8612958-Bobcat 442 Mini Excavator Service Repair Manual Download S N 522311001 Above S N 528911001 Above S N 528611001 Above

442
Service Manual
S/N 522311001 & Above S/N 528911001 & Above S/N 528611001 & Above
Printed in U.S.A.
6901801 (11-07)
Bobcat Company 2007
MAINTENANCE SAFETY
WARNING
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operators Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.
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
CORRECT
B-10731a
B-16637
B-16638
Never service the Hydraulic Excavator instructions.
Bobcat without
Use the correct procedure to lift and support the excavator. Always lift the blade fully before installing jackstands.
Cleaning and maintenance are required daily.
WRONG
WRONG
WRONG
B-16672
B-16673
B-16671
Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.
Vent exhaust to outside when engine must be run for service. Exhaust system must be tightly sealed. Exhaust Fumes can kill without warning.
Always lower the bucket and blade to the ground before doing any maintenance. Never modify equipment or add attachments not approved by Bobcat Company.
WRONG
WRONG
WRONG
B-16670
Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust machine with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame.
Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep tailgate closed except for service, Close and latch tailgate before operating the excavator.
B-16669 B-16102
Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.
B-6589 B-16102
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.
MSW23-0805
ALPHABETICAL INDEX ACCUMULATOR..................................................... 20-01 AIR CLEANER ............................................. 10-01, 60-01 AIR CONDITIONING COMPRESSOR BELT.......... 10-01 AIR CONDITIONING SERVICE.............................. 70-01 AIR CONDITIONING SYSTEM FLOW ................... 70-01 ALTERNATOR ........................................................ 50-01 ALTERNATOR BELT............................................... 10-01 ARM ........................................................................ 40-01 ARM CYLINDER ..................................................... 20-01 AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE..... 20-01 AUXILIARY HYDRAULIC FLOW CONTROL VALVE ............................................... 20-01 AUXILIARY HYDRAULICS SELECTOR VALVE..... 20-01 BASIC TROUBLESHOOTING ................................ 70-01 BATTERY................................................................ 50-01 BATTERY DISCONNECT SWITCH........................ 50-01 BLADE .................................................................... 30-01 BLADE CYLINDER ................................................. 20-01 BLADE FLOAT VALVE ............................................ 20-01 BLADE VALVE ........................................................ 20-01 BOOM ..................................................................... 40-01 BOOM CYLINDER .................................................. 20-01 BOOM LOAD HOLDING VALVE............................. 20-01 BOOM OFFSET CYLINDER................................... 20-01 BOOM OFFSET VALVE.......................................... 20-01 BUCKET ................................................................. 40-01 BUCKET CYLINDER .............................................. 20-01 CAB......................................................................... 40-01 CAB TILT PROCEDURE......................................... 10-01 COMPONENTS ...................................................... 70-01 COMPRESSOR ...................................................... 70-01 CONDENSER ......................................................... 70-01 CONTROL LEVERS ............................................... 40-01 CONVERSIONS ................................................SPEC-01 COOLING SYSTEM................................................ 10-01 COUNTER WEIGHT ............................................... 40-01 DUMP VALVE ......................................................... 20-01 ELECTRICAL SYSTEM INFORMATION ................ 50-01 ENGINE .................................................................. 60-01 ENGINE BOLT TORQUE...................................SPEC-01 ENGINE COMPONENENTS AND TESTING ......... 60-01 ENGINE LUBRICATION SYSTEM.......................... 10-01 ENGINE SPECIFICATIONS...............................SPEC-01 ENGINE SPEED CONTROL .................................. 40-01 EVAPORATOR/HEATER UNIT ............................... 70-01 EXCAVATOR BOLT TORQUE ...........................SPEC-01 EXPANSION VALVE ............................................... 70-01 FAN/FUEL PUMP BELT ..........................................10-01 FLOORMAT .............................................................40-01 FLYWHEEL..............................................................60-01 FRESH AIR FILTER ................................................10-01 FRONT CAB LIGHT ................................................50-01 FUEL COOLANT AND LUBRICANTS............... SPEC-01 FUEL LEVEL SENDER ...........................................50-01 FUEL SYSTEM........................................................10-01 FUEL TANK .............................................................40-01 GENERAL AIR CONDITIONING SERVICE GUIDELINES ..........................................................70-01 GREASE CYLINDER ..............................................30-01 HEATER/AC FAN ....................................................70-01 HEATER COIL/EVAPORATOR................................70-01 HEATER VALVE ......................................................70-01 HORN ......................................................................40-01 HYDRAULIC BREAKER APPLICATION VALVE .....20-01 HYDRAULIC EXCAVATOR SPECIFICATIONS. SPEC-01 HYDRAULIC FILTER MOUNT.................................20-01 HYDRAULIC FLUID SPECIFICATIONS............ SPEC-01 HYDRAULIC GEAR PUMP .....................................20-01 HYDRAULIC PISTON PUMP ..................................20-01 HYDRAULIC PISTON PUMP DRIVE COUPLER....20-01 HYDRAULIC RESERVOIR......................................20-01 HYDRAULIC SYSTEM ............................................10-01 HYDRAULIC SYSTEM INFORMATION ..................20-01 INSTRUMENT PANEL............................................50-01 JOYSTICK CONTROL PATTERN SELECTOR VALVE.....................................................................20-01 JOYSTICK LOCKOUT/TWO SPEED VALVE ..........20-01 LEFT CONSOLE .....................................................40-01 LEFT CONTROL LEVER (JOYSTICK) ...................20-01 LIFTING AND BLOCKING THE EXCAVATOR ........10-01 LIFTING THE EXCAVATOR ....................................10-01 LOWER TRACK ROLLER .......................................30-01 LUBRICATION OF THE EXCAVATOR ....................10-01 MUFFLER................................................................60-01 OIL COOLER...........................................................20-01 OIL TEMPERATURE REGULATOR ........................20-01 OPERATOR CAB ....................................................10-01 PORT RELIEF VALVES...........................................20-01 PRESSURE REDUCING VALVE.............................20-01 PRESSURE SWITCH..............................................70-01
ALPHABETICAL INDEX (CONTD) RADIATOR/OIL COOLER....................................... 60-01 REAR COVER ..............................................10-01, 40-01 RECEIVER/DRYER.................................................70-01 RECONDITIONING THE ENGINE ..........................60-01 REGULAR MAINTENANCE ....................................70-01 RELIEF VALVES......................................................20-01 RIGHT CONSOLE ...................................................40-01 RIGHT CONTROL LEVER (JOYSTICK) .................20-01 RIGHT SIDE COVER ...................................10-01, 40-01 SAFETY...................................................................70-01 SEAT AND SEAT MOUNT.......................................40-01 SECONDARY FRONT AUXILIARY VALVE .............20-01 SERVICE SCHEDULE ............................................10-01 SIX SPOOL HYDRAULIC CONTROL VALVE .........20-01 STARTER ................................................................50-01 SWING BRAKE RELEASE VALVE..........................20-01 SWING BRAKE VALVE ...........................................20-01 SWING FRAME .......................................................40-01 SWING MOTOR ......................................................20-01 SWING MOTOR DRIVE CARRIER .........................20-01 SWIVEL JOINT........................................................20-01 SYSTEM CHARGING AND RECLAMATION ..........70-01 SYSTEM TROUBLESHOOTING CHART ...............70-01 TEMPERATURE/PRESSURE .................................70-01 THERMOSTAT.........................................................70-01 THREE SPOOL HYDRAULIC CONTROL VALVE...20-01 TORQUE SPECIFICATIONS FOR BOLTS........ SPEC-01 TRACK DAMAGE IDENTIFICATION.......................30-01 TRACK FRAME .......................................................30-01 TRACK IDLER .........................................................30-01 TRACKS ..................................................................30-01 TRANSPORTING THE EXCAVATOR......................10-01 TRAVEL LEVER/FOOT PEDAL VALVE ..................20-01 TRAVEL MOTOR..........................................10-01, 20-01 TROUBLESHOOTING.............................................60-01 TWO SPEED SWITCH ............................................50-01 UPPER TRACK ROLLER........................................30-01 UPPERSTRUCTURE ..............................................40-01 UPGRADED AIR CONDITIONING SYSTEM ..........70-01 WIPER MOTOR.......................................................50-01
CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX BOBCAT EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . XI SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 UNDERCARRIAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 UPPERSTRUCTURE & SWING SECTION . . . . . . . . . . . . . . . . 40-01 ELECTRICAL SYSTEM AND ANALYSIS . . . . . . . . . . . . . . . . . . 50-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01 HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 70-01 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
UNDERCARRIAGE UPPERSTRUCTURE & SWING SECTION ELECTRICAL SYSTEM AND ANALYSIS ENGINE SERVICE
HVAC
SPECIFICATIONS
442 Excavator Service Manual
II
FOREWORD
This manual is for the Bobcat Hydraulic Excavator mechanic. It provides necessary servicing and adjustment procedures for the hydraulic 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 hydraulic excavator has had service or repair:
1. Check that the ROPS/TOPS/ FOPS is in good condition and is NOT modified.
9. Safety treads must be in good condition.
2. Check that ROPS mounting hardware is tightened and is Bobcat approved.
10. Check for correct function of indicator lamps (Optional on some models.
3. The seat belt must be correctly installed, functional and in good condition.
11. Check hydraulic fluid level, engine oil level and fuel supply.
4. Inspect for loose or broken parts or connections.
12. Inspect for fuel, hydraulic fluid leaks.
oil
or
5. Machine signs must be legible and in the correct location.
13. Lubricate the excavator.
6. Steering levers, control levers and foot pedals must return to neutral. Check that foot pedals lock and control lever locks are in working order. 7. Inspect the air cleaner for damage or leaks. Check the condition of the element.
