floor plate.

P-50547
Remove the three spacers (Item 1) [Figure 40-110-2].

FLOOR MAT AND FLOOR PLATE (CONT’D)
Removal And Installation (Cab Equipped Excavators)
Figure 40-110-5
P-50422
Remove the floor mat [Figure 40-110-5] from the cab.
Figure 40-110-6
1
1
1
1
P-50423
Remove the five bolts (Item 1) [Figure 40-110-6].
Remove the floor plate.

FUEL TANK Remove the bolts (Item 1) [Figure 40-120-1].
Removal And Installation Figure 40-120-2
Installation (Canopy Equipped Excavators) on Page 40- 2
Remove the travel controls. (See Removal And

Remove the seat and seat mount. (See Removal And 1

Installation on Page 40-40-1 or See Removal And
Remove the heater unit (If equipped). (See Description

on Page 70-10-1.)
P-56269
Remove the left console upper and lower console covers.
(See Lower Console Cover Removal And Installation on
Page 40-60-1 and See Upper Console Cover Removal Remove the bolt (Item 1) and cover (Item 2) [Figure 40-
And Installation on Page 40-60-3.) 120-2].
Remove the boom swing cylinder. (See Removal And

Drain the fuel tank. (See Draining The Fuel Tank on Page
10-80-3.)
WARNING
explosion or fire.
W-2103-0508
Figure 40-120-1
P-56268

FUEL TANK (CONT’D) Figure 40-120-5
Figure 40-120-3
1
P-56272
Remove the bolts (Item 1). Remove the floor pan (Item 2)
P-56270 [Figure 40-120-5].
Figure 40-120-6
Figure 40-120-4
P-22993
P-56271
Pull out on the cab frame and remove the rear floor pan
Loosen the top bolt (Item 1) [Figure 40-120-3] and [Figure 40-120-6] (if equipped.)
bottom bolt (Item 1) [Figure 40-120-4] and remove the
console side frame (Item 2) [Figure 40-120-4].

FUEL TANK (CONT’D) Figure 40-120-9
Figure 40-120-7
1 2 P-56274
Remove the fuel fill hose (Item 1) and vent hose (Item 2)
P-56273 [Figure 40-120-9].
Figure 40-120-10
Remove the fuel sending unit wire harness (Item 1) and
hoses (Item 2) [Figure 40-120-7].
Figure 40-120-8
1
2
1
2 2
P-56276
Remove the bolts (Item 1) and fuel tank mount (Item 2)

P-56277 [Figure 40-120-10].
Installation: Route the wire harness (Item 1) between

the ribbed sections (Item 2) [Figure 40-120-8] of the fuel
tank.

FUEL TANK (CONT’D)
Figure 40-120-11
P-56275
Remove the fuel tank [Figure 40-120-11].

HORN Figure 40-130-3
Access the horn through the right front side of the 1

upperstructure.
Figure 40-130-1
1 P-73800A
1
Remove the nut (Item 1) [Figure 40-130-3] and remove

the horn.
P-55425
Remove the bolts (Item 1). Remove the cover (Item 2)

[Figure 40-130-1].
Figure 40-130-2
P-73799
NOTE: Horn shown removed for visual clarity [Figure

40-130-2].
Disconnect the wire harness (Item 1) from the horn (Item

2) [Figure 40-130-2].

SWING FRAME Figure 40-140-3
Boom Swing Bracket Removal And Installation
Rotate the upperstructure so the blade is to the rear of

the excavator.
Remove the arm. (See Removal And Installation on Page

40-160-1.)
Remove the boom. (See Removal And Installation on

Page 40-150-1.)
1
Figure 40-140-1
P-23474
Remove the hose bracket (Item 1) [Figure 40-140-3].

1 1
Reposition the hoses to gain clearance.
Figure 40-140-4
2
2
P-23472
Remove the bolts (Item 1) and the clamp (Item 2) [Figure

40-140-1]. 1
NOTE: When the hoses have been removed from the
clamped position, the hoses must be
measured for correct clamped length and
position. (See Boom Swing Bracket Hose
P-23475
Figure 40-140-2
Install the boom pin (Item 1) using spacers to position a
2 lifting clevis (Item 2) [Figure 40-140-4] on the center of
the boom pin.
NOTE: The spacers will prevent the clevis from

sliding on the boom pin causing the boom
swing bracket to tip from side to side.
P-23473
Remove the snap ring (Item 1), washer, and pin (Item 2)
[Figure 40-140-2] from the boom swing bracket.

SWING FRAME (CONT’D) Figure 40-140-6

(Cont’d)
Figure 40-140-5
P-23566
1
Install a porta-power between the top and bottom pins

and press the top pin out [Figure 40-140-6].
P-23476
Figure 40-140-7

washer from the top pin.
IMPORTANT
Do Not use a porta-power to press out the swing
frame pivot pins without the lower pin being
supported. Excess pressure can cause the swing
frame casting to crack. 2
I-2092-1204
P-23567
Support the bottom pin with a jack.

washer from the pin.
Install a spacer tube (Item 2) [Figure 40-140-7] and jack

under the swing bracket to support the casting. The
spacer tube must be large enough to allow the pin to be
driven in the center of the spacer for pin removal.


(Cont’d)
Figure 40-140-8
P-23569
Remove the top and bottom spacer (Item 1) [Figure 40-

140-9] from the swing bracket.
Remove the swing bracket.
Inspect the bushings for damage. Replace damaged

bushings as necessary. (See Bushing Removal on Page
40-140-6.)
P-23568
Use a large punch (Item 1) [Figure 40-140-8] and drive

the bottom swing bracket pin out.
NOTE: Do not use a porta-power to press out the

bottom pin because the top casting cannot be
supported and possible damage to the
casting could occur.


(Cont’d)
Figure 40-140-10
1
1
P-23476
Installation: Install the top pin, washer and snap ring

1
(Item 1) [Figure 40-140-12].
P-23569
Installation: Install the top and bottom spacer (Item 1)

[Figure 40-140-10] on the swing bracket. Install the
swing bracket.
Figure 40-140-11
P-23567
Installation: Align the boom swing bracket and install the

lower pin. Install the washer and snap ring (Item 1)
[Figure 40-140-11]. Lift up on the boom swing bracket.

Boom Swing Bracket Hose Installation
Figure 40-140-13
2 5
1 6
3 4
P-23470
Route the hoses through the boom swing bracket as

follows [Figure 40-140-13]:
1. Arm Rod End Hose

2. Bucket Base End Hose
3. Female Quick Coupler Hose
4. Male Quick Coupler Hose
5. Bucket Rod End Hose
6. Arm Base End Hose
P-23471
Install the hoses and hose clamp (Item 7) [Figure 40-
140-13]. Do not tighten the clamp at this time.
Measure the length of the hoses from the top of the
clamp to the end of each hose [Figure 40-140-14].
Tighten the clamp bolts when the auxiliary hoses are 29

in. (737 mm) and the arm and bucket hoses are 31 in.
(787 mm) from the top of the clamp.

SWING FRAME (CONT’D) Install the washer (Item 3) [Figure 40-140-15] onto the
opposite end of the bushing. This washer must be
Bushing Removal centered on the bushing and must not contact the
casting.
Install the bolt (Item 4) and the nut (Item 5) [Figure 40-
140-15] through the washers and the spacer.
IMPORTANT
Tighten the bolt and nut to remove the bushing from the
Do Not point (hammer) on the boom swing bracket. casting.
Excess pressure can cause the casting to crack.
I-2095-1195
The following parts will be needed for removal and

installation of the boom swing bracket bushings:
Bolt - 5/8 x 4.0 in. or (15 x 101 mm) long.
Nut - 5/8 in. or (15 mm).
Washer -3/4 I.D. x 3 O.D. x 3/8 in. thick or (19 mm I.D.

x 79 mm O.D. x 10 mm thick.
Washer - 3/4 I.D. x 3-1/2 O.D. x 3/8 in. thick or (19 mm

I.D. x 79 mm O.D. x 10 mm thick).
Washer - 3/4 I.D. x 4-1/2 O.D. x 1 in. thick or (19 mm

I.D. x 114 mm O.D. x 25 mm thick).
Spacer - 3-9/16 I.D. x 4-5/16 O.D. x 1-1/2 in. thick or

(90 mm I.D. x 110 mm O.D. x 25 mm thick).
Figure 40-140-15
4
2
5
P-23570
Install the spacer (Item 1) and washer (Item 2) [Figure

40-140-15] over the flanged end of the bushing.
The spacer (Item 1) [Figure 40-140-15] must be

centered over the bushing to avoid contact between the
bushing and the spacer during removal.

Bushing Installation
Apply a film of grease to the outer diameter of the

bushing and to the inner diameter of the casting.
Center the bushing on the casting hole.
NOTE: The bushing must be centered in the casting

hole and started in the hole evenly and
square.
Figure 40-140-16
P-23573
Figure 40-140-18
5
1
2
3
4 P-23571
Put the washer (Item 1) [Figure 40-140-16] over the

flanged end of the bushing.
P-23572
Put the spacer (Item 2) and the washer (Item 3) [Figure
40-140-16] over the bushing hole casting. Center the
spacer and the washer over the bushing hole. The same procedure is used to remove and install the
bushings into the frame castings [Figure 40-140-17] &
Install the bolt (Item 4) through the washers, the spacer [Figure 40-140-18].
and the bushing. Install the nut (Item 5) [Figure 40-140-
16].
Tighten the bolt and nut until the bushing is seated in the
casting.

BOOM Figure 40-150-2
Remove the arm. (See Removal And Installation on Page 1

40-160-1.)
Remove the boom cylinder. (See Removal And

Figure 40-150-1
P-53227
2
Remove the tubeline clamp (Item 1) [Figure 40-150-2].

2 Mark and remove the hoses (Item 2) [Figure 40-150-2].
Figure 40-150-3
1
P-56633
Disconnect the wire harness (Item 1) [Figure 40-150-1]. 2
Cut and remove the cable ties (Item 2) [Figure 40-150-

1].
1
IMPORTANT
P-53228
parts clean. Always use caps and plugs on hoses, Remove the snap ring (Item 1), washers (Item 2) [Figure
tubelines and ports to keep dirt out. Dirt can quickly 40-150-3] and pin.
damage the system.
I-2003-0888

BOOM (CONT’D) Figure 40-150-6
Figure 40-150-4
0.197” (5 mm)
TS-1614A
Install the bushings until they are seated 0.197 in. (5 mm)
P-53229 in the pin boss [Figure 40-150-6] (both sides.)
Install new seals on both sides of the arm.

Remove the boom [Figure 40-150-4].
Figure 40-150-5
P-53230
Remove the seals (Item 1) [Figure 40-150-5] from both

sides of the boom.
Remove the bushings from both sides of the boom.
Install the new bushings in the boom.

ARM Arm To Boom Bushing Removal And Installation
Removal And Installation Remove the dust seal (if equipped) from both sides of the
arm.
Figure 40-160-1
Figure 40-160-3
P-55989
N-16505
Support the boom [Figure 40-160-1].

Remove the bushings (Item 1) [Figure 40-160-3] from
Remove the arm cylinder. (See Removal And Installation both sides of the arm.
on Page 20-21-3.)
Figure 40-160-4
Support the arm with a chain hoist.
Figure 40-160-2
1
1
0.197” (5 mm) TS-1614

2
P-6997 Install the bushings until they are seated 0.197 in. (5 mm)
in the pin boss [Figure 40-160-4] (both sides).
Disconnect the bucket cylinder hoses (Item 1) [Figure Install new dust seals (if equipped).
40-160-2].
Remove the nut (Item 2) [Figure 40-160-2] and the

washer (Item 3) [Figure 40-160-2] from the boom
mounting pin.
Installation: Tighten the lock nut until it is seated firmly

against the boom. Do not over tighten and deflect the
boom mounting plates. The arm must pivot freely.
Remove the arm.

ARM (CONT’D) Figure 40-160-7
Arm To Bucket And Bucket Link Bushing Removal

And Installation
Figure 40-160-5
1
0.197” (5 mm) TS-1614
Install the bushings until they are seated 0.197 in. (5 mm)
in the pin boss [Figure 40-160-7] (both sides).
N-16507
Install the dust seals (Item 1) [Figure 40-160-5] on both
sides of the arm.
Remove the dust seals (Item 1) [Figure 40-160-5] from
both sides of the arm.
Figure 40-160-6
N-16506
Remove the bushings (Item 1) [Figure 40-160-6] from

both sides of the arm.

BUCKET Figure 40-170-2
Bucket Teeth Removal And Installation
1
WARNING
• Pressurized fluids and springs or other stored
energy components. 2
• Tools are being used. P-23376
W-2505-0604
Remove the two nuts (Item 1) and bolts from the tooth
Position the bucket so the bucket teeth are at a 30° angle shank (Item 2) [Figure 40-170-2]. Remove the tooth
up from the ground for accessibility to the teeth. shank.
Lower the boom until the bucket is fully on the ground. Installation: Tighten the nuts to 90 - 100 ft.-lb. (125 - 135
N•m) torque.
Stop the engine and exit the excavator.
Later Style Bucket Teeth
NOTE: Early and later style tooth points and retaining
pins are not interchangeable. The removal and installation procedure for the later style
tooth point and tooth assembly is the same as the early.
Early Style bucket Teeth style.
Figure 40-170-1 Figure 40-170-3
1
2
1 2
2
3
3
P-23374
P-69201A
Remove the retaining pin (Item 1) from the tooth point The later style tooth has a unique retaining pin (Item 1).
(Item 2) [Figure 40-170-1]. The retaining pin must be installed as shown [notch (Item
2) to the front] for proper fit and tooth retention. The side
Remove the tooth point (Item 2) from the shank (Item 3) of the tooth point (Item 3) [Figure 40-170-3] also shows
[Figure 40-170-1]. the correct orientation of the retaining pin.
Installation: Position the new tooth point on the shank Installation: Position the new tooth point on the shank
and install a new retaining pin. Install the retaining pin and install a new retaining pin. Install the retaining pin
until it is flush with the top of the point. until it is flush with the top of the point.

BUCKET (CONT’D)
Bucket Side Cutting Edge Removal And Installation
Figure 40-170-4
P-23377
The bucket side cutting edges (Item 1) [Figure 40-170-4]

are reversible.
Figure 40-170-5
1
1 2
P-23373
Remove the two bolts and nuts (Item 1) [Figure 40-170-

5].
Installation: Tighten the nuts to 90 - 100 ft.-lb. (125 - 135

N•m) torque.
Remove the cutting edge (Item 2) [Figure 40-170-5].

CLAMP Figure 40-171-3
Removal And Installation 1 2 4

Figure 40-171-1
2
TS1573
1
Remove the retainer clip (Item 1), washer (Item 2) and
N-15514 pivot pin (Item 3) [Figure 40-171-3].
Remove the clamp (Item 4) [Figure 40-171-3].

171-1] from the cylinder pin.
Remove the pin (Item 2) [Figure 40-171-1] from the rod

end of the cylinder.
Figure 40-171-2
P-65832
Attach a chain (Item 1) [Figure 40-171-2] and lifting

device.

TAILGATE Figure 40-180-3
Figure 40-180-1
1
1
P-55647
Remove the bottom bolt (Item 1) [Figure 40-180-3] and

P-55644 nut.

Install a sling (Item 1) [Figure 40-180-1] through the top N•m) torque.
tailgate brace.
Figure 40-180-4
Figure 40-180-2
P-55648
Remove the top bolt (Item 1) [Figure 40-180-4] and nut.
Installation: Tighten the bolt to 25 - 28 ft.-lb. (34 - 38

N•m) torque.
Remove the tailgate.
P-55646
Install an overhead hoist on the sling [Figure 40-180-2].

TAILGATE (CONT'D) Figure 40-180-7
Latch Removal And Installation
Figure 40-180-5 2
4
2
1
1
P-55651
3
Remove the bolt (Item 1). Remove the latch assembly

P-55649 (Item 2) [Figure 40-180-7] from the tailgate.
Remove the bolt (Item 1), locknut (Item 2), outer rollers
(Item 3) and inner roller (Item 4) [Figure 40-180-5].
Figure 40-180-6
2
1
P-55650
For ease of assembly, mark around the outside edge

(Item 1) [Figure 40-180-6] of the latch bracket.
Remove the bolts (Item 2), latch bracket and washers

(Item 3) [Figure 40-180-6].
See latch adjustment. (See Adjusting The Latch on Page

10-40-1.)

X-CHANGE Figure 40-190-3

1
Remove the bucket. See the Operation And Maintenance
Manual for the correct removal procedure. (See the
Operation And Maintenance Manual.)
1
Figure 40-190-1
P-15087
Remove the washers (Item 1) [Figure 40-190-3].
Figure 40-190-4
N-23184 1
Support the boom with a hoist [Figure 40-190-1].
Figure 40-190-2
1
P-15086
Remove the plate (Item 1) [Figure 40-190-4].
P-15088
Remove the snap rings (Item 1) [Figure 40-190-2].

X-CHANGE (CONT’D) Figure 40-190-7
Figure 40-190-5
1 P-15083
Remove the washer (Item 1) [Figure 40-190-7].

P-15084
Figure 40-190-8
Figure 40-190-6
P-15081
Remove the pin (Item 1) [Figure 40-190-8] and remove

P-15082 the X-Change from the arm.

Disassembly
Figure 40-190-9
1
2
1
P-15058
Remove the rubber hose (Item 1) [Figure 40-190-11].

P-15056
Figure 40-190-12
Remove the bolt (Item 1) and nut (Item 2) [Figure 40-

190-9].
2
Figure 40-190-10 1
P-15059
Remove the snap ring (Item 1) and washer (Item 2)

[Figure 40-190-12].
P-15057
Remove the springs (Item 1) [Figure 40-190-10].

Figure 40-190-13
1
3
1
P-15063
2
Partially remove the pin (Item 1) [Figure 40-190-15].

P-15060
Figure 40-190-16
Remove the pin (Item 1), link (Item 2) and latch (Item 3)
[Figure 40-190-13].
1
Figure 40-190-14
P-15064
1
Remove the pin far enough to remove the spacer (Item 1)

[Figure 40-190-16].
P-15062

Figure 40-190-17
2 1
P-15067
1
Remove the seal (Item 1) from both sides of the catch.

P-15065 Remove the bushings (Item 2) [Figure 40-190-19] from
inside the catch.
Remove the spring (Item 1) [Figure 40-190-17]. Figure 40-190-20
Figure 40-190-18
1 1
P-15076
P-15066
Remove the four seals (2 per side) (Item 1) [Figure 40-
190-20] from the top pivot point of the link.
Completely remove the pin and remove the catch (Item
1) [Figure 40-190-18].

Figure 40-190-21
1
1
2
P-15071
Use thick walled tubing (Item 1) [Figure 40-190-22] &

P-15077 [Figure 40-190-23] with an inside diameter larger than
the outside diameter of the link bushings to support the
link (Item 2) [Figure 40-190-22] & [Figure 40-190-23]
Remove the two seals (one per side) (Item 1) [Figure 40- and remove the bushings.
190-21] from the bottom pivot point of the link.
NOTE: Properly support the cast link to prevent
Figure 40-190-22 damage when installing or removing the
bushings.
Figure 40-190-24
P-15070
P-15072
Remove the two bushings (Item 1) [Figure 40-190-24]

from the X-Change frame.

X-CHANGE (CONT’D) Assembly
Disassembly (Cont’d) Figure 40-190-27
Figure 40-190-25
1 1
1
P-34081
P-34082
Install the bushings (Item 1) [Figure 40-190-27].
Remove the O-ring (Item 1) [Figure 40-190-25] (both Figure 40-190-28

sides).
Figure 40-190-26
1 1
P-34082
P-34081 Install the O-ring (Item 1) [Figure 40-190-28] (both

sides). Use grease to hold the O-rings in place.
Remove the bushings (Item 1) [Figure 40-190-26].

Assembly (Cont’d)
Figure 40-190-29
1
1
P-15074
Press the bushings (Item 1) [Figure 40-190-31] in until

P-15072 the seal will fit flush in the link.
Figure 40-190-32
Install the two bushings (Item 1) [Figure 40-190-29] and
apply grease to all four bushings.
Figure 40-190-30
P-15077
Install the seal (Item 1) [Figure 40-190-32] (both sides.)

P-15069
Install the bushings in both sides of the link [Figure 40-

190-30].

damage when installing or removing the
bushings.

Assembly (Cont’d)
Figure 40-190-33 1
1
P-15076
Install the four seals (Item 1) [Figure 40-190-35] (one per

P-15068 side).
Figure 40-190-36
Install the bushings in both sides of the link [Figure 40-
190-33].

damage when installing or removing the 1
bushings.
Figure 40-190-34
P-15067
Install the bushings (Item 1) [Figure 40-190-36] in the

catch.
Install the seal (Item 2) [Figure 40-190-36] on both sides

1 of the catch.
P-15073
Press the bushings (Item 1) [Figure 40-190-34] in until

the seal will fit flush.

Assembly (Cont’d)
Figure 40-190-37
P-15064
1
2
Install the spacer (Item 1) [Figure 40-190-39].
P-15066
Figure 40-190-40
Partially install the pin (Item 1) [Figure 40-190-37].
Install the catch (Item 2) [Figure 40-190-37] on the pin.
Figure 40-190-38
P-15063
2
Completely install the pin (Item 1) [Figure 40-190-40].
3
P-15065
Install the spring on the pin, with the angled end of the
spring (Item 1) engaging the hole in the catch. Put the
straight end of the spring (Item 2) under the spring
retainer (Item 3) [Figure 40-190-38].

Assembly (Cont’d)
Figure 40-190-41
2
1 P-15060
Install the link (Item 1) and completely install the pin (Item
P-15062 2) [Figure 40-190-43].
Figure 40-190-44
Figure 40-190-42
2
1
2 P-15059
3 Install the washer (Item 1) and snap ring (Item 2) [Figure

P-15061
40-190-44].
Align the latch (Item 1) and partially install the pin (Item 2)
[Figure 40-190-42].
Rotate the catch toward the latch so the end of the catch
(Item 3) [Figure 40-190-42] is under the latch.

Assembly (Cont’d)
2
Figure 40-190-45
P-15056
Apply thread lock adhesive (Loctite® 242) to the bolt

P-15058 threads and install the bolt (Item 1) and nut (Item 2)
[Figure 40-190-47].
Install the hose (Item 1) [Figure 40-190-45] in the spring. Tighten the bolt to 118 - 133 ft.-lb. (160 - 180 N•m)
torque.
NOTE: The hose helps prevent the spring from being
filled with dirt or mud. When replacing the
hose, cut to a length of 2.750 - 3.0 in. (108 - 118
mm).
Figure 40-190-46
2
2
1
P-15057
Install the springs (Item 1) [Figure 40-190-46] in the X-

Change.
Pull the latch up until the springs (Item 1) seat over the
roll pins (Item 2) [Figure 40-190-46].

Check Proper Latch Engagement

Latch Pivot Pin
Figure 40-190-48
Cross Section View (Latch Engaged)

Latch
Latching X-Change
Latch Length
Engagement
Dimension
MS2006A
La
tch Measure the installed latch length. Measure from the
edge of the latch pivot pin to the end of the latch. The
latch does not need to be removed to measure.
Maximum latch length is 3.52 in. (89,4 mm) [Figure
40-190-49].
If the latch length is greater than maximum, it should be

Attachment Interface replaced or the end can be ground to achieve maximum
latch length.
MS2019A Figure 40-190-50
Latch (end view)

Maximum latch length and minimum latch engagement
dimensions are provided. Latch length must be
checked before checking latch engagement [Figure
40-190-48].
Before making any measurements, clean the excavator

X-Change and the attachment interface. Inspect both
components to be certain they are free of debris and are
not damaged.
Maintain
Rounded Profile
MS2026
If you grind the latch, maintain the rounded profile of the

end [Figure 40-190-50].
After verifying the latch length, check the attachment

interface.
Install the attachment.

Check Proper Latch Engagement (Cont’d) Cross Section View (Latch Engaged)
Figure 40-190-51
Place Mark
On Interface
Engagement
La
tch
Latc
h
MS2007
MS2019A
With the attachment installed on the machine and

lowered to the ground, place a mark on the interface just If latch engagement is less than 0.50 in. (12,7 mm),
above the latch [Figure 40-190-51]. remove material from the ramp of the interface [Figure
40-190-52] & [Figure 40-190-53].
Note: The mark should reflect the line of sight
across the top edge of the latch. It is not Figure 40-190-54
intended to reflect the actual contact point of
the latch and interface. Grind Here
Remove the attachment.
Figure 40-190-52
MS2010
Using a grinder, remove material from the interface ramp

Interface Ramp MS2011
in the area shown. The grind area must be wider than
the latch, but does not need to extend all the way to
the sides of the interface. Maintain the original profile
Measure the latch engagement. Measure from the mark and flatness of the ramp. Remove between 0.06 - 0.12 in.
previously made to the center of the radius at the top of (1,5 - 3,0 mm) of material [Figure 40-190-54].
the interface ramp. Two rulers are required. Minimum
latch engagement is 0.50 in. (12,7 mm) [Figure 40- Install the attachment on the machine, mark the interface
190-52]. [Figure 40-190-51] and measure the new latch
engagement [Figure 40-190-52].

X-CHANGE (CONT’D)
Check Proper Latch Engagement (Cont’d)
WARNING
W-2019-0907
If latch engagement is less than 0.50 in. (12,7 mm),

remove more material from the ramp of the interface.
Install the attachment on the machine, mark the interface

and measure the new latch engagement again to verify
latch engagement is 0.50 in. (12,7 mm) or more.
Figure 40-190-55
Cross Section View (Latch Engaged)
Stop
Increased
Engagement
La
tc
h
MS2017A
The latch may wear and become shorter, increasing latch

engagement. Latch wear is dependent on the type of
attachment used and the application. If wear becomes
excessive, the latch will rest on the stop. The attachment
will remain securely installed on the machine in this
position, however the attachment can exhibit rattling
noise during operation because the attachment interface
is shifting slightly within the X-Change. Visual inspection
can detect if the latch is resting on the stop without
measurement. Latch replacement is recommended when
wear becomes this excessive. [Figure 40-190-55].

UPPERSTRUCTURE SLEW LOCK Disassembly And Assembly
Remove the floor mat and floor panel. (See Removal And
Installation (Cab Equipped Excavators) on Page 40-110-
2).
Figure 40-200-1
P-71787
1 Remove the nut (Item 1) [Figure 40-200-2].

1
Figure 40-200-3
P-71786
Remove the upperstructure slew lock.
P-71786
Remove the spacer (Item 1) [Figure 40-200-3].

UPPERSTRUCTURE SLEW LOCK (CONT’D) Figure 40-200-6
Figure 40-200-4
1
3
2
P-71792
2 3
Remove the bolt (Item 1), washer (Item 2) and spacer
P-71789 (Item 3) [Figure 40-200-6].
Figure 40-200-7
Remove the bolt (Item 1), washer (Item 2) and spacers
(Item 3) [Figure 40-200-4].
Remove the pin.
Figure 40-200-5
1
2
P-71793
Separate the slide (Item 1) from the housing (Item 2)

[Figure 40-200-7]
P-71791
Remove the nut (Item 1) [Figure 40-200-5].

RIGHT SIDE COVER Figure 40-210-3
Open the cover.
Figure 40-210-1
P-23420
Open the cover. Loosen the two bolts (Item 1) [Figure

40-210-3] and nuts.
P-23418 Figure 40-210-4
Remove the gas spring retaining clip (Item 1) [Figure 40-

210-1] and disconnect the gas spring.
Rotate the gas spring towards the rear of the excavator.
Figure 40-210-2
P-23422
1
Fully open and support the cover (Item 1) [Figure 40-
210-4].
P-55563
Close the cover. Remove the stop bolts and nuts (Item 1)
[Figure 40-210-2].

RIGHT SIDE COVER (CONT’D)
Figure 40-210-5
P-23423
Remove the two nuts and bolts (Item 1) [Figure 40-210-

5].
Remove the cover.

ELECTRICAL SYSTEM AND ANALYSIS
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-1
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-6
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-7
Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .50-30-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-5
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-9
Engine Accessory Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-1
Engine Accessory Drive Belt Tensioner Removal And Installation 50-30-2
Full Field Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-6
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-8
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . .50-30-14
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-13
Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-30-5
ELECTRICAL
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-1 SYSTEM AND
Removing And Installing The Battery. . . . . . . . . . . . . . . . . . . . . . .50-20-2 ANALYSIS
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-20-1
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . .50-20-2
DELUXE INSTRUMENT PANEL SETUP . . . . . . . . . . . . . . . . . . . . . .50-90-1

Changing The Owner or Operator Password. . . . . . . . . . . . . . . . .50-90-1
Job Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-2
Password Entry (For Starting And Operating The Machine) . . . . .50-90-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-2
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-1
RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-90-2
DIAGNOSTICS SERVICE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-80-1

Number Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-80-1
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . .50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-2
Fuse And Relay Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-10-1
FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-70-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-70-1

ELECTRICAL SYSTEM AND ANALYSIS (CONT’D)
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-50-1
Boom Light Bulb Replacement . . . . . . . . . . . . . . . . . . . . . . 50-50-2
Boom Light Removal And Installation . . . . . . . . . . . . . . . . . 50-50-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-40-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-11
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-8
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
TWO SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-60-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-60-1

TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS
OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD

ITEMS MAY VARY.

WIRING SCHEMATIC
WORKGROUP D25 AND D31

SWITCHED POWER RELAY
PWM WORKGROUP D37

J3 J1 J5 J6 J2
TRAVEL PEDAL SWITCH

J4
SPARE KEYLESS SOL

SENSOR POWER (+8V)
RED = RED
CONTROL MODULE
SPARE RELAY OUT

WIRES CONNECT BY LETTER BATTERY FEED 1000-1999 RED, RED/WHT, RNG
ENGINE SPEED HALL

GLOW PLUG STATUS
FUEL PULL STATUS

325 (S/N AAC511001 AND ABOVE) RNG = ORANGE
ENGINE SPEED VR
STARTER STATUS
ACROSS CONNECTORS
SENSOR GROUND
GROUND 2000-2999 BLK
LOAD MOMENT
DIVERTER OUT
BLK = BLACK
2 SPEED PWM
HYD OIL FILTER
ENG OIL PRESS

CONNECTORS J1-J6
SPARE ANG #2
FRONT BASE
R POT SIGNAL
SPARE DIG #2
SPARE DIG #1
ENGINE TEMP
GLOW PLUG
LBL = LIGHT BLUE
FRONT ROD
SPARE ANG #1
FUEL SENDER
MONITORING 3000-3999 LBL
FUEL HOLD
L POT SIGNAL
R SKI DOWN
PIEZO OUT
CAN SHIELD
L SKI DOWN
A B
FUEL PULL
UNUSED #3
UNUSED #2
UNUSED #1
(S/N A9K011001 AND ABOVE) DBL = DARK BLUE
STARTER
BATTERY
BATTERY
GROUND
GROUND
CAN HIGH
CAN LOW
HYD TEMP
HYDRAULIC 4000-4999 LGN
CONSOLE
R SKI UP
LGN = LIGHT GREEN
2 SPEED
B A
L SKI UP
DETENT
LIGHT
CRANK
ATTACHMENT CONTROLS 5000-5999 YEL DGN = DARK GREEN
328 (S/N A9K111001 AND ABOVE) YEL = YELLOW
KEY
LIGHTS 6000-6999 PNK PNK = PINK
SOME CONNECTOR WHT = WHITE K J G E C H D A B F
ACCESSORIES 7000-7999 WHT F K G H D A B J C E K G J B C D A E F H J H K A B F E G D C F E D C B A
(PRINTED FEBRUARY 2008) BODIES NOT SHOWN BRN = BROWN F G D C H A B E
ENGINE 8000-8999 TAN TAN = TAN
FOR DRAWING CLARITY
V-0979 COMMUNICATION 9000-9999 PUR PUR = PURPLE
RIGHT HAND CONSOLE
GRY = GRAY
4330
4340
3710
9320
4500
4450
4970
HARNESS 6810761
9700
9600
4320
4960
4920
2120
2120
2100
2110
9500
8000
8110
8150
6210
9370
1110
1120
8510
3600
3430
3500
8550
9350
8120
9330
3720
9360
4830
4300
3900
3300
4310
3100
3200
C158
LEFT HANDLE A A 3100
FUEL SENDER 20-270 ohm RIGHT HANDLE
B B 3310
3100 B B 3100
A A 4830 3310 C C 3310 4920 B B BRN
B A DETENT
RED C C 1720 4830 D D 4830 4960 1780 1770 C C RED
C467
C456
D D 4400 4370 E TWO-SPEED
E 4370
(BLADE LEVER)
4360 E E WHT
E 4390 4380 F
C457
E F 4380 4320 A A GRN
PWM
DETENT
BRN B B 9200 3900 H H 3900 4350 D D BLK
LOAD MOMENT
9200 G G 9200 (OPTIONAL)
3700 J J 3700 3700 3710
3910
A 1730 A A 1730
LH CONSOLE CONSOLE
C 3920 K K 9200 TRAVEL PEDAL SWITCH
SENSOR
HARNESS B 3900
B A
HORN 3720 1490
7102874 FRAME
LIGHT
1 2 1720
C458
3700
3
A 7130
1730
B 2650
4
2900 6 5 LOAD MOMENT TRAVEL
2610
9320
2950 (OPTIONAL) ALARM
(OPTIONAL)
2950
6230
HYD TEMP
-
+
t
SENDER
3300
1 2 538-1824 ±30
6310 6300
3
1460 1 ohm 3320 BUZZER
2
A B
4 1750 3
7120
C413
2900 6 5 HYD FILTER A 4450
4 A B SWITCH 3430
2930 7110 B 2450
7100
BEACON 5 6
SWITCH TWO-SPEED
C414
(OPTIONAL) 8 ohm nominal at 12 VDC (325/328) A A 4970
WIPER SWITCH YELLOW TIE STRAP
(OPTIONAL) 6230 E E 6230 6 ohm mominal at 12VDC (331/331E/334)
B B 2480
7110 F F 7110
1460 D D 1460
6300 C C 6300
C461
2930 J J 2930
WORK GROUP
6240 B B 6240 LOCKOUT
C415A
2790 G G 2790
8 ohm nominal A A 4510
ORANGE TIE STRAP
6400 A A 6400 at 12 VDC B B 2510
H H WORK GROUP
6310
6240
6400
2950
1750
7120
7100
2960
K K LOCKOUT
C415B
GREEN TIE STRAP
at 12 VDC B B 2520
AUX
SOCKET FRONT ROD
A B C A B A C B
C419
6400 6 ohm nominal A A 4330
C463 C469 C464
C465
1 7210 BLUE TIE STRAP
at 12 VDC B B 2330
CAB HARNESS 7102834 A B C A B A C B 2 2840
(IF EQUIPPED) FRONT BASE
C420
RED TIE STRAP
WIPER at 12 VDC
B B 2340
6310
6240
1750
C462
6400
2950
GRN
BRN
+
YEL
HARNESS 7110
DOME LIGHT 7100772
- 2820
WASHER I
6400 6400 WHT
BOTTLE 9330 C C
B RED
C455
1000 C A B A A
8 1000 9340 B B
C A B
C460
6220 A A 6220 ST
7 9400 D D DGN
RADIO CONNECTOR
2975 2940 B B 2940

PARK
9 1750
BOOM LIGHT
2 2980 - LEFT
+ HARNESS
SPEAKER
6 7980 A B 7135895
M
V
START
6240
2860
HIGH
5 2990
- RIGHT RUN
+ SPEAKER OFF
4 7990 GROUND
A B
1 OPEN WIPER
A B
3 OPEN MOTOR IGNITION
C625 SWITCH
C619
6220
2940
BRN A A 6310 A B
BLK B B 2870
120 ohm
6240
2860
BEACON WORK LIGHT

HARNESS
RIGHT WORK
LIGHT (OPT)
2090
2090
ACD & REMOTE START
C626
C627
LEFT WORK A A PNK A A BOOM CONNECTOR

LIGHT (OPT) LIGHT
B B BLK B B
A B C D G E F
C453
A B C D G E F
ENGINE HARNESS
9500
9600
9700
2710
1320
1140
7125860
FUEL SHUT OFF HOLD

A A 8150 8150 A A 8150
C101
HOLD = 0.33 OHM

C450
PULL = 24.5 OHM B B 8100 8100 B B 8100

PULL
C C 2800 8500 C C 8500
FUEL SHUTOFF SOLENOID
HR 8500 K K
GLOW PLUGS
8550 8550 C C 8550
0.4 ohm 3600 G G 3600
3630 H H 3630
C451
3500 D D 3500
2000, 2330, 2340, 2450, 2480, 2510,
3200 E E 3200 2310
C160
3600 A A 3600 2520,2650, 2710, 2820, 2830, 2940

SPEED 3210 F F 3210
SENSOR (VR) 3630 B B 3630
9360 J J 9360 GROUNDS
9390 A A 9390 RADIO
ENGINE OIL 3500 MEMORY
8100
8120
2100, 2110, 2610, 2740,
PRESSURE 1480 B B 1480 2300
2790, 2840, 2930
SWITCH FUSE 4
ACD POWER 25A 1
8110
t 1320
ENGINE COOLANT 1150
6200
6210
C159
3200 A A 3200 FUEL

SENDER
FUSE 1 SHUTOFF 1070 1040
500-3000 ± 30 ohm 3210 B B 3210 WIPER POWER
7210
7220
5A 87A 87 86 LIGHT 1330
8000
8550
8510
1460 RELAY POWER LEADS
C161
9390
9380
STARTER 1310
HEATER C B A FUSE 3 SWITCHED 86 87 87A GLOW 1060 1030
B M ALT / HEATER 25A POWER 30 85 PLUG
S 1480 1050 STARTER 1360
1080 9360
2010
2030
9390 85 30 87A 87 86
GROUNDS
2740
1190
1740
87A 87 86 87A 87 86
1740
2060
1140
FUSE 2 15A 25A 25A
2030
2040
30 85
S
2800 SWITCH POWER 20A AUX ACD FUEL
30 85 30 85
BAT
G
1350
EXC 7200 FUSE 12 GLOW FUEL FUSE 4 FUSE 8
1110
1120
7220
9400
1080 1480 STARTER LIGHTS
2040
2050
1060
20A PLUGS PULL
1370
25A 5A
6300
25A
1330
2000
2010
1070
7200
2050
LIGHTS ALT HEATER IGN

ALTERNATOR FUSE 10
1150
25A 1470 + RADIO 25A FUSE 11 FUSE 3 FUSE 7
FUSE 6 2830 - CONN FUSE 8 25A 15A 5A 25A 20A 25A
1310
20A FUSE 7
BATTERY FUSE 9 FUSE 12 ACD SW POWER HEATER
+ - RELAY GROUNDS 2000-2050

1310
FUSE 11
1150
1360
FUSE 10 SWITCH FUSE 6
1310
FUSE 2
1360
ARE CONNECTED IN SERIES

25A POWER 5A
CONTROLLER WIPER
1030 FUSE 9 FUSE 1 FUSE 5

1040
V-0979 (1-17-08)
WIRING SCHEMATIC
(S/N A9K0111001 AND ABOVE)
(PRINTED FEBRUARY 2008)
V-0980
TO RIGHT HAND
CONSOLE HARNESS
C458
B A B A
3720
1490
7130
2650
C635
3730 3710 A A
1480 B B
MOTION
ALARM
C634
1470 A A
MOTION ALARM 3700 B B
HARNESS - 6818273
V-0980 (1-17-08)
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart WARNING

The following troubleshooting chart is provided for
assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
making repairs, adjustments or servicing. Check for
W-2003-0807
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn engine. 2, 3, 4, 6, 7, 8, 9
KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.

ELECTRICAL SYSTEM INFORMATION (CONT’D) Fuse And Relay Location
Description A decal is inside the cover to show location and amp

ratings.
Figure 50-10-1
Remove the cover to check or replace the fuses and
relays.
Figure 50-10-2
P-49427
The excavator has a 12 volt, negative ground electrical

system. The electrical system is protected by fuses
B-19812
located under the right side cover of the excavator (Item
1) [Figure 50-10-1]. The fuses will protect the electrical
system when there is an electrical overload. The reason The location and sizes are shown below and [Figure 50-
for the overload must be found before starting the engine 10-2].
again.
REF DESCRIPTION AMP REF DESCRIPTION AMP
The battery cables must be clean and tight. Check the 5 Not Used -- 11 Lights 20
electrolyte level in the battery. Add distilled water as 6 Heater 25 12 ACC Plug 15
needed. Remove acid or corrosion from the battery and 7 Ignition 5
cables with a sodium bicarbonate and water solution. 8 Fuel Solenoid 25
1 Wiper 5
Put Battery Saver P/N 6664458 or grease on the battery 2 Switch Power 20
terminals and cable ends to prevent corrosion. 3 Alternator/ 25
Heater
4 ACD 25
9 Controller 25
WARNING 10 ACD 25
Always replace fuses using the same type and capacity.

Batteries contain acid which burns eyes and skin on REF DESCRIPTION
contact. Wear goggles, protective clothing and E Switch Power
rubber gloves to keep acid off body. F Fuel Solenoid
G Lights
In case of acid contact, wash immediately with water. H Glow Plug
In case of eye contact get prompt medical attention J Starter
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

BATTERY The original equipment battery is maintenance free. If a
replacement battery is installed, check the electrolyte
Servicing level in the battery.
Figure 50-20-1 If electrolyte level is lower than 1/2 in. (13 mm) above the
plates, add distilled water only.
Put battery saver P/N 6664458 or grease on the battery

terminals and cable ends to prevent corrosion
1 1
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
P-19227
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
The battery is located under the right side cover [Figure
50-20-1].
minutes.
The battery cables (Item 1) [Figure 50-20-1] must be
clean and tight. Remove acid or corrosion from the
battery and cables using a sodium bicarbonate and water
solution. Cover the battery terminals and cable ends with W-2065-0807
battery saver grease to prevent corrosion.
Figure 50-20-2
P-9589 P-9590
Clean the battery terminals and cable ends even when

installing a new battery [Figure 50-20-2].
Check for broken or loose connections.
If the battery cables are removed for any reason,

disconnect the negative (-) cable first. When installing the
battery cables, make the last connection the negative (-)
cable to the battery.

BATTERY (CONT’D) Using A Booster Battery (Jump Starting)
Removing And Installing The Battery
Figure 50-20-3
IMPORTANT
If jump starting the excavator from a second
3 machine:
When jump starting the excavator from a battery

installed in a second machine, make sure the engine
is NOT running while using the glow plugs. High
voltage spikes from a running machine can burn out
2
1 the glow plugs.
I-2060-0906
If it is necessary to use a booster battery to start the

engine, BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and
P-19227
disconnect the battery cables.
Be sure the key switch is OFF. The booster battery must

Disconnect the negative (-) cable (Item 1) [Figure 50-20- be 12 volt.
3] first.
Open the tailgate.
Disconnect the positive (+) cable (Item 2) [Figure 50-20-
3]. Figure 50-20-4
Remove the bolts (Item 3) [Figure 50-20-3] and remove

the hold down clamp.
Remove the battery.
Always clean the terminals and the cable ends, even

1
when installing a new battery.
Install the battery. Install the hold down clamp and tighten
the bolts.
Connect the battery cables. Connect the negative (-) 2

cable (Item 1) [Figure 50-20-3] last to prevent sparks.
P-49428
Connect one end of the first cable to the positive (+)

terminal of the booster battery. Connect the other end of
the same cable to the positive (+) terminal (Item 1)
[Figure 50-20-4] of the excavator starter.
Connect one end of the second cable to the negative (-)

terminal of the booster battery. Connect the other end of
the same cable to the negative excavator cable (Item 2)
[Figure 50-20-4] where it is fastened to the frame.