14. Check the condition of the battery and cables.
Recommend to the owner 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 know to the state of California to cause cancer, birth defects and other reproductive harm.
8. Check the electrical charging system.
III
IV
SAFETY INSTRUCTIONS
Safety Alert Symbol

This symbol with a warning statement means: Warning, be alert! Your safety is involved! Carefully read the message that follows.
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments: The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition. 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 be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer. Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer. An Operators Handbook fastened to the operator cab. Its brief instructions are convenient to the 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. The AEM Safety Manual delivered with the machine gives general safety information. The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work. The Compact Excavator Operator Training Course is available through your local dealer or at www.training.bobcat.com or www.bobcat.com. This course is intended to provide rules and practices of correct operation of the Bobcat excavator. The course is available in English and Spanish versions. 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. The Bobcat compact excavator Safety Video is available from your Bobcat dealer or at www.training.bobcat.com or www.bobcat.com.
WARNING
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operators Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.
W-2003-0903
WARNING
Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.
W-2044-1285
IMPORTANT
This notice identifies procedures which must be followed to avoid damage to the machine.
I-2019-0284
SI EXC-1007 SM
SAFETY INSTRUCTIONS (CONTD) 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-1007 SM
VI
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 The machine and some attachments have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is 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. The operators area, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating. All fuels, most lubricants and some coolants mixtures are flammable. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire. Operation Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases. Electrical
Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents. Fueling
Stop the engine and let it cool before adding fuel. No smoking! Do not refuel a machine near open flames or sparks. Fill the fuel tank outdoors. Starting Do not use ether or starting fluids on any engine that has glow plugs. These starting aids can cause explosion and injure you or bystanders. Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.
Spark Arrestor Exhaust System The spark arrestor exhaust system is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still 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 staring. 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-1007 SM
VII
FIRE PREVENTION (CONTD) 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-1007 SM
VIII 442 Excavator Service Manual
SERIAL NUMBER LOCATIONS Always use the serial number of the excavator when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation. Excavator Serial Number Figure 1
Engine Serial Number Figure 2
S/N 522311001 & Above
P-32601
Figure 3 1
P-56394
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 Module 2. - Production Sequence (Series) Module 1. - Model / Engine Combination 1. The four digit Model/Engine Combination Module number identifies the model number and engine combination. 2. The five digit Production Sequence Number identifies the order which the excavator is produced. The engine serial number (Item 1) [Figure 2] & [Figure 3] is located on the engine in the locations shown.
S/N 528911001 & Above S/N 528611001 & Above
P-56395
IX
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].
BOBCAT EXCAVATOR IDENTIFICATION ARM CYLINDER OPERATOR HANDBOOK ARM BOOM OPERATOR SEAT With SEAT BELT GRAB HANDLE
RETURN TO TANK COUPLER AUXILIARY COUPLERS BUCKET

CYLINDER
BOOM CYLINDER
BUCKET
BLADE CYLINDER
P-16589
RIGHT SIDE COVER REAR COVER
AUXILARY COUPLERS
UPPERSTRUCTURE
BLADE
TRACK
TRACK FRAME
B-16590
XI
XII
SAFETY AND MAINTENANCE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 Daily Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 Replacing The Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 AIR CONDITIONING COMPRESSOR BELT (S/N 522311001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 AIR CONDITIONING COMPRESSOR BELT (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) . . . . . . . . . . . . . . . 10-151-1 Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-151-1 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 Adjusting Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1 CAB TILT PROCEDURE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1 Installing The Cab Tilt Hinges . . . . . . . . . . . . . . . . . . . . . 10-160-1 Tilting The Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-2 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Coolant Level (S/N 522311001 & Above) . . . . . Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . Replacing The Coolant (S/N 522311001 & Above) . . . . . . 10-70-1 10-70-1 10-70-1 10-70-2
DRIVE SYSTEM
ELECTRICAL SYSTEM & ANALYSIS ENGINE SERVICE