BATTERY (CONT’D)
WARNING
WARNING AVOID INJURY OR DEATH
Keep arcs, sparks flames and lighted tobacco away
AVOID INJURY OR DEATH from batteries. When jumping from booster battery
Batteries contain acid which burns eyes and skin on make final connection (negative) at machine frame.
rubber gloves to keep acid off body. Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
In case of acid contact, wash immediately with water. connecting to a charger. Unplug charger before
In case of eye contact get prompt medical attention connecting or disconnecting cables to battery. Never
and wash eye with clean, cool water for at least 15 lean over battery while boosting, testing or charging.
minutes.
Battery gas can explode and cause serious injury.
If electrolyte is taken internally drink large quantities W-2066-0705
W-2065-0807
NOTE: See “Cold Temperature Starting Procedure” in the

correct Operation & Maintenance Manual)
IMPORTANT
Start the engine. After the engine has started, remove the Damage to the alternator can occur if:
ground (-) cable first (Item 2) [Figure 50-20-4 on Page • Engine is operated with battery cables
2]. disconnected.
• Battery cables are connected when using a fast
Disconnect the cable from the excavator starter (Item 1) charger or when welding on the excavator.
[Figure 50-20-4 on Page 2]. (Remove both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2222-0903
WARNING
Batteries contain acid which burns eyes and skin on
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
minutes.

W-2065-0807

ALTERNATOR
Engine Accessory Drive Belt
Open the tailgate.
Figure 50-30-1
P-49429
The engine accessory drive belt (Item 1) [Figure 50-30-

1] must be checked and adjusted as needed, every 100
hours of operation. (See Belt Adjustment on Page 10-
140-1.)

ALTERNATOR (CONT’D) Figure 50-30-4
Engine Accessory Drive Belt Tensioner Removal And

Installation
Remove the alternator. (See Removal And Installation on

Page 50-30-3.)
Figure 50-30-2
2
1
P-56438
Remove the bolt, washer (Item 1) and spacer (Item 2)

1 [Figure 50-30-4].
Remove the bracket.
P-56436
Figure 50-30-3
P-56437
Remove the nuts (Item 1) [Figure 50-30-3].

Open the tailgate.
Disconnect the negative (-) battery cable. (See Removing

And Installing The Battery on Page 50-20-2.)
2
Figure 50-30-5
1 P-56418
2
Loosen the bolt (Item 1) on the tensioner and remove the
belt (Item 2) [Figure 50-30-7] from the alternator.
1
Figure 50-30-8
P-56295
2
Remove the bolts (Item 1) and guard (Item 2) [Figure 50-

30-5].
Figure 50-30-6
1
1
P-56419
Remove the bottom bolt (Item 1) and nut. Remove the

top bolt (Item 2) [Figure 50-30-8].
1
P-56303
Remove the wires (Item 1) [Figure 50-30-6] from the

alternator.

Bracket Removal And Installation

Page 50-30-3.)
Figure 50-30-9 1
P-56421
Figure 50-30-11
P-56420

1
P-56422
Remove the bolts (Item 1) [Figure 50-30-10] and

washers (Item 1) [Figure 50-30-11].
Remove the bracket.

ALTERNATOR (CONT’D) Tests
Description Perform the following alternator tests in this order:
Figure 50-30-12 Alternator Output Test: Tests the alternator and regulator
output.
1 Full Field Test: Tests the maximum amperage output of

3
the alternator.
4 Alternator Regulator Test: Tests the regulator voltage

2 output.
P-10023
The output terminal (Item 1) [Figure 50-30-12].
The open terminal (Item 2) [Figure 50-30-12] is not used

in the excavator harness.
The ignition terminal (Item 3) [Figure 50-30-12].
The open terminal (Item 4) [Figure 50-30-12] is not used

in the excavator harness.
Access hole for full field test (Item 5) [Figure 50-30-12].

ALTERNATOR (CONT’D) Full Field Test
Alternator Output Test Start the engine and run at full RPM.
Check battery and battery connections. (See BATTERY Figure 50-30-14

on Page 50-20-1.)
Figure 50-30-13
P-10021
P-56620 Place a small screwdriver in the test port (Item 1) [Figure

50-30-14] to provide a ground to the alternator case. This
will give maximum amperage output from the alternator.
Use the induction meter and loop around positive (+) wire
(Item 1) [Figure 50-30-13] at the alternator. NOTE: The Full Field Test should only last long
enough to get ammeter reading to prevent
Start the engine and run at full RPM. damage to the alternator.
The ammeter reading should be between 35 and 40 The ammeter reading should be above 35 amps.
amps.
If the ammeter reading is low, repair or replace the
If the ammeter reading is less than 35 amps do the full alternator.
field test.
WARNING WARNING
AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh
When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust
air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust
fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible
outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.
gases which can kill without warning. W-2050-0807
W-2050-0807

ALTERNATOR (CONT’D)
Alternator Regulator Test
Figure 50-30-15
P-56621
Disconnect the fuel stop solenoid connector (Item 1)

[Figure 50-30-15].
Turn the lights on and crank the engine for 30 seconds to

discharge the battery.
Connect the fuel stop solenoid connector.
Start the engine and run at full RPM.
The ammeter reading should be around 35 amps and

slowly decrease with alternator output.
If ammeter reading is low or does not decrease with time,

replace the alternator’s regulator.
Disconnect the negative (-) cable from the battery.
Reconnect the alternator wires.
Reconnect the negative (-) cable from the battery.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

ALTERNATOR
1. Nut
2. Pulley
3. Spacer
4. Frame Assy.
5. Stud
6. Bearing
7. Plate
8. Screw
9. Screw
10. Rotor Assy. 12
11. Bearing 11
10
12. Cover
13. Frame End
14. Nut
9
15. Insulator 5
16. Nut
17. Bolt 6
18. Rectifier
19. Regulator 4
20. Screw
21. Brush
22. Spring
23. Screw
7
24. Screw
25. Seal 8
3
26. Brush Holder 2
27. Cover
28. Bolt
1 27
28
24
25
26
16
15
14
22 23
13
21
20
19
17 18
C-3456A

Remove the alternator.
Figure 50-30-16
P10051
Assembly: Tighten the pulley nut to 70 - 94 ft.-lb. (94 -

127 N•m) torque [Figure 50-30-18].
P10048 Remove the alternator.
Figure 50-30-19
Wrap a V-belt in the alternator pulley and clamp the
pulley into a vise as shown [Figure 50-30-16].
Do not over tighten the vise.

2
Figure 50-30-17
1
3
1
1
2
P10020
Remove the screws (Item 1), the nut, and insulator (Item
3 2) and the end cover (Item 3) [Figure 50-30-19].
P10050
Use a box end wrench (Item 1) to remove the nut while

the pulley shaft (Item 2) is held firmly with a 6-point
socket (Item 3) [Figure 50-30-17] (10 mm).
NOTE: A six point box end wrench should be used, a

twelve point box end wrench may damage the
corners of the nut.


1
Figure 50-30-20
1
2 1
1
1 2
P10033
Loosen the screws (Item 1) that hold the rectifier lead

P10031 wires. Unwrap and straighten the rectifier lead wires from
the screws, and lift the rectifier (Item 2) [Figure 50-30-
22] from the stator.
Remove the screws (Item 1) and remove the brush
holder (Item 2) [Figure 50-30-20]. Remove the alternator.
Figure 50-30-21 Figure 50-30-23
1
2
1
2
2 1
P10032 P10034
Remove the screws (Item 1) and remove the regulator Remove the bolts (Item 1) and nuts (Item 2) [Figure 50-
(Item 2) [Figure 50-30-21]. 30-23].
NOTE: The lengths of the screws are different, and

must be marked prior to disassembly. If the
wrong screw is used, damage to the alternator
may occur.

ALTERNATOR (CONT’D) With the nut (Item 2) [Figure 50-30-25] on the pulley
shaft, tap the rotor out of the bearing. A press may be
Disassembly And Assembly (Cont’d) needed if the bearing is stuck to the rotor shaft.
Figure 50-30-24 NOTE: Care should be used not to damage the fan,
slip ring, etc.
Figure 50-30-26
P10036
Remove the screws (Item 1) and remove the retainer

plate (Item 2) [Figure 50-30-26].
Remove the alternator.
P10035 Figure 50-30-27
Using a puller (Item 1) [Figure 50-30-24] remove the rear

housing.
Figure 50-30-25 1
2
1
P10039
Support the alternator housing (Item 1) [Figure 50-30-

27] on the blocks, and press the bearing from the
housing.
P10037
Support the alternator housing (Item 1) [Figure 50-30-

25] on blocks.

ALTERNATOR (CONT’D)
Figure 50-30-28
P10040
Assembly: Press a new bearing in the housing [Figure

50-30-28].
Figure 50-30-29
P10042
Remove the bearing (Item 1) from the rotor shaft, using a

puller (Item 2) [Figure 50-30-29].
NOTE: A vise with padded jaws may be used to

secure the rotor assembly. Do not over
tighten the vise.

Rotor Continuity Test
Figure 50-30-30
P10041
Measure the slip ring shaft [Figure 50-30-32].

P10043
Standard measurement is 0.57 in. (14,45 mm) allowable
limit is 0.55 in. (14,0 mm).
Touch the probes to the slip rings [Figure 50-30-30].
Check the slip ring for stained or rough surfaces, use fine
Figure 50-30-31 sandpaper to clean the shaft.
P13179
Check the continuity across the slip rings (Item 1) to the

core of the rotor (Item 2) [Figure 50-30-31] with an
ohmmeter.
If there is continuity, replace the rotor.

Rotor Continuity Test 1
Figure 50-30-33
P1
P2
P3
P4
P10047
Test 3: Touch the positive (+) test probe (Item 1) to the

P13177 ground terminals. Touch the (-) test probe (Item 2)
[Figure 50-30-35] to the P1, P2, P3, and P4 terminals.
There should be a reading.
Check the continuity across each of the four leads of the
stator coil with an ohmmeter [Figure 50-30-33]. Test 4: Reverse the positions of the test probes from test
3, there should be no reading.
If there is no continuity, replace the stator.
Figure 50-30-36
Rectifier Continuity (Diode) Test
Figure 50-30-34
P1
P4
P10044
P2
P3 P10046 Measure the length of the brush protruding from the

brush holder [Figure 50-30-36].
Test 1: Touch the positive (+) test probe (Item 1) to the Standard measurement is 0.41 in (10,5 mm) allowable
positive terminal. Touch the (-) negative test probe (Item limit is 0.18 in (4,5 mm).
2) [Figure 50-30-34] to the P1, P2, P3, and P4 terminals.
There should be no reading.
Test 2: Reverse the positions of the test probes from Test

1, there should be a reading.

STARTER Figure 50-40-3
Disconnect the negative (-) cable from the battery. (See

Removing And Installing The Battery on Page 50-20-2.)
Figure 50-40-1 1
2
1
P-22551
Remove the bottom mounting bolt (Item 1) and ground

cable (Item 2) [Figure 50-40-3].
Figure 50-40-4
P-22549
Cut and remove the cable tie (Item 1) [Figure 50-40-1]

from the starter frame bolt.
Figure 50-40-2 1
P-22552
1 Remove the top mounting bolt (Item 1) [Figure 50-40-4].
Remove the starter.
P-22550
Disconnect the wires (Item 1) [Figure 50-40-2] from the

starter.

STARTER (CONT’D)
1. Screw
2. Bolt
3. Brush Cover
4. Brush Holder 1
5. Bearing
6. Armature
7. Bearing
8. O-Ring
9. Frame 2
10. Bolt 5
11. Cover 6
12. Gasket
4 13. Switch
3
7 14. Nut
8 15. Nut
9 16. Housing
17. Idler Gear
18. Roller
8 19. Retainer
20. Spring
21. Ball
22. Pinion Shaft
11 10
12
13
14
15 20
17 21
15
18 22
19
23 23. Spring
16 24. Clutch
24 25. O-Ring
26. O-Ring
29 27. Washer
28. Bolt
29. Housing
30 30. Spring Seat
32 31
33 25 31. Spring
34 32. Pinion Gear
27 33. Collar
34. Snap Ring
26
28
D-2396

STARTER (CONT’D) Figure 50-40-7
Disassembly
Figure 50-40-5
1
2 2
N-15021
Remove the frame (Item 1) [Figure 50-40-7] from the

N-15019 magnetic switch.
Figure 50-40-8
Remove the cable (Item 1) [Figure 50-40-5] from the
magnetic switch.
Mark the frame and magnetic switch (Item 2) [Figure 50-

40-5] for ease of assembly.
Figure 50-40-6 2
N-15022
1
1
Remove the screws (Item 1) from the brush cover (Item
2) [Figure 50-40-8].
Remove the cover (Item 2) [Figure 50-40-8].

N-15020

Figure 50-40-9
1 1
1
N-15025
3 Remove the bearings (Item 1) [Figure 50-40-11] from

N-15023 both ends of the armature.
Figure 50-40-12
Using a needle nose pliers, pull the brush springs (Item
1) back and remove the brushes (Item 2) [Figure 50-40-
9].
NOTE: The brushes are non-replaceable, If the

brushes are worn, order a new brush holder
(for the negative brushes) and yolk (for the
positive brushes).
1 1
Remove the brush holder (Item 3) [Figure 50-40-9] from
the end of the armature.
Figure 50-40-10
N-15026
1
starter housing.
N-15024
Remove the armature (Item 1) [Figure 50-40-10] from

the frame.

Disassembly (Cont’d) 3
Figure 50-40-13 2
N-15029
1 Remove the idler gear (Item 1), rollers (Item 2) and

N-15027 retainer (Item 3) [Figure 50-40-15].
Figure 50-40-16
Remove the starter housing (Item 1) [Figure 50-40-13]
from the magnetic switch housing.
Figure 50-40-14
2.0”
(50,8 mm)
0.605”
1 (15,4 mm) N-15042
In order to remove the snap ring from the pinion shaft, a

N-15028 tube 0.605 in. (15,4 mm) in diameter by 2.0 in. (50,8 mm)
in length is needed [Figure 50-40-16].
Remove the ball (Item 1) [Figure 50-40-14] from the

pinion shaft.

Figure 50-40-17
N-15047
1 Remove the snap ring (Item 1) [Figure 50-40-19].

N-15045
Figure 50-40-20
Install the tube (Item 1) [Figure 50-40-17] in the over

running clutch.
Figure 50-40-18 2
4
3 1
3
1
N-15053
2 Remove the collar (Item 1), pinion (Item 2), spring (Item
3), and spring seat (Item 4) [Figure 50-40-20].
N-15046
Press down on the starter carrier (Item 1) to extend the

pinion shaft. Press down on the pinion (Item 2) [Figure
50-40-18].
Press the collar (Item 3) [Figure 50-40-18] down to gain

access to the snap ring.

Figure 50-40-21
1 2
N-15035

N-15033 starter housing.
Figure 50-40-24
Remove the pinion shaft (Item 1) and spring (Item 2)
[Figure 50-40-21] from the starter drive.
Figure 50-40-22
1
1
N-15030
Remove the spring (Item 1) [Figure 50-40-24] from the

N-15034 magnetic switch.
Remove the over running clutch (Item 1) [Figure 50-40-

22].

STARTER (CONT’D) Inspection And Repair
Disassembly (Cont’d) Inspect the brush cover for discoloration, indicating the
starter has been overheated.
Figure 50-40-25
Inspect the pinion teeth for wear and damage.
Figure 50-40-27
1
1
N-15031

B-14455
magnetic switch cover.
Figure 50-40-26 Armature Short-Circuit Test: Use a growler tester, put the
armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 50-40-27]. A short-circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.
3 2 1
Figure 50-40-28
N-15032
Remove the cover (Item 1), gasket (Item 2) and switch

(Item 3) [Figure 50-40-26].
N-15036
Armature Winding Ground Test: Use a circuit tester,

touch one probe to a commutator segment and the other
probe to the armature core [Figure 50-40-28]. There
should be no continuity. If there is continuity, the
armature is grounded and must be replaced.

Inspection And Repair (Cont’d)
Figure 50-40-29
1
B-14460
Measure the segment mica depth (Item 1) [Figure 50-40-

N-15037 31].
Service Limit - 0.008 in. (0,2 mm)

Armature Winding Continuity Test: Use a circuit tester,
touch the probes to two commutator segments [Figure If it is worn, replace the armature.
50-40-29]. There must be continuity at any point. If there
is no continuity, the winding is open-circuited, replace the Check the commutator surface for burned spots which
armature. usually indicates an open-circuit, and correct it using
#400 sand paper.
Figure 50-40-30
Check the field windings for wear and damage.
Check all the connections for clean and tight solder

joints.
Figure 50-40-32
B-14458
Commutator Run-Out Test: Check the commutator run-

out as shown in [Figure 50-40-30].
Service Limit - 0.020 in. (0,4 mm)

N-15039
If the commutator exceeds the service limit, repair as

needed. Field Winding Ground Test: Use a circuit tester, touch
one probe to the field winding end of the brush and the
other probe to the surface of the frame [Figure 50-40-
32]. There should be no continuity. If there is continuity,
the field windings are grounded.
Replace the field windings.

Inspection And Repair (Cont’d)
Figure 50-40-33
N-15059
Brush Holder Insulation Test: Use a circuit tester, touch

N-15040 one probe to the positive brush holder plate and the other
probe to the holder plate [Figure 50-40-34]. There
should be no continuity. If there is continuity, replace or
Field Windings Continuity Test: Use a circuit tester, touch repair.
one probe to the wire and the other probe to the brush
[Figure 50-40-33]. There must be continuity. If there is Figure 50-40-35
no continuity, the field windings are open-circuited.
Replace the yoke if the field windings have an open
circuit.
1
Inspect the brushes for wear and damage.
Replace the brush holder or yoke assembly if the

brushes are worn or damaged.
Check brush springs, for damage or rust. Replace as

needed.
N-15043
Inspect the over running clutch (Item 1) [Figure 50-40-

35], it must rotate freely in the direction of the starter
rotation and locked in the opposite rotation.

Assembly
Place the starter drive on the bench, and press down on

the starter drive housing.
1
Figure 50-40-36
1
N-15056
Install the pinion (Item 1) [Figure 50-40-38].
Figure 50-40-39
N-15054
Install the spring seat (Item 1) [Figure 50-40-36] on the

pinion shaft. 1
Figure 50-40-37
N-15057
Install the collar (Item 1) [Figure 50-40-39].
N-15055
Install the spring (Item 1) [Figure 50-40-37].

Assembly (Cont’d)
Figure 50-40-40
1
1
N-15041
Install the rollers (Item 1) [Figure 50-40-42] in the

N-15047 retainer.
Figure 50-40-43
Install the snap ring (Item 1). Pull the collar (Item 2)
[Figure 50-40-40] over the snap ring.
Figure 50-40-41 1
N-15029
1
Install the roller/retainer assembly (Item 1) [Figure 50-
N-15058 40-43] on the starter housing.
Install the idler gear (Item 2) [Figure 50-40-43] over the

With the pinion shaft extended, extend and release the roller/retainer assembly.
pinion (Item 1) [Figure 50-40-41]. The pinion must return
to the fully retracted position.

Assembly (Cont’d)
Figure 50-40-44
1 N-15026
Install the two bolts (Item 1) [Figure 50-40-46]. Tighten

N-15028 the bolts to 60 - 104 in.-lb. (7 - 12 N•m) torque.
Figure 50-40-47
Install the ball (Item 1) [Figure 50-40-44] in the pinion
shaft.
Figure 50-40-45
1 2
N-15025
1
Install the bearings (Items 1 & 2) [Figure 50-40-47] on
N-15027 the armature.
Install the starter drive (Item 1) [Figure 50-40-45] on the

magnetic switch.

Assembly (Cont’d)
Figure 50-40-48
1
2
N-15049
Install the frame (Item 1) [Figure 50-40-50] over the

N-15048 armature.
NOTE: Make sure the tab (Item 2) [Figure 50-40-50] on

Install the armature (Item 1) [Figure 50-40-48] in the the frame is aligned with the slot in the
magnetic switch housing. magnetic switch housing.
Figure 50-40-49 Figure 50-40-51
1 3
N-15050 N-15051A
Install the new O-rings (Item 1) [Figure 50-40-49] on Install the brush holder (Item 1) [Figure 50-40-51] on the
both ends of the frame. armature.
Using a needle nose pliers, pull the spring (Item 2) back

and install the brushes (Item 3) [Figure 50-40-51].

Assembly (Cont’d)
Figure 50-40-52
1 N-15019
Install the cable (Item 1) [Figure 50-40-54] on the

N-15052 terminal. Tighten the terminal nut to 4 - 7 ft.-lb. (5 - 9
N•m) torque.
Install the brush cover and screws (Item 1) [Figure 50-

40-52].
Figure 50-40-53
1
1
N-15020
Install the bolts (Item 1) [Figure 50-40-53]. Tighten the

bolts to 60 - 104 in.-lb. (7 - 12 N•m) torque.

LIGHTS Figure 50-50-3
Figure 50-50-1
1
1
P-22943
Remove the light bulb assembly (Item 1) [Figure 50-50-

P-55652 3] from the lens.
To remove the upperstructure light, pivot the light (Item 1)

[Figure 50-50-1] back inside the frame.
Figure 50-50-2
P-55653

LIGHTS (CONT’D) Boom Light Bulb Replacement
Boom Light Removal And Installation Figure 50-50-6
Figure 50-50-4
3
2
1 1
P-73785
P-73785
Disconnect the wire harness (Item 1) [Figure 50-50-4]. Rotate light bulb assembly (Item 2) counterclockwise and
pull straight out from the boom light (Item 3) [Figure 50-
Figure 50-50-5 50-6].
Figure 50-50-7
2
3
4
P-73787
P-73788
Remove the nut (Item 1) and bolt (Item 2). Remove the
boom light (Item 3) from the boom light guard (Item 4)
[Figure 50-50-5]. NOTE: Do not touch glass of halogen bulb with your
fingers or allow bulb to come in contact with
oils. If contaminated, the bulb should be
cleaned with mild alcohol and clean cloth
[Figure 50-50-7].

TWO SPEED SWITCH
Figure 50-60-1
P-24649
The two-speed switch (Item 1) [Figure 50-60-1] is

located in the blade handle.
Figure 50-60-2
P-24241
Remove the blade control lever from the excavator

[Figure 50-60-2]. (See Lever Removal And Installation
on Page 40-80-1.)
NOTE: If the two-speed switch needs to be replaced,

the complete blade control lever must be
replaced.

FUEL LEVEL SENDER Testing
Removal And Installation Use an ohmmeter to check the resistance of the fuel
sender.
Remove the negative battery cable. (See Removing And
Installing The Battery on Page 50-20-2.) Figure 50-70-3
Remove the floor mat and floor plate. (Removal And

110-1 or Removal And Installation (Cab Equipped
Figure 50-70-1
1
1
P11765
Insert one of the ohm tester leads into each of the fuel
sender electrical connectors (Item 1) [Figure 50-70-3] in
the end of the fuel sender.
P-50550 Figure 50-70-4
Disconnect the harness connector (Item 1) [Figure 50-

70-1] from the fuel sender.
Figure 50-70-2
P11766
1 With the fuel sender in the position shown [Figure 50-70-

4], read the ohms in the empty position. Slide the float
upwards and the ohm reading will decrease. See
P-50551 resistance chart below.
The resistance should read as follows:

Remove the fuel sender (Item 1) [Figure 50-70-2]. The
sender threads into the tank, use a wrench to remove the FULL: 15-35 Ohms.
sender. HALF: 82-97 Ohms.
EMPTY: 230-250 Ohms.

FUEL LEVEL SENDER (CONT’D)
Testing (Cont’d)
Figure 50-70-5
P11767
Inspect the O-ring (Item 1) [Figure 50-70-5] and replace

as needed

DIAGNOSTICS SERVICE CODE
Number Codes List
CODE CODE
02-16 Hydraulic charge filter not connected 20-02 Two speed output error ON
02-17 Hydraulic charge filter plugged 20-03 Two speed output error OFF
03-09 Battery voltage low 21-02 Glow plug output error ON

03-10 Battery voltage high 21-03 Glow plug output error OFF
03-11 Battery voltage extremely high
03-14 Battery voltage extremely low 22-02 Starter relay output error ON
03-22 Battery voltage out of range low 22-03 Starter relay output error OFF
04-14 Oil pressure extremely low 26-02 Front base output error ON
04-15 Oil pressure shutdown level 26-03 Front base output error OFF
05-09 Hydraulic charge pressure low 27-02 Front rod output error ON
05-14 Hydraulic charge pressure extremely low 27-03 Front rod output error OFF
05-15 Hydraulic charge pressure shutdown level
05-21 Hydraulic charge pressure out of range high 28-02 Diverter output error ON
05-22 Hydraulic charge pressure out of range low 28-03 Diverter output error OFF
06-10 Engine speed high 30-28 Watch dog failure

06-11 Engine speed extremely high
06-15 Engine speed shutdown level 31-28 Recovery mode failure
06-18 Engine speed out of range high
33-23 Controller not calibrated
07-10 Hydraulic oil temperature high
07-11 Hydraulic oil temperature extremely high
07-15 Hydraulic oil temperature shutdown level 60-21 Sec. aux. thumbswitch out of range high
07-21 Hydraulic oil temperature out of range high 60-22 Sec. aux. thumbswitch out of range low
07-22 Hydraulic oil temperature out of range low 60-23 Sec. aux. thumbswitch not calibrated
08-10 Engine coolant temperature high 62-04 Load moment monitoring in error
08-11 Engine coolant temperature extremely high
08-15 Engine coolant temperature shutdown level 63-05 Work group/travel console sensor
08-21 Engine coolant temperature out of range high 63-06 Work group/travel console sensor
08-22 Engine coolant temperature out of range low
64-05 Switched power/acc. relay short to battery
09-09 Fuel level low 64-06 Switched power/acc. relay short to ground
09-21 Fuel level out of range high 64-07 Switched power/acc. relay open circuit
09-22 Fuel level out of range low
65-02 Work group/travel lockout solenoid error ON
12-21 Primary auxiliary PWM switch out of range high 65-03 Work group/travel lockout solenoid error OFF
12-22 Primary auxiliary PWM switch out of range low 65-05 Work group/travel lockout solenoid short to battery
12-23 Primary auxiliary PWM switch not calibrated 65-06 Work group/travel lockout solenoid short to ground
65-07 Work group/travel lockout solenoid open circuit
13-05 Fuel shut-off hold solenoid short to battery
13-06 Fuel shut-off hold solenoid short to ground 66-05 Travel solenoid short to battery
66-06 Travel solenoid short to ground
14-02 Fuel shut-off hold solenoid short to batter
14-03 Fuel shut-off hold solenoid short to ground

DELUXE INSTRUMENT PANEL SETUP Figure 50-90-1
Passwords
1
2
All new machines with Deluxe Instrumentation arrive at
Bobcat Dealerships with the panel in locked mode. This
means that a password must be used to start the engine.
For security purposes, your dealer may change the

password and also set it in the locked mode. Your 3
dealer will provide you with the password.
Master Password:
A permanent, randomly selected password is set at
the factory which cannot be changed. This password
is used for service by the Bobcat dealer if the Owner B-15819
Password is not known; or to change the Owner
Password.
Changing The Owner or Operator Password
Owner Password:
There is only one Owner Password (CodE 0). It must Perform Password Entry at left, but do not start the
be used to change the owner or operator passwords. engine.
(See Password Entry (For Starting And Operating
The Machine) on Page 50-90-1.) Press and hold the ENTER CODE button (Item 1) for
three seconds. CodE 1 will appear on the LCD (Item 2)
Operator Password: [Figure 50-90-1].
There can be up to three operator Passwords (CodE
1, CodE 2, CodE 3). See below for changing the Press the ENTER CODE button until the desired Code
Operator Password. (CodE 0, CodE 1, CodE 2, CodE 3) appears. CodE 0 is
Owner Password. The other codes are Operator
Password Entry (For Starting And Operating The passwords. You now have 40 seconds to use the keypad
Machine) (Item 3) [Figure 50-90-1] to enter each digit of a new four
digit password.
Press ENTER CODE button (Item 1). The panel will
become lighted and there will be two short beeps. CodE Enter the new four digit password. After the fourth digit is
will appear on the LCD (Item 2) [Figure 50-90-1]. entered, there will be two short beeps and rPEAt will
appear.
NOTE: After you press ENTER CODE you have 40
seconds to use the keypad (Item 3) [Figure 50- Re-enter the new four digit password to verify. If the new
90-1] to enter the password. (If more than 40 passwords match, there will be two short beeps, Code
seconds is used, the process will abort and will appear for one second and then the LCD will return to
you will need to start over. HOURMETER function.
Enter the password. For each digit that you enter, a dash NOTE: If the new passwords do not match, there will
will appear on the LCD. If the password was entered be one long beep and Error will appear for one
correctly, there will be one long beep. second and then the LCD will return to
HOURMETER function.
NOTE: If the password was incorrect there will be
three short beeps and Error will appear on the
LCD. Press the ENTER CODE button again
and start over. After three failed attempts, you
must wait three minutes to try again.
You are now ready to start and operate the machine.
If you will be changing passwords, do not start the

engine. (See Changing The Owner or Operator
Password on Page 50-90-1.)

DELUXE INSTRUMENT PANEL SETUP (CONT’D) Job Clock
Password Lockout Feature The JOB CLOCK can be set to record accumulated
hours for a particular job.
This allows the operator to Unlock the password feature
so that a password does not need to be used every time Press and release the HOURS/JOB/RPM button (Item 4)
you start the engine. until JOB light is ON at the top, center of the LCD (Item 5)
[Figure 50-90-2].
Perform Password Entry (See Password Entry (For
Starting And Operating The Machine) on Page 50-90-1.) While the JOB light is ON, press and hold the HOURS/
The Password Entry can be performed with the engine JOB/RPM button (Item 4) [Figure 50-90-2] until the LCD
off or with the engine running. returns to zero.
Figure 50-90-2 This process will clear the accumulated hours and will
begin recording JOB CLOCK time again. (This does not
4 5 affect the HOURMETER which continues to record the
2 total operating hours of the excavator.)
Pressing the HOURS/JOB/RPM button again or pressing

the START button will return the LCD to HOURMETER
function.
RPM
The LCD (Item 5) [Figure 50-90-2] can be set to display

engine RPM.
1
3 With the engine running, press and release the HOURS/
B-15819 JOB/RPM button (Item 4) until RPM light is ON at the top,
center of the LCD (Item 5) [Figure 50-90-2].
Press the Lock/Unlock button (Item 1) [Figure 50-90-2]. Engine RPM is now displayed in the LCD.
The LCD will continuously alternate from UnLoc to CodE
for 1 second periods. Press the HOURS/JOB/RPM button (Item 4) [Figure 50-
90-2] again the return to HOURMETER function.
Perform Password Entry again.
UnLoc will appear in the LCD (Item 5), the Unlocked Icon
(Item 2) will appear in the Icon Display Area (Item 3)
[Figure 50-90-2] and there will be two short beeps.
To start an Unlocked system, press the ENTER CODE

button and press the START button.
When you stop the engine with the system unlocked, you
will hear one long beep every three seconds for 15
seconds.
To lock the system again, press the Lock/Unlock button

(Item 1) [Figure 50-90-2] and enter the password during
the 15 second period.

ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
ENGINE COMPONENTS AND TESTING. . . . . . . . . . . . . . . . 60-50-1

Checking The Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Engine Compression Checking . . . . . . . . . . . . . . . . . . . . . 60-50-1
Fuel Injection Pump Check . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Fuel Injection Pump Removal And Installation . . . . . . . . . 60-50-7
Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Fuel Injector Nozzle Check . . . . . . . . . . . . . . . . . . . . . . . 60-50-14
Fuel Injector Nozzles Removal And Installation. . . . . . . . 60-50-12
Fuel Shut-Off Solenoid Removal And Installation . . . . . . . 60-50-4
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . 60-50-2
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . 60-50-15
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-15
ENGINE FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1 ENGINE

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . 60-70-1 SERVICE
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-4
Hydraulic Pump Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-3
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1

ENGINE SERVICE (CONT’D)
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Camshaft Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-14
Checking Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-19
Crankshaft And Bearings Removal And Installation . . . . . . . . 60-80-25
Crankshaft And Bearings, Servicing . . . . . . . . . . . . . . . . . . . . 60-80-27
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . 60-80-17
Cylinder Bore, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-31
Cylinder Head Disassembly And Assembly. . . . . . . . . . . . . . . . 60-80-4
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . 60-80-1
Cylinder Head Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-5
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-5
Fuel Camshaft Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-17
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . . 60-80-16
Idler Gear And Camshaft Removal And Installation. . . . . . . . . 60-80-13
Idler Gear And Shaft Servicing . . . . . . . . . . . . . . . . . . . . . . . . 60-80-15
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-80-18
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-18
Piston And Connecting Rod Removal And Installation . . . . . . 60-80-20
Piston And Connecting Rod Servicing . . . . . . . . . . . . . . . . . . . 60-80-22
Reconditioning The Valve And Valve Seat. . . . . . . . . . . . . . . . . 60-80-8
Rocker Arm And Shaft Checking . . . . . . . . . . . . . . . . . . . . . . . 60-80-10
Timing Gearcase Cover Removal And Installation . . . . . . . . . 60-80-10
Timing Gears Checking Backlash . . . . . . . . . . . . . . . . . . . . . . 60-80-16
Valve Guide Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-6
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-9
Valve Tappets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-20
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . 60-80-31
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . 60-80-32
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

SPECIFIED.

MAY VARY.

TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.
PROBLEM CAUSE
Slow cranking speed 1, 2, 3, 4
Engine will not start 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine 8, 9, 10, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28, 29
Engine is mis-firing 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53
Vibration 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure 4, 33, 36
Overheating 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure 22, 27, 29, 30, 40, 49
Poor compression 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop 9, 10, 11
KEY TO CORRECT THE CAUSE

1. Battery capacity low 28. Worn valves and seat
2. Bad electrical connections 29. Broken or worn piston rings
3. Faulty starter motor 30. Worn valve stems or guides
4. Incorrect grade of oil 31. Worn or damaged bearings
5. Low cranking speed 32. Not enough oil in the oil pan
6. Fuel tank empty 33. Switch is defective
7. Faulty stop control operation 34. Oil pump worn
8. Plugged fuel line 35. Relief valve is stuck open
9. Plugged fuel filter 36. Relief valve is stuck closed
10. Restriction in the air cleaner 37. Broken relief valve spring
11. Air in the fuel system 38. Faulty suction pipe
12. Faulty fuel injection pump 39. Plugged oil filter
13. Faulty fuel injectors 40. Piston seizure
14. Broken injection pump drive 41. Incorrect piston height
15. Incorrect injection pump timing 42. Faulty engine mounting
16. Incorrect valve timing 43. Incorrect alignment of flywheel
17. Poor compression 44. Faulty thermostat
18. Plugged fuel tank vent 45. Restriction in water jacket
19. Incorrect grade of fuel 46. Loose alternator belt
20. Exhaust pipe restriction 47. Plugged radiator
21. Cylinder head gasket leaking 48. Plugged breather pipe
22. Over heating 49. Plugged breather pipe
23. Cold running 50. Damaged valve stem oil deflectors
24. Incorrect tappet adjustment 51. Coolant level too low
25. Sticking valves 52. Plugged oil pump pipe strainer
26. Incorrect high pressure fuel lines 53. Broken valve spring
27. Worn cylinder bores

MUFFLER Figure 60-20-3
Remove the air cleaner. (See Removal And Installation

on Page 60-30-1.)
1
Open the tail gate.
Figure 60-20-1
P-56283
Remove the top bolt (Item 1) [Figure 60-20-3].
Remove the muffler.

1
Figure 60-20-4
P-56281
Figure 60-20-2 1
P-22561
1 Remove the gasket (Item 1) [Figure 60-20-4] from the

exhaust manifold.
P-56282

AIR CLEANER Figure 60-30-2
Open the tailgate. 1
Figure 60-30-1
2 3
1 P-22557
Remove the two bolts (Item 1) [Figure 60-30-2] from the

air cleaner mount.
P-22556 Remove the air cleaner.
Loosen the hose clamp (Item 1) [Figure 60-30-1] on the

air intake hoses.
Remove the hose (Item 2) [Figure 60-30-1] from the air

cleaner.

intake manifold.
NOTE: Plug the intake manifold hole to prevent any

contamination from getting into the engine.

RADIATOR Figure 60-40-3
Remove the hydraulic oil cooler. (See Removal And

Drain the radiator. (See Replacing The Coolant on Page

10-70-3.)
WARNING
1
AVOID BURNS
P-56632
Do not remove radiator cap when the engine is hot.
W-2070-1203
Remove the bottom bolts and nuts (Item 1) [Figure 60-
40-3].
Figure 60-40-1
Figure 60-40-4
P-56630
P-22736

Figure 60-40-2
Remove the radiator, mount and shroud assembly from
the excavator.
P-56631
325/328 Excavator
RADIATOR (CONT’D) Figure 60-40-7
Removal And Installation (Cont’d) 2
Figure 60-40-5 1
1
1
1
P-22740
2
P-22738
Remove the radiator from the mount (Item 2) [Figure 60-
40-7].
Remove the bolts, washers and spacers (Item 1) from the
coolant recovery tank (Item 2) [Figure 60-40-5]. Remove
the tank.
Figure 60-40-6
P-22739
Remove the three bolts and nuts (Item 1). Remove the
fan shroud (Item 2) [Figure 60-40-6].
325/328 Excavator
ENGINE COMPONENTS AND TESTING
Engine Compression Checking
The tools listed will be needed to do the following

procedure:
MEL10630 - Engine Compression Kit

MEL 1352 - Compression Adapter
The engine must be at operating temperature.
Remove the glow plugs. (See Glow Plugs Removal And

Figure 60-50-1
P-52702
Install the correct compression adapter into the cylinder

head [Figure 60-50-1].
Connect the compression gauge [Figure 60-50-1].
Make sure the speed control lever is at low engine idle.
Disconnect the fuel stop solenoid.
Crank the engine with the starter at 200-300 RPM.
Compression Pressure 470 - 540 PSI

(32 - 37 Bar)
Allowable Limit 370 PSI
(minimum) (26 Bar)
The compression must be no lower than the allowable

limit, with no more than 10% variance among cylinders.
Connect the fuel stop solenoid.

ENGINE COMPONENTS AND TESTING (CONT’D) Figure 60-50-4
Glow Plugs Removal And Installation
Disconnect the negative (-) cable from the battery. 1 1
Figure 60-50-2
P-52700
Remove the three glow plugs (Item 1) [Figure 60-50-4].
Installation: Tighten the glow plugs to 15 - 18 ft.-lb. (20 -

P-52698 24 N•m) torque.
Remove the nut and wire harness (Item 1) [Figure 60-

50-2].
Figure 60-50-3
1
1
P-52699
Remove the nut (Item 1) [Figure 60-50-3] from the three

remaining glow plugs.
Remove the connecting strap (Item 2) [Figure 60-50-3]

from the glow plugs.

ENGINE COMPONENTS AND TESTING (CONT’D)
Checking The Glow Plug
Disconnect the glow plug wire harness and connecting

strap.
Figure 60-50-5
P-56440
Use an ohmmeter to check the glow plugs [Figure 60-50-

5].
Touch one probe to the end of the glow plug and the
other probe to the body of the glow plug.
The reading should be approximately 1.0 ohms. If the

resistance is infinite, the coil of the glow plug is broken. If
the resistance is 0 the glow plug is short circuited.
Repeat the procedure for each glow plug.

Fuel Shut-Off Solenoid Removal And Installation
Disconnect the glow plug wire harness and connecting

strap.
1
Figure 60-50-6
P-56424
2

1
Figure 60-50-9
P-56295
Remove the bolts (Item 1) and guard (Item 2) [Figure 60-

50-6].
Figure 60-50-7
P-56425
Remove the tie strap (Item 1) [Figure 60-50-9].
P-56423

Fuel Shut-Off Solenoid Removal And Installation

(Cont’d)
Figure 60-50-10
1
1
P-56426
Remove the nuts (Item 1) and wire harness (Item 2)

[Figure 60-50-10].
NOTE: The alternator is shown removed for photo

clarity.
Figure 60-50-11
2 2
1
B-23134
Installation: The guide (Item 1) on the fuel shut-off

solenoid must contact the boost lever (Item 2) [Figure
60-50-11].

ENGINE COMPONENTS AND TESTING (CONT’D) Move the speed control lever to the high engine idle
position.
Fuel Injection Pump Check
Turn the flywheel to increase the pressure. If the
The injection pump contains parts which have a very pressure can not reach the allowable limit, replace the
close tolerance and its operation has a direct effect on injection pump assembly.
the performance of the engine.
Fuel Tightness of Pump 1991 PSI
Element Allowable Limit (137,3 Bar)
WARNING With the speed control lever at the low engine idle
position, turn the flywheel until the pressure is at 1991
PSI (187 - 201 Bar).
Diesel fuel or hydraulic fluid under pressure can Turn the flywheel back approximately one-half turn. Keep
penetrate skin or eyes, causing serious injury or the flywheel at this position, and measure the time it
death. Fluid leaks under pressure may not be visible. takes the pressure to decrease from 1991-1849 PSI
Use a piece of cardboard or wood to find leaks. Do (137.3 - 127.5 Bar).
enters skin or eyes, get immediate medical attention Fuel Tightness of Delivery 5 Seconds
from a physician familiar with this injury. Valve Allowable Limit
W-2072-0807
The tools listed will be needed to do the following

procedure:
MEL 1237 - Adapter Fuel Line

MEL 1173-1 Pressure Gauge
To check the discharge pressure at the fuel injection

pump, use the following procedure:
Disconnect a high pressure fuel line from the injection

pump. Loosen the other end of the same fuel line so it
can be turned away from the fitting.
Figure 60-50-12
B-8235
Connect the adapter fuel line (Item 1) to the fitting and

connect the pressure gauge (Item 2) [Figure 60-50-12].

Fuel Injection Pump Removal And Installation
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them. 1
I-2029-0289
P-56428
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment. Figure 60-50-15
I-2028-0289
Disconnect the negative (-) cable from the battery.

2
Page 50-30-3.)
Remove the alternator mount. (See Bracket Removal

Clean around the injection pump.

1
Figure 60-50-13
P-56429
2
Remove the tie straps (Item 1) and loosen the clamps
(Item 2) [Figure 60-50-15].
P-56427
Loosen the clamp (Item 1). Remove the hose (Item 2)

[Figure 60-50-13].


(Cont’d) 2
Figure 60-50-16
1 1
1
2
P-56432
Remove the bolts (Item 1) and remove the intake

1 manifold (Item 2) [Figure 60-50-18].
P-56430
Figure 60-50-19
Remove the fuel lines (Item 1) [Figure 60-50-16].
Disconnect the high pressure fuel lines (Item 2) [Figure

60-50-16] from the fuel injectors and fuel injection pump.
Remove the fuel shut-off solenoid. (See Fuel Shut-Off

Solenoid Removal And Installation on Page 60-50-4.)
1 2
Figure 60-50-17
2 1
P-56433
Remove the nuts (Item 1) and bolts (Item 2) [Figure 60-

50-19].
Remove the injection pump.

1
P-56431
Remove the high idle body (Item 1) [Figure 60-50-17].
Installation: Tighten the high idle body to 33 - 36 ft.-lb.

(44 - 49 N•m) torque.


(Cont’d)
Figure 60-50-20
B-14423
Installation: When the injection pump is installed, the

rack pin (Item 1) [Figure 60-50-20] must be aligned with
the slot in the engine block and positioned on the left side
of the fork lever.
If the rack pin is not installed correctly engine damage

can result.
NOTE: Make sure the same number of shims with the

same thickness are installed under the
injection pump. The shims are used for
engine timing.

Fuel Injection Pump Timing
Timing the injection pump is done by changing the

number of shims between the injection pump and engine
block.
Figure 60-50-21
P-56435
2
Continue to turn the engine slowly (for approximately one
and three-quarter turn after fuel stops flowing from the
injection pump nozzle), until the timing mark on the side
of the flywheel is at the bottom edge of the timing hole
(Item 1) [Figure 60-50-22] in the flywheel housing.
P-56634
Slowly turn the engine counterclockwise: as soon as fuel
starts to flow at the top of the injection pump nozzle, stop
Turn the fuel supply lever to the ON position. Install a turning the engine.
short plastic tube (Item 1) [Figure 60-50-21] in the fitting
of the number one cylinder port. Point the tube up
(vertical).
Turn the engine counter clockwise until fuel flows out of

the injection pumps number one cylinder nozzle. (Install
a tool on the crankshaft at the front of the engine to turn
the engine.)
NOTE: The fuel must flow out of the nozzle for one
firing cycle before timing can be attempted.
Pull the stop lever (Item 2) [Figure 60-50-21] 0.232 -

0.302 in. (5.9 - 7.7 mm) from the free position toward the
stop position.

Fuel Injection Pump Timing (Cont’d)
Figure 60-50-23
2 3 4
B-23192
The correct engine timing is 15.5 - 17.0 B.T.D.C. Add or

subtract shims (Item 1) [Figure 60-50-23] to time the
engine to 15.5 - 17.0 B.T.D.C. The engine is correctly
timed when the correct mark on the flywheel is aligned
with the notch in the timing hole.
NOTE: Shims (Item 1) are available in three

thicknesses, shims with the two holes (Item 2)
are 0.20 mm thick, shims with one hole (Item
3) are 0.25 mm thick, and shims with no holes
(Item 4) [Figure 60-50-23] are 0.30 thick.
NOTE: Increasing the thickness of the shim pack by

0.050 mm retards the injection timing by
0.500°. Decreasing the shim pack by 0.050 mm
advances the timing by 0.500°.

Fuel Injector Nozzles Removal And Installation
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them. 1
I-2029-0289
Open the tailgate.
P-56442
Figure 60-50-24
Figure 60-50-27
2
3
P-52698 1
Remove the fuel line (Item 1) [Figure 60-50-24].
P-56443
Remove the nut (Item 2) and wire harness (Item 3)
[Figure 60-50-24].
Disconnect the high pressure fuel lines (Item 1) [Figure
Figure 60-50-25 60-50-27] from the fuel injectors.
Disconnect the fuel lines from the fuel injection pump.
Remove the high pressure fuel lines.
P-56441

Fuel Injector Nozzles Removal And Installation

(Cont’d)
Figure 60-50-28
2 B-5971
1
1
Remove the fuel injector nozzle from the engine [Figure
60-50-30].
P-56444
Remove the nuts (Item 1) from the three injectors.

Figure 60-50-29
1
1
B-5970
Loosen the fuel injector with a special socket (MEL-1485)

[Figure 60-50-29].
Installation: Tighten the injectors to 37 - 50 ft.-lb. (49 - 68

N•m) torque.

Fuel Injector Nozzle Check

2
WARNING 4
5
AVOID INJURY OR DEATH 1
Diesel fuel or hydraulic fluid under pressure can 6
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do 7
enters skin or eyes, get immediate medical attention P-62152
W-2072-0807
1.Nozzle Holder
The tool listed will be needed to do the following 2.Adjusting Spacer.
procedure:
3.Nozzle Spring
MEL 10018 - Injector Nozzle Tester
4.Push Rod
Figure 60-50-31
5.Distance Piece
6.Nozzle Piece
7.Nozzle Retaining Nut
Tighten the Nozzle Holder (Item 1) [Figure 60-50-32] to

26 - 28 ft.-lb. (35 - 39 N•m) torque.
Tighten the Overflow pipe nut to 15 - 18 ft.-lb. (20 - 24

N•m) torque.
Tighten the Nozzle Holder Assembly to 37 - 50 ft.-lb.

(49,0 - 68 N•m) torque.
A-2513
NOTE: You can adjust the release pressure of the

Connect the nozzle to the tester with the nozzle down injector nozzle by adding or removing
[Figure 60-50-31]. spacers (Item 2) from the top of the nozzle
spring (Item 3) [Figure 60-50-32]. Spacers are
Operate the hand lever at a slow rate and record the available in different thicknesses.
opening pressure. If the pressure is not correct, replace
the fuel injection nozzle.
Fuel Injection Pressure 1991 - 2134 PSI

(137 - 147 Bar)

ENGINE COMPONENTS AND TESTING (CONT’D) Valve Clearance Adjustment
Fuel Injector Nozzle Check Adjust the valve clearance with the engine stopped and
cold.
Figure 60-50-33
Figure 60-50-35
CORRECT WRONG
0.007-0.009 in.
(0,18-0,22 mm)
A-2621
MC-1368
Check that the spray pattern is correct [Figure 60-50-

33]. The correct valve clearance is 0.007 - 0.0087 in. (0,18 -
0,22 mm) [Figure 60-50-35].
1. Fuel does not come out the side of the nozzle.
Make sure the piston is at T.D.C. when making the
2. Drops of fuel are not present at the nozzle. adjustment for the valves of the particular cylinder.
3. The injector has an even flow coming from the nozzle. Figure 60-50-36
Valve Seat Tightness
Figure 60-50-34
B-11621
Put the correct size feeler gauge between the rocker arm
A-2513 and valve stem. Turn the adjustment bolt until the
clearance is correct [Figure 60-50-36].
Connect the injector nozzle to the tester with the nozzle

in the down position [Figure 60-50-34].
Check for inside leakage. Operate the hand lever until

the pressure reaches 1849 PSI (127 bar). Make a record
of the pressure. Release the hand lever. Check the
pressure decrease in 10 seconds. If any leak is found,
replace the nozzle.

ENGINE Figure 60-60-2
Disconnect the negative ( - ) cable on the battery. (See

Removing And Installing The Battery on Page 50-20-2.)

Drain the radiator. (See Replacing The Coolant on Page

10-70-3.)
3 2 1
Remove the muffler. (See Removal And Installation on
Page 60-20-1.)
P-56296
on Page 60-30-1.)
Remove the nut (Item 1) [Figure 60-60-2].
Remove the starter. (See Removal And Installation on
Page 50-40-1.) Loosen the nut (Item 2) and remove the engine speed
control cable (Item 3) [Figure 60-60-2].
Remove the hydraulic pump. (See Removal And
Installation on Page 20-50-8.) Remove the cable from the mount.
2
1
2 1
P-56295 P-56297
Remove the nuts (Item 1) and guard (Item 2) [Figure 60- Disconnect the fuel shut off solenoid (Item 1) and oil
60-1]. pressure sending unit (Item 2) [Figure 60-60-3]
connectors.

ENGINE (CONT’D) Figure 60-60-6
Figure 60-60-4
1
2
1 P-56300
Remove the ground cable (Item 1) and oil drain hose

P-56298 (Item 2) [Figure 60-60-6].

Cut and remove the tie straps (Item 1) [Figure 60-60-4]. from the engine speed sensor.
Figure 60-60-5
P-56299


1
Figure 60-60-7
1
1
2
P-56303
Remove the wires (Item 1) [Figure 60-60-9] from the

P-56301 alternator.
Remove the wire (Item 1) [Figure 60-60-7] from the glow

plug.
Figure 60-60-8
P-56302
Remove the bolt (Item 1) and ground cables (Item 2)

[Figure 60-60-8].

Figure 60-60-10
P-56306
Mark and remove the fuel lines (Item 1) [Figure 60-60-

P-56304 12].
Plug the fuel lines.

Remove the wire harness (Item 1) [Figure 60-60-10]
from the temperature sensor. Figure 60-60-13
Figure 60-60-11
P-56309
P-56305
Loosen the hose clamp (Item 1) and remove the top
radiator hose (Item 2) [Figure 60-60-13].
Remove the bolt (Item 1) [Figure 60-60-11] from the wire
harness clamp.

Figure 60-60-14
2
1
1 P-56308
Figure 60-60-17
P-56307
Loosen the clamp (Item 1) and remove the lower radiator

hose (Item 2) [Figure 60-60-14] from the radiator.
Figure 60-60-15
1
1
1
P-56310
Remove the four engine mount bolts and nuts (Item 1)

[Figure 60-60-16] & [Figure 60-60-17].
P-56393
Remove the heater hose (Item 1) [Figure 60-60-15] (if

equipped.)

Figure 60-60-18
P-55911
1
Attach a hoist to the chain, slightly raise and support the
P-55909 engine. and rotate the pump end of the engine toward the
back of the excavator [Figure 60-60-20].
Attach a lifting bracket (Item 1) [Figure 60-60-18] and Relocate all wires and hoses away from the engine.
chain to the pump end of the engine.
Raise the hoist and remove the engine.
Figure 60-60-19
P-55910
Attach a chain (Item 1) [Figure 60-60-19] to the lifting

bracket on the front of the engine.

ENGINE FLYWHEEL Figure 60-70-2
Flywheel Removal And Installation
Open the tailgate.

on Page 60-30-1.)

Remove the muffler. (See Removal And Installation on

Page 60-20-1.)
1
Remove the hydraulic pump. (See Removal And P-56290
Remove the starter. (See Removal And Installation on Slightly raise the flywheel end of the engine, and place a
Page 50-40-1.) support (Item 1) [Figure 60-70-2] under the oil pan.
1
1
1
P-56289 P-56291
Remove the bolts (Item 1) [Figure 60-70-1] from the Remove the bolts (Item 1) [Figure 60-70-3].
engine mount.

ENGINE FLYWHEEL (CONT’D) Figure 60-70-6
Flywheel Removal And Installation (Cont’d)
Figure 60-70-4 2 1
1
1
1
1 P-59314
Remove the three bolts (Item 1) from the hydraulic pump

P-56292 coupler (Item 2) [Figure 60-70-6].
Installation: Apply Loctite® 242. to bolts and tighten the

Remove the two flywheel housing bolts (Item 1) [Figure bolts to 27 - 32 ft.-lb. (37 - 43 N•m) torque.
60-70-4] from the front side of the engine.
Remove the coupler.
Installation: Position the housing over the alignment
pins and tighten the bolts to 30 - 37 ft.-lb. (40 - 50 N•m)
torque.
Figure 60-70-5
P-56293
Remove the flywheel housing (Item 1) [Figure 60-70-5]

from the engine.

ENGINE FLYWHEEL (CONT’D) Hydraulic Pump Coupler
Flywheel Removal And Installation (Cont’d) Figure 60-70-9
Figure 60-70-7
1 2
P-59314
P-59312
Remove the three bolts (Item 1) from the hydraulic pump
coupler (Item 2) [Figure 60-70-9].
Each hydraulic pump coupler bolt has a spacer (Item 1)
[Figure 60-70-7] between the coupler and flywheel. Installation: Apply Loctite® 242 to bolts and tighten the
bolts to 27 - 32 ft.-lb. (37 - 43 N•m) torque.
Figure 60-70-8
Remove the hydraulic pump coupler.
Figure 60-70-10
1
1
1
1
P-59313
Remove the five bolts (Item 1) [Figure 60-70-8] from the

P-59312
flywheel.
Installation: Tighten the bolts to 40 - 43 ft.-lb. (54 - 59 Each hydraulic pump coupler bolt has a spacer [Figure
N•m) torque. 60-70-10] between coupler and flywheel.
Remove the flywheel.

ENGINE FLYWHEEL (CONT’D)
Flywheel Ring Gear
WARNING
W-2019-0907
The ring gear on the flywheel is an interference fit. Heat

the ring gear enough to expand it and hit it with a
hammer evenly to remove it.
Clean the outer surface of the flywheel to give a smooth

fit.
Clean the new ring gear and heat it to a temperature of

450 - 500° F (232 - 260° C).
Fit the ring gear over the flywheel. Make sure the gear is
seated correctly.

RECONDITIONING THE ENGINE Figure 60-80-3
Cylinder Head Removal And Installation
Figure 60-80-1
2 4 1
2
3
P-47243
Remove the glow plugs (Item 1) and fuel injector holder

P-47241 assemblies (Item 2) [Figure 60-80-3].
Installation: Tighten the glow plugs to 15 - 18 ft.-lb. (20 -

Remove the glow plug lead (Item 1), breather hose (Item 24 N•m) torque.
2), and valve cover bolts (Item 3) [Figure 60-80-1].
Tighten the injector holders to 26 - 28 ft.-lb. (35 - 39 N•m)
Remove the valve cover (Item 4) [Figure 60-80-1] and torque.
gasket.
Figure 60-80-4
Installation: Tighten the valve cover bolts to 5 - 8 ft.-lb.
(7 - 11 N•m)
1
Figure 60-80-2
2
2 2
P-47244
Remove the rocker arm bolts and remove the rocker arm
P-47242 assembly (Item 1) [Figure 60-80-4].

Loosen the bolts on the clamps (Item 1) and remove the N•m) torque.
injection tubes (Item 2) [Figure 60-80-2].
Remove the pushrods (Item 2) [Figure 60-80-4].
Remove the overflow tube assembly.

RECONDITION THE ENGINE (CONT’D) Figure 60-80-7
Cylinder Head Removal And Installation (Cont'd) 10 2 7

14 6 3 11
Figure 60-80-5
13 5 4 12
9 1 8
P-69750
Remove the cylinder head bolts in order of 14 to 1

P-47245 [Figure 60-80-7].
NOTE: (A) is the gearcase side, (B) is the flywheel

Installation: The push rod (Item 1) must be seated in the side.
tappet (Item 2) [Figure 60-80-5] correctly or the push
rods will be damaged. Installation: Put oil on the bolt threads. Tighten the bolts
in the correct sequence in order of 1 through 14 to 69 - 72
After installing the rocker arm assembly and push rods, ft.-lb. (93 - 98 N•m).
the valve lash must be adjusted. (See Valve Clearance
Adjustment on Page 60-50-15.) NOTE: Re-tighten the cylinder head bolts in the
correct sequence after the engine has been
Figure 60-80-6 run for 30 minutes.
Figure 60-80-8
1
1
P-47246
P-47248
Remove the clamps (Item 1) and remove the hose (Item
2) [Figure 60-80-6].
Remove the cylinder head (Item 1) and gasket (Item 2)
[Figure 60-80-8].

Cylinder Head Removal And Installation (Cont'd) Gasket Size

Piston Protrusion
(Number)
Figure 60-80-9 0,500 - 0,540 mm
15
0.0197 - 0.0212 in.
0,550 - 0,590 mm
20
0.0217 - 0.0232 in.
25 0,600 - 0,640 mm
0.0237 - 0.0251 in.
0,650 - 0,690 mm
30
0.0256 - 0.0271 in.
35 0,700 - 0,740 mm
0.0276 - 0.0291 in.
Select the correct gasket size (thickness) from the chart

1
P-47249 [Figure 60-80-11].
Find the measurement of the highest piston protrusion

When replacing just the gasket, use a new gasket that and the lowest piston protrusion (recorded earlier) for
has the same mark (Item 1) [Figure 60-80-9] as the each piston.
original gasket.
If the highest measurement exceeds the piston
When replacing the gasket after an engine rebuild, the protrusion of the selected gasket, use the gasket which is
piston protrusion must be measured. (See Cylinder Head one size larger. If the measurement exceeds gasket size
Top Clearance on Page 60-80-5.) 35, the engine must be disassembled, clearances
checked, and reassembled.
Figure 60-80-10
If the measurement is two sizes smaller than the selected
gasket or smaller than gasket size 15, the engine must
1
be disassembled, clearances checked, and
reassembled.
After the gasket and cylinder head have been installed,

turn the crankshaft by hand to be sure there is no
interference between the piston, cylinder, and valves.
P-47252
Measure and record the protrusion of each piston in the

four places shown (Item 1) [Figure 60-80-10]. Find the
average of each piston, then find the combined average
of the four pistons.

Cylinder Head Disassembly And Assembly
Figure 60-80-12
2 1
1
3
4 5
4 Valve
5 3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
7
6
8 Remove the valve cap (Item 1) and valve spring collet
5 7
5 P-47253 (Item 2) [Figure 60-80-13] & [Figure 60-80-14].
Remove the valve spring retainer (Item 3) and the spring

Remove the bolts (Item 1), housing (Item 2), gasket (Item (Item 4) [Figure 60-80-13] & [Figure 60-80-14].
3) and thermostat (Item 4) [Figure 60-80-12].
Remove the seal (Item 6) and the valve (Item 5) [Figure
Remove bolts (Item 5), nut (Item 6), top and bottom 60-80-13] & [Figure 60-80-14].
housing (Item 7), and gasket (Item 8) from the cylinder
head [Figure 60-80-12].
Figure 60-80-13
PI-9987
Use a valve spring compressor to compress the valve

spring [Figure 60-80-13].

RECONDITIONING THE ENGINE (CONT'D) Cylinder Head Top Clearance
Cylinder Head Servicing Figure 60-80-17
Clean the surface of the cylinder head.

2
Figure 60-80-15
1
3
2 PI-9989
Install the cylinder head gasket. Put the piston (Item 1)

A-2735 [Figure 60-80-17] being checked at T.D.C.
Put three pieces of 0.06 in. (1,5 mm) diameter solder

Put a straight edge (Item 1) [Figure 60-80-15] on the (Item 2) [Figure 60-80-17] on the top of the piston. Use
cylinder head. grease to hold them in position.
NOTE: Do not put the straight edge across NOTE: Put the solder in position so they do not touch
combustion chambers. the valves.
Put a feeler gauge (Item 2) [Figure 60-80-15] between Turn the piston to bottom dead center.
the straight edge and the surface of the cylinder head.
Install the cylinder head and tighten to the correct torque
Figure 60-80-16 in the correct sequence. (See Cylinder Head Removal
Turn the crankshaft until the piston exceeds T.D.C.

Remove the cylinder head.
Remove the solder wire (Item 3) [Figure 60-80-17] and

measure it.
If the measurement exceeds the specifications, check the

oil clearance of the crank pin journal or the piston pin.
Top Clearance 0.0227 - 0.0265 in.

(0.575 - 0.675 mm)
PI-9988
Put the straight edge on the cylinder heads four sides

and two diagonal as shown [Figure 60-80-16].
The maximum distortion of the head surface is ± 0.002 in.

(± 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.

RECONDITIONING THE ENGINE (CONT'D) Figure 60-80-20
Valve Guide Checking
Remove the valve and spring from the cylinder head.

(See Cylinder Head Disassembly And Assembly on Page
60-80-4.)
Clean the valve seat and combustion chamber.
Figure 60-80-18
B-14335
Measure the valve stem O.D. [Figure 60-80-20].
Measure the valve guide I.D. [Figure 60-80-20].
Calculate the clearance. If the clearance exceeds the

allowable limit, replace the valve and/or valve guide.
B-3634 Valve Guide I.D. 0.3156 - 0.3161 in.

(8,015 - 8,03 mm)
Valve Stem O.D. 0.3134 - 0.3139 in.
Install the valve into the guide. Measure the valve
(7,96 - 7,98 mm)
recessing or protrusion with a depth gauge [Figure 60-
Clearance Between 0.0016 - 0.0027 in.
80-18].
Valve Stem and Guide (0,04 - 0,07 mm)
Figure 60-80-19 Allowable Limit 0.0039 in.
(0,1 mm)
1. Cylinder Head
Surface
2. Recessing
3. Protrusion
PI-9990
If the measurement exceeds the allowable limit, replace

the valve or cylinder head [Figure 60-80-19].
Protrusion 0.002 in. (0,05 mm)

Recessing 0.006 in. (0,15 mm)
Allowable Limit (Recessing) 0.016 in. (0,4 mm)
Remove the carbon from the valve guide.

RECONDITIONING THE ENGINE (CONT'D)
Valve Guide Checking (Cont’d)
Figure 60-80-21
8.86” (225 mm)
0.79” 2.76” (70mm) 1.77”

(20 mm) (45 mm)
0.460-0.468”
(11,7-11,9 mm) 0.256-0.259”
(6,5-6,6 mm)
0.2” 0.350-0.358” 0.787”
(5,0 mm) (8.9-9.1 mm) (20,0 mm)
0.263-0.275” 0.98” 0.490-0.50”

(6,7-7 mm) (25,0 mm) (12.5-12.8 mm)
MC-1364
To remove and replace the valve guide, make the driver

tool as shown [Figure 60-80-21].
Figure 60-80-22
PI-9992
Press the used valve guide out of the cylinder head using
the special driver tool [Figure 60-80-22].
Put oil on the outside diameter of the new valve guide.

Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 & 2)
[Figure 60-80-22], press the new guide until the tool
contacts the cylinder head.
Ream the valve guide to the correct specifications.

Reconditioning The Valve And Valve Seat 1 2
Figure 60-80-23
PI-9995
Check the seat surface and valve face (Item 1) [Figure

PI-9993 60-80-25].
If the seat surface is too wide, use a 15 degree cutter on

Grind the valve face to the correct angle using a valve re- the exhaust or a 30 degree cutter on the intake (Item 2)
facer [Figure 60-80-23]. to get the correct width (Item 3) [Figure 60-80-25].
Figure 60-80-24 Valve Seat Width
Intake 0.0835 in. (2,12 mm)

Exhaust 0.0835 in. (2,12 mm)
Valve Seat & Face Angle
Intake 60°
Exhaust 45°
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 60-80-24].

Valve Spring
Figure 60-80-26
A-2759
Put the spring on a tester and compress to specified

B-3680 length [Figure 60-80-27].
Read the compressed load on the gauge. If the

Measure the length of the valve spring. If the measurement exceeds allowable limit, replace the
measurement is less than the allowable limit, replace the spring.
spring [Figure 60-80-26].
Setting Length 1.38 in.
Free Length 1.65 - 1.66 in. (35,0 mm)
(41,7 - 42,2 mm) Setting Load 26.5 lb.
Allowable Limit 1.622 in. (117,6 N)
(41,2 mm) Allowable Limit 22.5 lb.
(100,0 N)
Put the spring on a flat surface, place a square on the
side of the spring [Figure 60-80-26].
Rotate the spring and measure the maximum tilt. If the

measurement excess the allowable limit, replace the
spring.
Tilt 0.039 in.

(1,0 mm)

RECONDITIONING THE ENGINE (CONT'D) Timing Gearcase Cover Removal And Installation
Rocker Arm And Shaft Checking Remove the fuel injection pump. (See Fuel Injection
Pump Removal And Installation on Page 60-50-7.)
Figure 60-80-28
Remove the cylinder head, rocker arms and push rods.
(See Cylinder Head Removal And Installation on Page
60-80-1.)
Figure 60-80-29
1
2
7.90” (200 mm)
B-3697
Measure the rocker arm I.D. (Item 1) [Figure 60-80-28]

with an inside micrometer.
P-47254
Measure the rocker arm shaft O.D. (Item 2) [Figure 60-
80-28] with an outside micrometer.
Bend a hook on the end of a 7.90 in. (200 mm) long,
If the clearance exceeds the allowable limit, replace the 0.050 in. (1,2 mm) diameter hard wire [Figure 60-80-29].
bushing.
Figure 60-80-30
If the clearance still exceeds the allowable limit after the
bushing is replace, replace the rocker arm shaft.
Oil Clearance Between 0.0006 - 0.0017 in.

Rocker Arm & Shaft (0,02 - 0,05 mm)
Allowable Limit 0.004 in.
(0,10 mm)
1
Rocker Arm Shaft O.D. 0.5501 - 0.5506 in.
(13,97 - 13,98 mm)
Rocker Arm I.D. 0.5512 - 0.5520 in.
(14,0 - 14,02 mm)
P-47255
Disconnect the two governor springs (Item 1) [Figure 60-

80-30].

Timing Gearcase Cover Removal And Installation

(Cont'd)
Figure 60-80-31
P-47258
1
Use a puller and remove the crankshaft pulley. [Figure

60-80-33].
P-47256
Figure 60-80-34
Remove the speed control plate (Item 1) [Figure 60-80-

31].
Figure 60-80-32
1
2
1
B-14339
Remove the crankshaft pulley (Item 1) and key (Item 2)

[Figure 60-80-34].
P-47257
Remove the bolts from the timing gearcase cover.
Remove the wire (Item 1) [Figure 60-80-32] from the Installation: Tighten the bolts to 18 - 20 ft.-lb. (24 - 27
springs. N•m) torque.
Installation: Do not drop the governor springs into the

gear case.
Remove the crankshaft pulley nut.
Installation: Tighten the nut to 102 - 115 ft.-lb. (138 - 156

N•m) torque.

Timing Gearcase Cover Removal And Installation

(Cont'd)
Figure 60-80-35
Oil Seal O-Rings
B-3617
Installation: Install new O-rings and oil seal into the

timing gearcase cover [Figure 60-80-37].
P-47259
Remove the timing gearcase cover [Figure 60-80-35].
Figure 60-80-36
3
2
B-14340
Remove the crankshaft collar (Item 1), O-ring (Item 2)

and oil slinger (Item 3) [Figure 60-80-36].

RECONDITIONING THE ENGINE (CONT'D) Installation: Check the idler gear end play. If the
clearance exceeds the allowable limit, replace the gear
Idler Gear And Camshaft Removal And Installation collar.
Remove the timing gearcase cover. (See Timing Idler Gear End Play 0.048 - 0.018 in. (0,12 - 0,48 mm)
Gearcase Cover Removal And Installation on Page 60- Allowable Limit 0.04 in. (0,9 mm)
80-10.)
Figure 60-80-40
Figure 60-80-38
2
1
P-47262
P-47260
Align the holes (Item 1) on the camshaft gear with the

Remove the snap ring (Item 1) and collar from the idler camshaft retainer plate bolts (Item 2) [Figure 60-80-40].
gear shaft (Item 2) [Figure 60-80-38]. Remove the bolts.
Installation: Make sure the timing marks are in correct Installation: Tighten the camshaft retainer bolts to 18 -
alignment when installing the timing gears [Figure 60-80- 20 ft.-lb. (24 - 27 N•m) torque.
38].
Remove the camshaft from the engine block.
Figure 60-80-39
Figure 60-80-41
B-3699 0.0028-0.0087”
(0,07-0,22 mm)
PI-10002
Remove the idler gear (Item 1) [Figure 60-80-39].

Installation: Check the camshaft end play. If clearance
exceeds the allowable limit, replace the camshaft retainer
plate [Figure 60-80-41].
Camshaft End Play 0.0028 - 0.0086 in. (0,07 - 0,22 mm)

Allowable Limit 0.012 in. (0,3 mm)

Camshaft Servicing
Figure 60-80-42
B-5001
Measure the cam lobes at their highest point [Figure 60-

P-47263 80-44].
If the measurement is less than the allowable limit,

Measure the cylinder block bore in the engine block replace the camshaft.
[Figure 60-80-42].
Cam Lobe Height 1.335 in. (33,9 mm)
Figure 60-80-43
Allowable Limit 1.333 in. (33,85 mm)
Figure 60-80-45
A-2761
Measure the camshaft journal [Figure 60-80-43]. A-2760
Calculate the oil clearance. If the clearance exceeds the

Put the camshaft in V-blocks. Install a dial indicator
allowable limit, replace the camshaft.
[Figure 60-80-45].
Cylinder Block Bore I.D. 1.575 - 1.576 in. Turn the camshaft at a slow rate. If the misalignment
(40,0 - 40,025 mm) exceeds the allowable limit, replace the camshaft.
Journal O.D. 1.572 - 1.573 in.
(39,93 - 39,95 mm) Camshaft Alignment 0.0004 in.
Oil Clearance of 0.002 - 0.0036 in. Allowable Limit (0,01 mm)
Camshaft Journal (0,05 - 0,091 mm)
(0,15 mm)

Idler Gear And Shaft Servicing

1.49” (38 mm)
Figure 60-80-46
6.89” (175 mm)
1.77” 1.575”
(45 mm) (40 mm)
1.650-1.652”
(41,9-41,95 mm)
1.494-1.495”
(37,95-37,97 mm)
MC-1366
To replace the idler gear bushing, make a driver tool as

PI-10003 shown [Figure 60-80-47].
Figure 60-80-48
Measure the O.D. of the idler gear shaft [Figure 60-80-
46].
Measure the I.D. of the idler gear bushing [Figure 60-80-

46].
If the clearance exceeds the allowable limit, replace the

bushing.
Idler Gear Shaft O.D. 1.494 - 1.495 in.

(37,96 - 37,98 mm)
Idler Gear Bushing I.D. 1.496 - 1.497 in.
(38,0 - 38,03 mm)
Clearance Between Idler 0.001 - 0.0026 in.
Shaft & Gear Bushing (0,025 - 0,066 mm) PI-10004

(0,1 mm) Use a press and special driver tool, to remove the old
bushing and install the new bushing [Figure 60-80-48].

RECONDITIONING THE ENGINE (CONT'D) Fuel Camshaft Removal And Installation
Timing Gears Checking Backlash Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 60-
When the gears are installed, check the backlash of the 80-10.)
gears.
Remove the idler gear. (See Idler Gear And Camshaft
Figure 60-80-49 Removal And Installation on Page 60-80-13.)
Figure 60-80-50
P-47264
1 1
P-47265
Install a dial indicator [Figure 60-80-49].
Hold one gear while turning the other gear [Figure 60- Remove the three bolts (Item 1) [Figure 60-80-50].
80-49].
Remove the two bolts and fuel camshaft retainer plate
If the backlash exceeds the allowable limit, check the oil (Item 2) [Figure 60-80-50].
clearance of the shaft and gear. If the oil clearance is
correct, replace the gear. Figure 60-80-51
Crank Gear & Idler Gear 0.0016 - 0.0044 in.

(0,042 - 0,112)
(0,15 mm)
Cam Gear & Idler Gear 0.0016 - 0.0045 in.
(0,042 - 0,115 mm)
(0,15 mm)
Injection Pump Gear & Idler 0.0016 - 0.0045 in.
Gear (0,042 - 0,115 mm)
(0,15 mm)
Oil Pump Gear & Crank Gear 0.0016 - 0.0043 in. P-47266
(0,042 - 0,109 mm)
Remove the fuel camshaft and fork lever assembly at the
(0,15 mm)
same time [Figure 60-80-51].

RECONDITIONING THE ENGINE (CONT'D) Crankshaft Gear Removal And Installation
Fuel Camshaft Governor Remove the timing gearcase cover. (See Timing
The governor serves to keep the engine speed constant 80-10.)
by automatically adjusting the amount of fuel supplied to
the engine according to changes in the load. Remove the idler gear. (See Idler Gear And Camshaft
Figure 60-80-52
Figure 60-80-53
B-3686
1. Start Spring Remove the crankshaft gear with a puller [Figure 60-80-
2. Governor Spring 53].
3. Governor Spring
4. Fork Lever Remove the crankshaft key.
5. Fork Lever
6. Fork Lever Shaft
7. Fork Lever Holder
8. Governor Lever
9. Fuel Camshaft
10. Governor Ball Case
11. Steel Balls
12. Governor Sleeve
13. Steel Ball PI-10008
Disassemble and assemble the governor and fuel

camshaft as shown [Figure 60-80-52].
Check all the parts for wear or damage and replace as

needed.

RECONDITIONING THE ENGINE (CONT'D) Oil Pump Service
Oil Pump Removal And Installation Figure 60-80-55
Remove the timing gearcase cover. (See Timing

80-10.)
Remove the crankshaft gear. (See Crankshaft Gear

Figure 60-80-54
B-3616
2
Measure the clearance between the lobes of the inner
rotor and outer rotor [Figure 60-80-55].
Figure 60-80-56
B-3658
Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 60-80-54].
Remove the oil pump mounting bolts. Remove the oil

pump (Item 2) [Figure 60-80-54].
Installation: Tighten the oil pump mounting bolts to 60 -

72 in.-lb. (6,9 - 8,1 N•m) torque.
A-2732
Measure the clearance between the outer rotor and

pump body [Figure 60-80-56].

oil pump.
Clearance Between Inner & 0.0012 - 0.0055 in.

Outer Rotor (0,03 - 0,14 mm)
Clearance Between Outer 0.0044 - 0.0074 in.
Rotor & Body (0,11 - 0,19 mm)

RECONDITIONING THE ENGINE (CONT'D) Checking Engine Oil Pressure
Oil Pump Service (Cont’d) Remove the oil pressure sender.
Figure 60-80-57 Figure 60-80-58
PI-10009 PI-10010
Put a piece of press gauge on the rotor face [Figure 60- Install a pressure gauge [Figure 60-80-58].
80-57].
Start the engine and run until it is at operating
Install the cover and tighten the bolts. temperature.
Remove the cover carefully. Measure the width of the If the oil pressure is less than the allowable limit, check
press gauge [Figure 60-80-57]. the following items:
If the clearance exceeds the allowable limit replace the * Engine Oil Level Low
oil pump. * Oil Pump Defective
* Oil Galley Plugged
End Clearance 0.0041 - 0.0059 in. * Oil Strainer Plugged
(0,105 - 0,15 mm) * Excessive Clearance at the Rod & Main Bearings
* Oil Pump Relief Valve Stuck
At Idle Speed Allowable Limit 7 PSI

(0,48 bar)
At Rated Speed 43 - 64 PSI
(2,9 - 4,4 bar)
Allowable Limit 36 PSI
(2,48 bar)

RECONDITIONING THE ENGINE (CONT'D) Piston And Connecting Rod Removal And
Installation
Valve Tappets
Remove the cylinder head. (See Cylinder Head Removal
Figure 60-80-59 And Installation on Page 60-80-1.)
Remove the top edge from the cylinder bore with a ridge
reamer.
Remove the oil pan.
Figure 60-80-61
1 1
P-47267 2
Remove the valve tappets (Item 1) [Figure 60-80-59].
Figure 60-80-60
P-47269
Remove the oil pump strainer (Item 1) and O-ring (Item

2) [Figure 60-80-61] by tapping the edge of the strainer
with a soft faced hammer.
Turn the flywheel and put a pair of connecting rods at

bottom dead center.
Remove the connecting rod bolts.
Installation: Tighten the connecting rod bolts to 33 - 36

P-47268 ft.-lb. (44 - 49 N•m) torque.
Measure the O.D. of the tappet [Figure 60-80-60].
Measure the ID of the tappet bore [Figure 60-80-60].

tappets.
Tappet OD 0.943 - 0.944 in.

(23,96 - 23,98 mm)
Tappet Bore ID 0.945 - 0.946 in.
(24,0 - 24,021 mm)
Clearance Between Tappet and 0.0008 - 0.0024 in.
Tappet Bore (0,02 - 0,062 mm)
Allowable limit 0.003 in.
(0,07 mm)

Piston And Connecting Rod Removal And

Installation (Cont’d) 4
1 3
Figure 60-80-62
2
1
P-47270
Remove the piston rings [Figure 60-80-64].
PI-10013 Remove the snap ring (Item 1) and piston pin (Item 2)
[Figure 60-80-64].
Remove the rod cap and bearing [Figure 60-80-62]. Separate the piston (Item 3) from the connecting rod
(Item 4) [Figure 60-80-64].
Use a hammer handle and push the piston/connecting
rod assembly out of the cylinder bore [Figure 60-80-62]. Figure 60-80-65
NOTE: Make sure the pistons are marked so they will

be returned to the same cylinder bore.
2
Figure 60-80-63
1
3
1
PI-10015
Installation: When installing new rings, assemble the

ring so the mark (Item 1) near the gap faces the top of the
A-2903 piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
3) [Figure 60-80-65].
Installation: Make sure the marks (Item 1) [Figure 60-
80-63] on the connecting rod and bearing are aligned
when installing the bearing cap.
Repeat the procedure to remove the other piston/

connecting rod assemblies from the engine block.

RECONDITIONING THE ENGINE (CONT'D) Piston And Connecting Rod Servicing
Piston And Connecting Rod Removal And Figure 60-80-67

Figure 60-80-66
3
1
2
5
P-47272
4
P-47271 Measure the I.D. of the piston pin bore in both horizontal
and vertical directions [Figure 60-80-67].
Installation: When reassembling, align the marks on the If the measurement exceeds the allowable limit, replace
connecting rod (Item 1) and piston (Item 2). Heat the the piston.
piston in clean engine oil to 176° F. (80° C.) and tap the
piston pin into position. Place the piston rings so that Piston Bore I.D. 0.984 - 0.985 in.
there are gaps every 120° (Items 3, 4 & 5) [Figure 60-80- (25,0 - 25,013 mm)
66] with no gap facing the piston pin in the cylinder.
(25,05 mm)
Figure 60-80-68
P-47273
Measure the O.D. of the piston pin (Item 1) [Figure 60-

80-68].
Measure the I.D. of the connecting rod small end (Item 2)

[Figure 60-80-68].

Piston And Connecting Rod Servicing (Cont’d)
Calculate the oil clearance. If the clearance exceeds the

allowable limit, replace the bushing. If it still exceeds the
specifications, replace the piston pin.
Piston Pin O.D. 0.984 - 0.985 in.

(25,0 - 25,011 mm)
Bushing I.D. 0.985 - 0.986 in.
(25,025 - 25,04 mm)
Oil Clearance Between 0.0006 - 0.0015 in.
Piston Pin & Bushing (0,014 - 0,038 mm)
(0,15 mm) PI-10016
Figure 60-80-69 Use a press and special driver tool to remove the small
end bushing [Figure 60-80-70].
1.38” (35 mm)
1.06” (27 mm) Installation: Clean the small end bushing and bore. Put
oil on the bushing and press into the connecting rod until
6.38” (162 mm) it is flush [Figure 60-80-70].
1.38”
(35 mm) Figure 60-80-71
1.098-1.10”
(27,9-27,95 mm)
0.984-0.985”
(25,0-25,01 mm)
MC-1366
To replace the connecting rod small end bushing, make a

driver tool as shown [Figure 60-80-69].
B-3622
Install a piston ring into the lower part of the cylinder

bore. Measure the ring gap with a feeler gauge [Figure
60-80-71].
If the gap exceeds the allowable limit, replace the ring.
Top Ring Gap 0.009 - 0.015 in.

(0,25 - 0,40 mm)
Second Ring Gap 0.012 - 0.017 in.
(0,30 - 0,45 mm)
Oil Ring Gap 0.0098 - 0.0177 in.
(0,25 - 0,45 mm)
(1,25 mm)

RECONDITIONING THE ENGINE (CONT'D) Connecting Rod Alignment
Piston And Connecting Rod Servicing (Cont’d) NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
Figure 60-80-72 doing this check.
Install the piston pin into the connecting rod.
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate.
Figure 60-80-73
PI-10017
Remove the carbon from the ring grooves. Measure the

clearance between the ring and groove with a feeler
gauge [Figure 60-80-72].

ring. If the clearance still exceeds the allowable limit,
replace the piston.
B-4067
Compression Rings 0.0037 - 0.005 in.

(0,093 - 0,13 mm) If the gauge does not fit squarely against the face plate,
Oil Ring 0.0079 - 0.0023 in. measure the space between the gauge and face plate
(0.02 - 0.06 mm) [Figure 60-80-73].

the connecting rod.
Rod Alignment 0.002 in.

(0,05 mm)

Crankshaft And Bearings Removal And Installation

2
Remove the piston and connecting rod assemblies. (See
Piston And Connecting Rod Removal And Installation on
Page 60-80-20.)
Figure 60-80-74
1
2 5
4
P-47276
1
Install the bearing case cover (Item 1) with the casting
mark (Item 2) [Figure 60-80-76] in the upward position.
3
Figure 60-80-77
P-47274
Mark and remove the inside screws (Item 1) first, then

remove the outside screws (Item 2) [Figure 60-80-74].
NOTE: The inside bolts are different length than the

outside bolts.
Install two bolts in the bearing case cover and remove

the cover (Item 3) [Figure 60-80-74].
Remove the two gaskets (Item 4) and oil seal (Item 5)

[Figure 60-80-74] from the cover.
P-47277
Figure 60-80-75
Before removing the crankshaft/main bearings, check the

end play. Install a dial indicator. Move the crankshaft
[Figure 60-80-77] to the flywheel side, zero the dial
indicator. Measure the end play by pulling the crankshaft
toward the gearcase side.

the thrust washers [Figure 60-80-77].
1
End Play 0.006 - 0.012 in.
2 (0,15 - 0,31 mm)
(0,5 mm)
P-47275
Installation: Install the gaskets (Item 1) & (Item 2)

[Figure 60-80-75] as shown.

Crankshaft And Bearings Removal And Installation

(Cont’d)
Figure 60-80-78
B-4092
Remove the two bearing case bolts [Figure 60-80-80].
P-47278 Remove the bearing case and bearing.
Installation: Tighten the bearing case bolts to 34 - 37 ft.-

Remove the main bearing bolts (Item 1) [Figure 60-80- lb. (46 - 50 N•m) torque.
78].
Figure 60-80-81
Installation: Align the bearing case hole with the hole
(Item 2) [Figure 60-80-78] in the block. Put oil on the bolt
threads and tighten to 51 - 54 ft.-lb. (69 - 73 N•m) torque.
Figure 60-80-79
PI-10021
Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to the flywheel
P-47279 side of the engine block [Figure 60-80-81]. The thrust
washers oil grooves must face outward.
Remove the crankshaft/main bearing assembly from the

engine block [Figure 60-80-79].
NOTE: Turn the crankshaft as needed to allow the

crank pin journals to pass through the cut out
(Item 1) [Figure 60-80-79] of the engine block.
Mark the bearing case halves for correct installation.

Crankshaft And Bearings, Servicing
Figure 60-80-82
A-2716
Measure the crankpin O.D. [Figure 60-80-84].

A-2763
Calculate the oil clearance.
Put the crankshaft on V-blocks. Install a dial indicator on Crankpin Bearing I.D. 1.850 - 1.852 in.
the center journal [Figure 60-80-82]. (47,0 - 47,05 mm)
Crankpin O.D. 1.8488 - 1.8494 in.
Turn the crankshaft at a slow rate to obtain the (46,96 - 46,98 mm)
misalignment (one half of the alignment measurement). Oil Clearance 0.001 - 0.0034 in.
(0,025 - 0,087mm)
If the misalignment exceeds the allowable limit, replace Allowable Limit 0.008 in.
the crankshaft. (0,2 mm)
Alignment 0.0008 in. Figure 60-80-85

(0,02 mm)
1
Tighten the connecting rod bolts to 33 - 36 ft.-lb. (44 - 49
N•m) torque.
Figure 60-80-83
120
PI-10022
Check the wear on the crankshaft sleeve [Figure 60-80-

85].
A-2727
If the wear exceeds the allowable limit or the seal leaks
oil, replace the sleeve.
Measure the crankpin bearing I.D. [Figure 60-80-83]. Wear of Sleeve 0.0004 in.
(0,1 mm)

Crankshaft And Bearings, Servicing (Cont’d)
The special tool set will be needed to replace the

crankshaft sleeve.
Remove the sleeve.
Figure 60-80-86
2 2
1 3 B-3631
Measure the I.D. of the No. 1 crankshaft bearing [Figure

60-80-88].
Figure 60-80-89
PI-10023
Install the sleeve guide (Item 1) and stop (Item 2) [Figure

60-80-86].
Heat the sleeve to 302 - 392° F (150 - 200° C). Install the
sleeve on the crankshaft using the special driver tool
(Item 3) [Figure 60-80-86].
Figure 60-80-87
1 B-3618
Measure the O.D. of the crankshaft journal [Figure 60-

80-89].
Calculate the oil clearance.
PI-10022
NOTE: The sleeve is installed with the larger

chamfered surface (Item 1) [Figure 60-80-87]
to the front of the crankshaft.


crankshaft bearing.
Bearing I.D. 2.3615 - 2.3631 in.

(59,98 - 60,025 mm)
Crankshaft Journal O.D. 2.3591 - 2.3598 in.
(59,92 - 59,940 mm)
Oil Clearance 0.0016 - 0.0041 in.
(0,04 - 0,104 mm)
(0,2 mm)
PI-10024C
Figure 60-80-90
Removal Tool Remove the front bearing with the special removal tool
[Figure 60-80-92].
5.31” (135 mm)
0.8” Installation: Clean the new bearing and bore, apply oil to
(20 mm) the bearing and bore. Install the new bearing with the
2.039-2.043” seam (Item 1) [Figure 60-80-92] towards the exhaust
2.83” (51,8-51,9 mm) manifold side, using the installation driver tool.
(72 mm)
Clean the crankshaft journal and bearing. Put a strip of
press gauge on the center journal.Install the main
bearing case halves and tighten the bolts. Remove the
0.8” (20 mm) bearing case halves.
2.236-2.2402”
R1.57” 0.4” (56,8-56,9 mm) NOTE: DO NOT turn the crankshaft with the press
(R40 mm) (10 mm) MC-1367 gauge installed. Incorrect measurements will
be obtained.
To remove the front bearing make the tool as shown
[Figure 60-80-90].
Figure 60-80-91
Installation Tool
5.12” (130 mm)
0.8”
0.16” (20 mm)
(4 mm)
2.236-2.240”
2.83” (56,85-56.90 mm)
(72 mm)
2.68”
(68 mm)
0.8” (20 mm)
R 1.57” 2.039-2.043”
0.4” (51,8-51,9 mm)
(R40 mm) (9mm) MC-1365
To install the front bearing make the tool as shown

[Figure 60-80-91].

Figure 60-80-93
PI-10025
Measure the flattened press gauge [Figure 60-80-93].

crankshaft bearing.
Bearing I.D. 2.3614 - 2.3632 in.

(59,98 - 60,025 mm)
Crankshaft Journal O.D. 2.3591 - 2.3598 in.
(59,92 - 59,94 mm)
Oil Clearance 0.001 - 0.0034 in.
(0,025 - 0,087 mm)
(0,2 mm)

RECONDITIONING THE ENGINE (CONT'D) Water Pump Removal And Installation
Cylinder Bore, Checking Drain the cooling system.
Figure 60-80-94 Remove the radiator. (See Removal And Installation on

Page 60-40-1.)
Remove the alternator belt.
Remove the fan.
Remove the water pump bolts.
Figure 60-80-96
B-4066
Use a gauge to check the inside measurement of the

cylinder bore [Figure 60-80-94].
Figure 60-80-95
B-5318
Remove the water pump [Figure 60-80-96].
Installation: Always use a new gasket when installing

the water pump.
A-2717
Measure the six points as shown in figure [Figure 60-80-

95] to find the maximum wear.
The specifications is 3.4252 - 3.4260 in. (87,0 - 87,022

mm). The wear limit is +0.0059 in. (+0,15 mm).
If the cylinder bore is not within specifications, re-bore the

cylinder for oversize piston.

Water Pump Disassembly And Assembly
Figure 60-80-97
3
4
B-14424
Remove the flange (Item 1) [Figure 60-80-97].
Press the shaft (Item 2) and impeller (Item 3) [Figure 60-

80-97] out the impeller side of the water pump.
Remove the impeller (Item 3) [Figure 60-80-97] from the

shaft.
Remove the seal (Item 4) [Figure 60-80-97].
Install a new seal (Item 4) [Figure 60-80-97] when

assembling the water pump.

HEATER
BLOWER FAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Resistor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-60-3
HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
HEATER UNIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Filter Element Removal And Installation . . . . . . . . . . . . . . . . . . 70-20-1
Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . 70-30-1 HEATER
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-2

SPECIFIED.

MAY VARY.

HEATER SYSTEM Figure 70-10-3
Description
1
The heater system includes the heater unit which is
located on the floor under the seat. The heater unit
includes the heater coil, fan motor, blower cage, and
filter.
Components
Figure 70-10-1
2 3
P-73560
Control Panel: The panel (Item 1) [Figure 70-10-3] has

two separate components.
Fan Switch: This is a four position rotary switch (Item

2) [Figure 70-10-3].
Temperature Switch: The temperature switch (Item 3)

[Figure 70-10-3] controls the Heat Valve from fully
1 Off to fully On.
P-73586
Figure 70-10-4
Heater Unit: The heater unit (Item 1) [Figure 70-10-1] is
located on the floor under the seat. The unit delivers the
warm air for heat into the cab.
Figure 70-10-2
2
1
1
P-73555
Heater Valve: The heater valve (Item 1) [Figure 70-10-4]

manually controls the amount of engine coolant that
P-73624 flows to the heater coil.
Heater Coil: The heater coil (Item 1) [Figure 70-10-2]

supplies the warm air into the cab by passing air through
the coil
Heater Fan: The fan (Item 2) [Figure 70-10-2] is used to

push air through the heater coil and into the cab.

REGULAR MAINTENANCE Figure 70-20-3
Filter Element Removal And Installation
The recirculation filter must be cleaned regularly. The

filter is located at the left of the operator seat.
The heater filter must be cleaned regularly. The filter is

located at the left of the operator seat.
1
Figure 70-20-1
P-73460
Installation: Install the filter with the arrows that indicate

air flow direction (Item 1) [Figure 70-20-3] pointing
towards the heater housing.
1
The filter must be cleaned regularly.
2
P-73459
Turn the fastener (Item 1) 1/4 turn and remove the cover
(Item 2) [Figure 70-20-1].
Figure 70-20-2
P-73461
Pull the filter (Item 1) [Figure 70-20-2] out of the heater

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

REGULAR MAINTENANCE (CONT’D)
Heater Coil
Remove the operator seat and seat mount. (See

Figure 70-20-4
2
1
2
1
P-73586

heater unit front cover.
Remove the front cover from the unit.

heater cover and remove cover.
Figure 70-20-5
P-73624
The heater coil (Item 1) [Figure 70-20-5] can now be

cleaned with low pressure water or air. High pressure
may damage the fins of the heater coil.

TROUBLESHOOTING
Blower Motor Does Not Operate
Possible Cause Inspection Solution

1. Blown fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or bad connection. Check the fan motor ground and Repair the wiring or connector.
connectors.
3. Fan motor malfunction. Check the lead wires from the motor Replace motor.
with a circuit tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace resistor.
5. Fan motor switch malfunction. Check power into and out of the fan Replace fan switch.
switch.
Blower Motor Operates Normally, But Air Flow Is Insufficient
Possible Cause Inspection Solution

1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or water.
2. Air leak. Check to make sure air hoses are Repair or adjust.
properly hooked to louvers, and air
ducts.
3. Plugged cab filters. Check cab filter condition. Clean or replace filters.

TROUBLESHOOTING (CONT’D) If there is no voltage at the wiring harness, check the
harness for broken wires.
Electrical System
Figure 70-30-3
Figure 70-30-1
1
P-73603
P-73557
If there is voltage at the wiring harness, check the

Disconnect the wire harness (Item 1) [Figure 70-30-1]. resistance to the blower fan at the thermostat/blower fan
wiring connector (Item 1) [Figure 70-30-3].
Figure 70-30-2
Check the resistance between Pin 4 (BLACK wire #
2200) and Pin 3 (YELLOW wire # 5000).

2200) and Pin 2 (RED wire # 1200).

2200) and Pin 1 (ORANGE wire # 1010).
If there is no resistance value at any of these pins,

replace the blower fan. (See Removal And Installation on
1
Page 70-60-1.)
If there is resistance value at any of the pins, check the

P-73558 climate controls at the control panel inside the excavator
cab.
Check the wire harness (Item 1) [Figure 70-30-2] for
voltage to the blower fan.
In the cab, place the blower switch in position 1. Check

for voltage at the harness connector (Item 1) [Figure 70-
30-2], Pin 3. (YELLOW wire # 5000). The voltage should
be 12 volts.

30-2], Pin 2. (RED wire # 1200). The voltage should be
12 volts.

30-2], Pin 1. (ORANGE wire # 1010). The voltage should
be 12 volts.

TROUBLESHOOTING (CONT’D) Figure 70-30-6
Electrical System (Cont’d)
Figure 70-30-4
P-73562
Disconnect the wiring harness (Item 1) [Figure 70-30-6]

P-73560 from the blower switch.
Check the harness for voltage. The voltage should be

Remove the left rear console cover (Item 1) [Figure 70- approximately 12 volts.
30-4]. (See Console Switch Removal And Installation on
Page 40-60-15.) If there is no voltage at the wiring harness, check the
harness for broken wires.
Figure 70-30-5
P-73561
Position the console and wiring harness in the cab so the

wiring harness can be checked [Figure 70-30-5].

Figure 70-30-7
C
H
M B
1
L
P-73563

N-22288 from the potentiometer.
Figure 70-30-9
If there is voltage at the wiring harness, check the blower
switch [Figure 70-30-7] for resistance.
With the switch in the OFF position, there should be zero

resistance between all terminals.
With the switch in the 1 position, there should be

resistance between C terminal and the B terminal. And 1
also between the C terminal and the L terminal frame
[Figure 70-30-7].

resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 70-30-7]. P-73564

resistance between C terminal and the B terminal. And Check the wire harness (Item 1) [Figure 70-30-9] for
also between the C terminal and the H terminal frame voltage. Between pins A and C the voltage should be
[Figure 70-30-7]. approximately 12 volts.
If any of the above resistance tests fail, replace the If there is no voltage at the wiring harness, check the
blower switch. harness for broken wires.

Figure 70-30-10
C
A
N-22175
B
To check the resistance of the white wire, turn the

N-22290 potentiometer control (Item 1) [Figure 70-30-12] to the
full A/C position.
If there is voltage at the wiring harness, check the Figure 70-30-13

potentiometer [Figure 70-30-10] for resistance.
The resistance should be 10K ohms between wire

terminal A and wire terminal C frame [Figure 70-30-10].
If no resistance is found replace the potentiometer.

C
A
Figure 70-30-11
N-22290
The resistance between the wire terminal A and wire

terminal B frame [Figure 70-30-13] should be
1 approximately 49K ohms.
Check the resistance between the wire terminal C and

N-22201 wire terminal B frame [Figure 70-30-13] should be
approximately 39K ohms.
The white wire B, (Item 1) [Figure 70-30-11], on the

potentiometer, is a resister wire.

Figure 70-30-14 2
1
P-73560
1
Turn the fan switch (Item 1) to the High Speed position.,
N-22175 Turn the temperature control (Item 2) [Figure 70-30-16]
to the High cold position, with the key switch OFF.
To check the resistance of the white wire, turn the Start the excavator and run at high idle, for ten minutes.
potentiometer control (Item 1) [Figure 70-30-14] to the
full heater position. Figure 70-30-17
Figure 70-30-15
C
A
1
B
P-73553
N-22290
Check the temperature of the heater hoses (Item 1)
[Figure 70-30-17].
Check the resistance between the wire terminal A and
wire terminal B frame [Figure 70-30-15] should be If the hoses are hot, the heater valve is leaking internally,
approximately 39K ohms. and needs to be replaced.
Check the resistance between the wire terminal C and

wire terminal B frame [Figure 70-30-15] should be
approximately 49K ohms.
If the resistance is not found replace the potentiometer.

HEATER UNIT Figure 70-40-3
Drain the engine coolant. (See Replacing The Coolant on 2

Page 10-70-3.)

2
Figure 70-40-1
1
1
P-73623
1 Remove the bolt (Item 1) [Figure 70-40-3] on the right

side of the heater unit.
Remove the bolts (Item 2) [Figure 70-40-3] from the left

side of the heater unit and remove the unit from the
excavator.
P-73586

Remove the front cover from the unity.
Figure 70-40-2
3
2
1
P-
Remove the clamps (Item 2) [Figure 70-40-2] from the

heater hoses.
Cap and plug the hoses with the proper caps and plugs.
Remove the heater hoses from the heater coil.

HEATER COIL Cap and plug the hoses with the proper caps and plugs.
Drain the engine coolant. (See Replacing The Coolant on

Page 10-70-3.)

Figure 70-50-1
1
1 P-73628
2
Remove the heater coil (Item 1) [Figure 70-50-3].

2
1
P-73585

Remove the front cover from the unit.

heater cover and remove cover.
Figure 70-50-2
P-73626
Clamp both heater hoses with clamping pliers. Remove

the hose clamps (Item 1) [Figure 70-50-2] from the
heater hoses.
Remove the heater hoses from the heater coil.

BLOWER FAN Figure 70-60-3

Removal And Installation on Page 40-40-1.) 2
Remove the heater unit. (See Removal And Installation

on Page 70-40-1.) 1
Figure 70-60-1
P-73624A
2 Lift the heater coil (Item 1) [Figure 70-60-3] straight up

1
from the heater unit.
Remove the blower fan (Item 1) [Figure 70-60-3].
P-73637
Disconnect the orange fan motor wire (Item 1) [Figure

70-60-1] from the resistor.
Disconnect the black fan motor wire (Item 2) [Figure 70-

60-1] from the black wire on the wire harness.
Figure 70-60-2
1
1
1
P-73631
Remove the four bolts (Item 1) [Figure 70-60-2] from the

blower fan housing in the heater unit.

BLOWER FAN (CONT’D) Figure 70-60-6

1
Figure 70-60-4
1 P-24459
Remove the outside ring (Item 1) [Figure 70-60-6] from

P-73646 the fan motor.
Figure 70-60-7
Remove the three mounting nuts (Item 1) [Figure 70-60-
4] from the blower fan housing.
Remove the blower motor and fan from the blower 1 1

housing unit.
Figure 70-60-5
P-24460
Remove the two mounting nuts (Item 1) [Figure 70-60-7]

2
from the fan motor mount bracket.
P-73654
Mark the fan shaft (Item 1) [Figure 70-60-5] and blower

wheel, for the proper installation of the blower wheel.
Remove the clamp (Item 2) [Figure 70-60-5] and remove

the blower wheel from the fan shaft.

BLOWER FAN (CONT’D) Resistor Removal And Installation
Disassembly And Assembly (Cont’d) Figure 70-60-9
Figure 70-60-8
1
1
2 3
P-73637
P-73653
Remove the four electrical wires from the resistor [Figure
70-60-9].
Remove the fan motor mount bracket (Item 2) [Figure
70-60-8] from the motor. Wire Installation
Inspect the fan motor, and if it needs replacing, it must be Install the Orange wire from the wire harness (Item 1)
replaced as a complete unit. [Figure 70-60-9] on the top terminal of the resistor.
Install the Red wire from the wire harness (Item 2)

[Figure 70-60-9] on the second terminal of the resistor.
Install the Yellow wire from the wire harness (Item 3)

[Figure 70-60-9] on the third terminal of the resistor.
Install the Orange wire from the heater fan motor (Item 4)
[Figure 70-60-9] on the bottom terminal of the resistor.

BLOWER FAN (LATER MODELS) (CONT’D)
Resistor Removal And Installation (Cont’d)
Figure 70-60-10
P-73632
Loosen the two resistor mount bolts [Figure 70-60-10].
Remove the resistor from the unit.
Figure 70-60-11
P-73643
Inspect the resistor (Item 1) [Figure 70-60-11] and

replace as needed.

HEATER VALVE Figure 70-70-2
Drain the engine coolant. (See Replacing The Coolant on 1

Page 10-70-3)

Removal And Installation on Page 40-40-1)
Remove the heater unit. (See Removal And Installation

on Page 70-40-1)
1
Figure 70-70-1 2
P-73082
Mark and remove the hoses (Item 1). Remove the two
bolts (Item 2) [Figure 70-70-2] from the heater valve.
1 Remove the heater valve from the excavator.
The heater valve is not serviceable and must be replaced

as a complete unit.
P-73082

from the heater valve.

SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . SPEC-70-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . SPEC-70-2
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Crankshaft Re-Grind Data . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Engine Bolt Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-5
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Tappet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-5
Timing Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Valve Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . SPEC-60-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . SPEC-40-1 SPECIFICATIONS

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-2
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . SPEC-40-1
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-5
Straight Thread O-Ring Fitting . . . . . . . . . . . . . . . . . . . SPEC-40-1
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1
HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . SPEC-50-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
SPEC-01 325/328 Service Manual

SPECIFICATIONS (CONT’D)
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
325 Excavator Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
325/328 Excavator Machine Dimensions. . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
325 With Long Arm Option And 328 Excavator Machine DimensionsSPEC-10-3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-7
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-7
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2
Torque for General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY

VARY.
SPEC-02 325/328 Service Manual

SPECIFICATIONS
325/328 Excavator Machine Dimensions
• 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.
MS1875
SPEC-10-1 325/328 Service Manual

325 Excavator Machine Dimensions
MS1876

325 With Long Arm Option And 328 Excavator Machine Dimensions
MS1877

Performance
325 operating weight w/ canopy, 6145 lb. (2788 kg)

rubber tracks, and 20 in. (508 mm)
bucket
325 With Long Arm Option & 328 6477 lb. (2939 kg)
operating weight w/ canopy, rubber
tracks, and 20 in. (508 mm) bucket
Travel Speed Low Range 1.2 mph (1,9 km/hr.)
High Range 1.9 mph (3,1 km/hr.)
Steel tracks add 146 lb. (66 kg)
Cab w/heater add 263 lb. (119 kg)
Controls
Steering Two hand levers or foot pedals

Hydraulics Two hand operated levers (joysticks) control boom, bucket, arm and
upperstructure slew
Auxiliary Hydraulics Electric switch in right joystick
Blade Right hand lever
Boom Swing Right foot pedal
Upperstructure Slew Lock
Service Hydraulic lock on motor
Holding Mechanical pin lock
Vehicle Steering Direction and speed controlled by two pilot operated hand levers/foot pedals.
Engine
Make/Model Kubota V 1703-M-E28

Fuel/Cooling Diesel/Liquid
Horsepower, Maximum 27.7 HP (20.6 kw)
High Idle Speed 2420 RPM
Low Idle Speed 1325 - 1375 RPM
Maximum Torque 73 ft.-lb. (103,4 N•m)
Number Of Cylinders 3
Displacement 104 ci (1,7L)
Bore/Stroke 3.43 x 3.64 in. (87 x 92,4 mm)
Lubrication Forced Lubrication by Trochoid Pump
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper dual cartridge
Ignition Diesel-Compression

Hydraulic System
Pump - Hydraulic Engine driven, dual outlet variable displacement piston/gear pump
Pump Capacity
Gear Pump (One) 7.03 GPM (26,6 L/min)
Piston Pump (Two) 5.23 GPM (19,8 L/min)
Auxiliary Flow 12.3 GPM (46,6 L/mm)
Control Valve 10 spool open center parallel/series
Drive Motor (Two) Axial piston
Slew Motor Orbit motor
System Relief Pressure
Boom, Boom Swing 2500 PSI (172 bar)
Bucket, Arm, Auxiliary 2500 PSI (172 bar)
Blade 3820 PSI (263 bar)
Slew Relief Pressure 1700 PSI (117 bar)
Joystick Pressure 428 PSI (30 bar)
Arm Port Relief Base And Rod End 2900 PSI (200 bar)
Boom Port Relief Base End
And Rod End 3335 PSI (230 bar)
Bucket Port Relief Base End 2900 PSI (200 bar)
Rod End 3335 PSI (230 bar)
Main Hydraulic Filter Bypass 50 PSI (3,5 bar)
Case Drain Filter Bypass 20 PSI (1,4 bar)
Hydraulic Cylinders
Cylinder Bore Rod Stroke

Boom (Cushion Up) 3.00 in. (76,2 mm) 1.62 in. (41,3 mm) 18.68 in. (423,7 mm)
Arm (Cushion Retract) 3.00 in. (76,2 mm) 1.5 in. (38,1 mm) 19.11 in. (485,4 mm)
Bucket 2.5 in. (63,5 mm) 1.5 in. (38,1 mm) 18.34 in. (465,8 mm)
Boom Swing (Cushion Left/Right) 2.38 in. (60,3 mm) 1.38 in. (34,9 mm) 15.75 in. (400 mm)
Blade 2.75 in. (69,9 mm) 1.50 in. (38,1 mm) 7.68 in. (195 mm)

Hydraulic Cycle Times
Bucket Curl 2.0 seconds

Bucket Dump 1.5 seconds
Arm Retract 3.0 seconds
Arm Extend 2.2 seconds
Boom Raise 3.4 seconds
Boom Lower 4.5 seconds
Boom Swing Left 5.8 seconds
Boom Swing Right 5.1 seconds
Blade Raise 2.4 seconds
Blade Lower 2.4 seconds
Slew 9.2 RPM
Drive System
Travel Motor Each track is driven by axial piston motor

Drive Reduction 44.3:1 two stage planetary
Max Draw Bar Pull (theoretical @ 5480 lbf (24376 N)
90% efficiency)
Undercarriage
Crawler Tractor Design

Rollers Sealed rollers with box section track roller frame
Track Adjusters Grease type track adjusters with shock absorbing recoil spring

Track
Width 12.6 in. (320 mm)

Number of shoes (steel track) 37
Number of rollers 3
325 Ground Pressure
Rubber Track 4.12 PSI (0,284 bar)
Steel Track 4.22 PSI (0,291 bar)
325 with Long Arm Option &
328 Ground Pressure
Rubber Track 4.12 PSI (0,284 bar)
Steel Track 4.22 PSI (0,291 bar)
Electrical
Alternator 12 volts, 40 Amp open frame w/ internal regulator

Battery 12 volts negative ground
12 volts 500 CCA @ 0° F (-18° C),
75 min. reserve capacity
Starter 12 volts gear reduction 1.9 HP (1,4 kW)

ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Fuel Injection Nozzles
Opening Pressure 2702 - 2916 PSI (187 - 201 bar)

Fuel Tightness Nozzle Seat Dry Nozzle at 1850 PSI (127,6 bar)
Fuel Injection Pump
Fuel Tightness Plunger 10 sec: initial pressure 1849 PSI (12,75 bar)
Allowable Limit 5 seconds
Injection Timing 15.5 - 17 degrees B.T.D.C.
Cylinder Head
Cylinder Head Surface Distortion 0.002 (0,05) in 19.70 (500) Max.

Top Clearance (Piston to Head) 0.0227 - 0.0265 (0.575 - 0.675)
Compression 470 - 540 PSI (32 - 37 bar) @ 290 RPM
Allowable Limit 370 PSI (26 bar) @ 290 RPM
Allowable Difference Between Cylinders 10% or less
Valves
Valve Seat Width (Intake & Exhaust) 0.0835 (2,12)

O.D. of Valve Stems 0.3134 - 0.3140 (7,96 - 7,98)
I.D. of Valve Guides 0.3156 - 0.3161 (8,015 - 8,03)
Clearance Between Valve Stem & Guide 0.0016 - 0.0027 (0,04 - 0,07)
Allowable Limit 0.0039 (0,1)
Valve Clearance (Cold) 0.007 - 0.0087 (0,18 - 0,22)
Valve Recessing (Protrusion) 0.002 (0,05)
(Recess) 0.006 (0,15)
Allowable Limit (Recess) 0.0157 (0,4)
Valve Seat Angle (Int.) 60 degrees
Valve Seat Angle (Exh.) 45 degrees

ENGINE SPECIFICATIONS (CONT’D)
parentheses.
Valve Springs
Free Length 1.65 - 1.661 (41,7 - 42,2)

Fitted Length 1.378 (35,0)
Compress to Fitted Length 26.5 lb. (118 N)
Allowable Limit 22.5 lb. (100,0 N)
Inclination Allowable Limit 0.039 (1,0)
Valve Timing
Intake Valve (Open) 12 degrees B.T.D.C.

(Close) 36 degrees A.B.D.C.
Exhaust Valve (Open) 57 degrees B.B.D.C.
(Close) 12 degrees A.T.D.C.
Rocker Arms
O.D. of Rocker Arm Shaft 0.5501 - 0.5506 (13,97 - 13,98)

I.D. of Rocker Arm 0.5512 - 0.5520(14,0 - 14,02)
Clearance Between Rocker Arm & Shaft 0.0006 - 0.0018 (0,02 - 0,05)
Camshaft
Journal O.D. 1.572 - 1.573 (39,93 - 39,95)

Cylinder Block Bore I.D. 1.575 - 1.576 (40,0 - 40,025)
Oil Clearance 0.002 - 0.0036 (0,05 - 0,091)
Alignment Allowable Limit 0.0004 (0,01)
Cam Lobe Height 1.335 (33,9)
End Clearance 0.0028 - 0.0087 (0,07 - 0,22)
Tappet
Clearance Between Tappet & Guide 0.0008 - 0.0024 (0,02 - 0,062)

Tappet O.D. 0.943 - 0.944 (23,96 - 23,98)
Tappet Guide I.D. 0.945 - 0.946 (24,0 - 24,021)

parentheses.
Cylinders
Cylinder Bore I.D. (Standard) 3.42519 - 3.42606 (87,00 - 87,022)

Allowable Limit (Standard) +0.0059 (+0,15)
Cylinder Bore I.D. (Oversize) 3.43503 - 3.43590 (87,250 - 87,272)
Allowable Limit (Oversize) +0.0059 (+0,15)
Piston Rings
Ring Gap (Top) 0.009 - 0.015 (0,25 - 0,40)

Ring Gap (2nd Ring) 0.012 - 0.017 (0,30 - 0,45)
Ring Gap (Oil Ring) 0.0098 - 0.0177 (0,25 - 0,45)
Allowable Limit (All Rings) 0.05 (1,25)
Side Clearance of Ring Groove:
Top Ring & 2nd Ring 0.0037 - 0.005 (0,093 - 0,13)
Oil Ring 0.008 - 0.0023 (0,2 - 0,06)
Pistons
Piston Pin Bore 0.984 - 0.985 (25,0 - 25,013)

Connecting Rods
Piston Pin O.D. 0.984 - 0.985 (25,0 - 25,011)

Small End Bushing I.D. 0.985 - 0.986 (25,025 - 25,04)
Clearance Between Piston Pin & Small End Bushing 0.0006 - 0.0015 (0,014 - 0,038)
Connecting Rod Alignment Limit Permitted 0.002 (0,05)
Oil Pump
Oil Pressure at Rated RPM 43 - 64 PSI (2,9 - 4,4 bar)

Allowable Limit 36 PSI (2,48 bar)
Idle Speed Allowable Limit 7 PSI (0,48 bar)
Clearance Between Inner Rotor & Outer Rotor 0.0012 - 0.0055 (0,03 - 0,14)
Outer Rotor & Pump Body 0.0044 - 0.0075 (0,11 - 0,19)
End Clearance Between Inner Rotor & Cover 0.0041 - 0.0059 (0,105 - 0,15)

parentheses.
Crankshaft
Crankshaft Alignment Allowable Limit 0.008 (0,02)

Oil Clearance Between Journal & Bearing #1 0.0016 - 0.0046
(0,04 - 0,118)
Journal O.D. #1 2.3591 - 2.3598
(59,921 - 59,940)
Bearing I.D. #1 2.3614 - 2.3637
(59,980 - 60,039)
Oil Clearance Between Journal & Bearing #2 0.0016 - 0.0041
(0,04 - 0,104)
Journal O.D. #2 2.3591 - 2.3598
(59,921 - 59,940)
Bearing I.D. #2 2.3614 - 2.3632
(59,980 - 60,025)
Oil Clearance Between Crank Pin & Bearing 0.001 - 0.0034
(0,025 - 0,087)
Crank Pin O.D. 1.8488 - 1.8494 (46,96 - 46,98)
Crank Pin Bearing I.D. 1.850 - 1.852
(47,0 - 47,05)
Crankshaft Side Clearance 0.006 - 0.012
(0,15 - 0,31)
Timing Gear
Timing Gear Backlash

Crank Gear - Idle Gear 0.0016 - 0.0044 (0,042 - 0,112)
Idle Gear - Cam Gear 0.0016 - 0.0045 (0,042 - 0,115)
Idle Gear - Injection Pump Gear 0.0016 - 0.0045 (0,042 - 0,115)
Crank Gear - Oil Pump Gear 0.0016 - 0.0043 (0,042 - 0,109)
Clearance Between Idle Gear Shaft & Idle Gear Bushing 0.001 - 0.0025 (0,025 - 0,066)
Idler Gear Side Clearance 0.005 - 0.019 (0,12 - 0,48)

parentheses.
Thermostat
Valve Opening Temperature 157° - 162° F (70° - 73° C)

Valve Fully Open 185° F (85° C)
Engine Bolt Torque
ft.-Lb. N•m
Camshaft Retainer Plate Bolts 18 - 20 24 - 27
* Connecting Rod Bolts 33 - 36 44 - 49
* Crankshaft Nut 101 - 116 137 - 157
* Cylinder Head Bolts 69 - 72 93 - 98
* Flywheel Bolts 72 - 80 98 - 108
Fuel Camshaft Retainer Bolts 5-6 6,8 - 8,1
Fuel Injection Tubeline Fittings 11 - 18 15 - 25
Glow Plugs 15 - 18 20 - 25
* Idler Gear Shaft Bolt 18 - 20 24 - 27
Injection Nozzle Clamp 19 - 21 26 - 29
Injection Pump Mounting Nuts 18 - 20 24 - 27
* Main Bearing Bolts 51 - 54 69 - 73
* Main Bearing Case Bolts 34 - 37 46 - 50
Oil Switch 11 - 15 15 - 20
Rear Bearing Case Cover Bolts 17 - 20 23,5 - 27,5
* Lightly Oiled Threads

ENGINE SPECIFICATIONS (CONT’D) 1. 0.1299 - 0.1457 in. (3,3 - 3,7 mm) radius.
Crankshaft Re-Grind Data 2. 0.1102 - 0.1260 in. (2,8 - 3,2 mm) radius.
If the standard size bearing cannot be used due to 3. Chamfer the oil hole circumference to 0.04 - 0.06 in.
excessive wear of the crankpin and crank journal use (1,0 - 1,5 mm) radius with an oil stone.
undersize or oversize bearings.
4. The crankpin must be fine finished to higher than
For undersize or oversize bearing use, follow the (0,8S).
precautions noted below.
5. The crank journal must be fine-finished to higher than
Figure SPEC-20-3 (0,8S).
6. The crank journal side surface must be fine-finished

to higher than (0,8S).
PI-10026A
Grind the crankpin and journal with a wheel which has

specified round corner and width without shoulder
[Figure SPEC-20-3].
SIZE CODE NO. NAME OF BEARING BEARING MARK CRANKSHAFT PROCESSING DIM.
-0.008 in. 1A091-23911 Crankshaft Bearing 1 020 US A 2.0363 - 2.037 in.
(0,2 mm) 0.008 in. minus (0,2 minus) (51,721 - 51,74 mm)
-0.008 in. 1A091-23931 Crankshaft Bearing 2 020 US
(0,2 mm) 0.008 in. minus (0,2 minus)
-0.016 in. 1A091-23921 Crankshaft Bearing 1 040 US A 2.0284 - 2.0291 in.
-0.016 in. 1A091-23941 Crankshaft Bearing 2 040 US
(0,4 mm) 0.016 in. minus (0,4 minus)
-0.008 in. 17331-22970 Crank Pin Bearing 020 US B 1.8409 - 1.8415 in.
-0.016 in. 17331-22980 Crank Pin Bearing 040 US B 1.8330 - 1.8337 in.
+0.008 in. 1A091-23951 Thrust Bearing 1 - 0.008 in. 020 OS C 1.0315 - 1.0335 in.
(+0,2 mm) plus (0,2 mm plus) (26,20 - 26,25 mm)
1A091-23971 Thrust Bearing 2 - 0.008 in.
plus (0,2 mm plus)
+0.016 in. 1A091-23961 Thrust Bearing 1 - 0.016 in. 040 OS C 1.0394 - 1.0413 in.
(+0,4 mm) plus (0,4 mm plus) (26,4 - 26,45 mm)
1A091-23981 Thrust Bearing 2 - 0.016 in.
plus (0,4 mm plus)

TORQUE SPECIFICATIONS
Torque for General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

in.-lb. (N•m) 0.250 80 - 90 (9,0 - 10,2) 110 - 120 (12,4 - 13,6)
0.3125 180 - 200 (20,3 - 22,6) 215 - 240 (24,2 - 27,1)
ft.-lb. (N•m) 0.375 25 - 28 (34 - 38) 35 - 40 (47 - 54)
0.4375 40 - 45 (54 - 61) 60 - 65 (81 - 88)
0.500 65 - 70 (88 - 95) 90 - 100 (122 - 136)
0.5625 90 - 100 (122 - 136) 125 - 140 (170 - 190)
0.625 125 - 140 (170 - 190) 175 - 190 (240 - 260)
0.750 220 - 245 (300 - 330) 300 - 330 (410 - 450)
0.875 330 - 360 (450 - 490) 475 - 525 (645 - 710)
1.000 475 - 525 (645 - 710) 725 - 800 (985 - 1085)
1.125 650 - 720 (880 - 975) 1050 - 1175 (1425 - 1600)
1.250 900 - 1000 (1200 - 1360) 1475 - 1625 (2000 - 2200)
1.375 1200 - 1350 (1630 - 1830) 2000 - 2200 (2720 - 2980)
1.500 1500 - 1650 (2040 - 2240) 2600 - 2850 (3530 - 3870)
1.625 2000 - 2800 (2720 - 2980) 3450 - 3800 (4680 - 5150)
1.750 2500 - 2750 (3390 - 3730) 4300 - 4800 (5830 - 6500)
1.875 3150 - 3500 (4270 - 4750) 5500 - 6100 (7450 - 8300)
2.000 3800 - 4200 (5150 - 5700) 6500 - 7200 (8800 - 9800)

TORQUE SPECIFICATIONS (CONT’D)
Torque For General Metric Bolts
GRADE STANDARD SCREW AND BOLT SPECIAL SCREW AND BOLT
4 7
NOMINAL
UNIT N•m KFG M ft.-lb. N•m KFG M ft.-lb.
DIAMETER
M6 7,9 - 9,3 0.80 - 0.95 5.8 - 6.9 9,8 - 11,3 1.00 - 1.15 7.23 - 8.32
M8 18 - 20 1.8 - 2.1 13.0 - 15 24 - 27 2.4 - 2.8 18 - 20
M10 40 - 45 4.0 - 4.6 29 - 33 49 - 55 5.0 - 5.7 37 - 41
M12 63 - 72 6.4 - 7.4 47 - 53 78 - 90 7.9 - 9.2 58 - 66

HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-Ring Fitting
O-ring Face Seal Connection Figure SPEC-40-5
IMPORTANT Nut Nut

Washer
clean the work area before disassembly and keep all Washer
parts clean. Always use caps and plugs on hoses, O-ring
damage the system. O-ring
I-2003-0888
Figure SPEC-40-4
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [Figure SPEC-40-
5].
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
B-7575 Replace hoses which show signs of wear, damage or

weather cracked rubber.
When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use Vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-40-4].

HYDRAULIC CONNECTION SPECIFICATIONS
(CONT’D)
Flare Fitting
Use the following procedure to tighten the flare fitting:
Figure SPEC-40-6
TS-1619
Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-40-6].
Use the chart below to find the correct tightness needed

(Item 2) [Figure SPEC-40-6]. If the fitting leaks after
tightening, disconnect and inspect the seat area for
damage.
FLARE FITTING TIGHTENING TORQUE
TUBELINE TORQUE NEW ROTATE RE-ASSEMBLY

WRENCH SIZE OUTSIDE THREAD SIZE ft.-lb. NO. OF HEX ROTATE NO. OF
DIAMETER (N•m) FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4

HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the O-ring flare
(CONT’D) fitting.
O-ring Flare Fitting Figure SPEC-40-8
Figure SPEC-40-7 Hex Flat Tightening Method
Primary O-Ring Flare

Seal
1
Secondary TS-1619
Seal
P13009
Tighten the nut until it contacts with the seat. Make a
mark across the flats of both the male and female parts of
The flare is the primary seal, the O-ring is the secondary the connection (Item 1) [Figure SPEC-40-8].
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-7]. Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC-40-8]. If the fitting leaks after
If necessary, the O-ring-flare fitting can be used without tightening, disconnect it and inspect the seat area for
an O-ring.
O-RING FLARE FITTING TIGHTENING TORQUE
** ***
TUBELINE TORQUE
NEW ROTATE RE-ASSEMBLY
WRENCH SIZE OUTSIDE THREAD SIZE ft.-lb.
NO. OF HEX ROTATE NO. OF
DIAMETER (N•m)
FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4
* If a torque wrench is used to tighten a new fitting to a ** If using the hex flat tightening method to tighten a new
used hose/tubeline. fitting to a new hose/tubeline.
* If a torque wrench is used to tighten a used fitting to a ** If using the hex flat tightening method to tighten a new
new hose/tubeline. fitting to a used hose/tubeline.
* If a torque wrench is used to tighten a new fitting to a new *** If using the hex flat tightening method to tighten a used
hose/tubeline. fitting to a new hose/tubeline.

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-40-10
(CONT’D)
O-ring Flare Fitting (Cont'd)
NOTE: O-ring flare fittings are not recommended in all 2

applications. Use the standard flare fittings in
these applications.
Do not use a O-ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing.
Figure SPEC-40-9 1
P13573
Copper Bonnet Orifice Always remove the O-ring (Item 1) [Figure SPEC-40-10]
from the flare face as shown.
An O-ring (Item 2) [Figure SPEC-40-10] is added to the

flat boss of the fitting to seal the connection in this
application.
P13572
Use a standard flare fitting (Item 1) [Figure SPEC-40-9]

as shown.
When a O-ring flare fitting is used as a straight thread

port adapter the O-ring flare face is not used to seal. The
O-ring may come off the fitting and enter the system.

HYDRAULIC CONNECTION SPECIFICATIONS Do not over tighten the port seal fitting.
(CONT'D)
Port Seal Fitting PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE
Figure SPEC-40-11 FITTING NUT THREAD SIZE TORQUE ft.-lb.
WRENCH SIZE (N•m) (N•m)
11/16" 9/16" - 18 22 (30)
15/16" 3/4" - 16 40 (54)
1-1/8" 7/8" - 14 60 (81)
1-1/4" 1-1/16" - 12 84 (114)
1-1/2" 1-5/16" - 12 118 (160)
NOTE: If a torque wrench cannot be used, use the hex

flat tightening method as an approximate
guideline.
Nut Seals to
Fitting NOTE: Port seal fittings are not recommended in all
applications. Use O-ring boss fittings in these
applications.
Nut Seals to Figure SPEC-40-12

Port
Secondary
O-Ring Seal
P13008
1
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC-40-11].
P13571
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Do not use port seal fittings when a thread in orifice (Item
Use the following procedure to tighten the port seal 1) [Figure SPEC-40-12] is used in the port. The orifice
fitting: may interfere with the fitting and prevent it from sealing.
Port seal and nut, washer and O-ring (O-ring Boss) Use an O-ring boss fitting (Item 1) [Figure SPEC-40-12]
fittings use the same tightening torque chart. as shown.
If a torque wrench cannot be used, use the following

method.
Tighten the nut until it just makes metal to metal contact,

you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.

HYDRAULIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18° C) are
common, the excavator must be kept in a warm building.
Specifications Extra warm-up time must be used each time the
excavator is started during cold temperature conditions.
Use only Bobcat hydraulic fluid. Cold fluid will not flow easily and it makes action of the
hydraulic function slower. Loss of fluid flow to the
DO NOT use automatic transmission fluids in the hydraulic pump can cause damage in less than 60
excavator or permanent damage to the hydraulic system seconds.
will result.
Bobcat hydraulic fluid is available in:
• 2.5 Gal. (9,5 L) qty 2 (P/N 6903117) WARNING

• 55 Gal. (208 L) (P/N 6903119)
During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
• 5 Gal. (18,9 L) (P/N 6903118)
five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
WARNING When temperatures are below -20°F (-30°C), the
hydrostatic oil must be heated or kept warm. The
AVOID INJURY OR DEATH hydrostatic system will not get enough oil at low
Diesel fuel or hydraulic fluid under pressure can temperatures. Park the machine in an area where the
penetrate skin or eyes, causing serious injury or temperature will be above 0°F (-18°C) if possible.
death. Fluid leaks under pressure may not be visible. W-2027-1285
enters skin or eyes, get immediate medical attention
W-2072-0807

FUEL, COOLANT AND LUBRICANTS
Chart
Use this chart for correct selection of Fuel, Coolant and Lubricants.
RECOMMENDED SAE VISCOSITY NUMBER CAPACITY

RESERVOIR KIND OF FLUID
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE) REFILL
Engine oil w/ filter *Use SAE 5.6 qt. (1.5 g)
Viscosity Number
as Listed With
API Classification
CD or Better
Fuel Tank Diesel Fuel Temp. F× No. 2 No.1 14.1 gal. (53,3 L)
No. 2-D +15× (9×) 100% 0%
(ASTM D975) Down to -20× (-29×) 50% 50%
Below -20× (-29×) 0% 100%
Cooling System **Coolant Mixture 4.5 Gal. (17,0 L)
Hydraulic Tank Bobcat Fluid P/N 6903117 - 2.5 Gal. (9,5 L) Tank Cap. 9.7 Gal.
P/N 6903118 - 5 Gal. (18,9 L) (18,2 L)
P/N 6903119 - 55 Gal. (208 L)
Travel Motor Gear Lube SAE-90W 0.55 qt. (0,5 L)
(each)
*ENGINE OIL SPECIFICATIONS ** COOLANT MIXTURE
When fuel sulphur content is less than 0.5% change the Propylene Glycol (Factory Installed)
engine oil and filter as shown See Service Schedule.
(See SERVICE SCHEDULE on Page 10-50-1.) Add premixed coolant; 47% water and 53% propylene
glycol to the recovery tank if the coolant level is low.
Change engine oil and filter according to the following
chart if fuel sulphur content is above 0.5%. Use one gallon and one pint of propylene glycol mixed
with one gallon of water is the correct mixture of coolant
FUEL SULPHUR CHANGE INTERVAL OF to provide a -34°F (-37°C) freeze protection.
CONTENT ENGINE & OIL FILTER
Use a refractometer to check the condition of propylene
0.5 to 1.0% 1/2 of Regular Interval glycol in the cooling system.
Above 1.0% 1/4 of Regular Interval

CONVERSIONS
Decimal And Millimeter Equivalents

CONVERSIONS (CONT’D)
U.S. To Metric Conversion

ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: 325 / 328 - 1

Date: 5 May 2009
Product: Bobcat Excavator
Model: 325 / 328
Manual No: 6986940 (5-09)
The following Sections are a revision to the above Service Manual.
COVER 70-01
MAINTENANCE SAFETY
ALPHABETICAL INDEX SPEC-01
FOREWORD
10-01
20-01
HYDRAULIC / HYDROSTATIC SCHEMATICS
20-30
20-32
20-50
20-220
30-01
30-30
30-70
40-01
40-171 ADDED
50-01
60-01
60-50
Printed in U.S.A.
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: 325 / 328 - 2

Date: 25 September 2009
Product: Bobcat Excavator
Model: 325 / 328
Manual No: 6986940 (10-09)
The following Sections are a revision to the above Service Manual.
COVER
30-30
30-70
Printed in U.S.A.

325-328 6986940 SM 10-09

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Service Manual

325/328 Compact Excavator

325 S/N AAC511001 & Above

6986940 (10-09) Printed in U.S.A. © Bobcat Company 2009

CORRECT CORRECT CORRECT

P-90216 B-19964 B-19959

B-19965 B-19960 B-19966

WRONG WRONG WRONG

B-19962 B-19958 B-19798

AIR CLEANER ............................................. 10-01, 60-01 FUEL TANK .............................................................40-01

DELUXE INSTRUMENT PANEL SETUP................ 50-01 MAIN RELIEF VALVES............................................20-01

ELECTRICAL SYSTEM INFORMATION ................ 50-01 OIL COOLER...........................................................20-01

Continued On Next Page

325/328 Service Manual

SEAT BELT ............................................................ 10-01

TAILGATE .....................................................10-01, 40-01

325/328 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV HYDRAULIC

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . VIII

BOBCAT EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . X UPPERSTRUCTURE

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

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

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

HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 HEATER

I 325/328 Service Manual

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

3. The seat belt must be 11. Check hydraulic fluid level,

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

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

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

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

II 325/328 Service Manual

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

III 325/328 Service Manual

• The Compact Excavator Operator Training Course is

DANGER available through your local dealer or at

WARNING • The Bobcat compact excavator Safety Video is

IV 325/328 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

V 325/328 Service Manual

Check hydraulic tubes, hoses and fittings for damage

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

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

Do not use the machine where exhaust, arcs, sparks or

Check the spark arrestor exhaust system regularly to

Battery gas can explode and cause serious injury. Use

VI 325/328 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Know where fire extinguishers and first aid kits are

VII 325/328 Service Manual

Always use the serial number of the excavator when Figure 2

Excavator Serial Number

Explanation of Excavator Serial Number:

1. The 4 digit Model/Engine Combination Module number