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . 10-90-1 Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1 Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2 FAN/FUEL PUMP BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1 Adjusting Belt Tension (S/N 522311001 & Above). . . . . . 10-140-1 FRESH AIR FILTER (S/N 522311001 & ABOVE) . . . . . . . . . . 10-61-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1 FRESH AIR FILTER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62-1
SPECIFICATIONS
Continued On Next Page
10-01
SAFETY AND MAINTENANCE (CONTD) FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 Draining The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-8 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 Fuel Filter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-7 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 Pre-Filter Installation (S/N 522311001 & Above) . . . . . . . . . . . . . . . . 10-80-4 Pre-Filter Removal (S/N 522311001 & Above) . . . . . . . . . . . . . . . . . 10-80-3 Pre-Filter Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-6 Removing Water From The Pre-Filter (S/N 522311001 & Above) . . . 10-80-2 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 Checking And Adding Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 Diagnostic Couplers (S/N 522311001 & Above) . . . . . . . . . . . . . . . 10-100-9 Diagnostic Couplers (S/N 528911001 & Above And S/N 528611001 & Above) 10-100-10 Hydraulic Filter Installation (S/N 522311001 & Above) . . . . . . . . . . 10-100-4 Hydraulic Filter Installation (S/N 528911001 & Above And S/N 528611001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-7 Hydraulic Filter Removal (S/N 522311001 & Above) . . . . . . . . . . . . 10-100-3 Hydraulic Filter Removal (S/N 528911001 & Above And S/N 528611001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-6 Replacing The Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2 LIFTING AND BLOCKING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . 10-10-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 LIFTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11-1 LUBRICATION OF THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2 Entering And Exiting The Excavator . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Raising And Lowering The Left Console . . . . . . . . . . . . . . . . . . . . . . 10-20-1 REAR COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1 Opening And Closing The Rear Cover . . . . . . . . . . . . . . . . . . . . . . . 10-40-1 RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41-1 Opening And Closing The Right Side Cover . . . . . . . . . . . . . . . . . . . 10-41-1
10-02
SAFETY AND MAINTENANCE (CONTD) SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 TRANSPORTING THE EXCAVATOR . . . . . . . . . . . . . . . . . . . . 10-30-1 TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1 Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1 Draining The Travel Motor . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
10-03
10-04
LIFTING AND BLOCKING THE EXCAVATOR Procedure Always park the machine on a level surface.
Figure 10-10-1
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
P-32889
WARNING
AVOID INJURY OR DEATH Keep fingers and hands out of pinch points when checking the track tension.
W-2142-0189
Figure 10-10-2
1 Raise one side of the machine (approximately 4 inches) using the boom and arm.
P-32888
Raise the blade fully and install jackstands (Item 1) [Figure 10-10-1] & [Figure 10-10-2] under the blade and the track frame. Lower the machine until all machine weight is on the jackstands. Stop the engine.
10-10-1
10-10-2
LIFTING THE EXCAVATOR Procedure
Figure 10-11-2
WARNING
AVOID INJURY OR DEATH Use a lifting fixture with sufficient capacity for the weight of the excavator plus any added attachments. Maintain center of gravity and balance when lifting. Do not swing boom or upperstructure. Never lift with operator on machine.
W-2434-0502
B-16594
Figure 10-11-1 2
Fasten chains to the ends of the blade (Item 1) [Figure 10-11-1] & [Figure 10-11-2] and up to a lifting fixture above the cab. The lifting fixture must extend over the sides of the cab to prevent the chains from hitting the cab [Figure 10-11-2]. Fasten a chain to the boom (Item 2) [Figure 10-11-1] & [Figure 10-11-2] and up to a lifting fixture.
P-32909
Fully retract the boom cylinder and fully extend the arm and bucket cylinders so the excavator is in the position as shown [Figure 10-11-1]. Raise the blade all the way. Put all the control levers in neutral. Stop the engine.
10-11-1
10-11-2
OPERATOR CAB Description The excavator has an operator cab as standard equipment.
Raising And Lowering The Left Console Raise the console before exiting the cab. Figure 10-20-2
WARNING
Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat.
W-2069-1299
1 Entering And Exiting The Excavator Figure 10-20-1

P-32906
Pull up on the handle (Item 1) [Figure 10-20-2] The lift spring will assist in raising the console. Lower the console before operating the excavator. Push down on the handle (Item 1) [Figure 10-20-2] until the console is in the down position. NOTE: When the console is raised, the hydraulic and traction systems are locked and will not operate.
P-32904
Use the grab handles and track to enter and exit the excavator [Figure 10-20-1].
10-20-1
OPERATOR CAB (CONTD) Emergency Exit The left door and right side window provide exits. Figure 10-20-3 S/N 522311001 & Above
Figure 10-20-5
P-32908
1 Exit through the window [Figure 10-20-5].
P-32710
Figure 10-20-4 S/N 528911001 & Above S/N 528611001 & Above
P-56400
Press the window latch (Item 1) [Figure 10-20-3] & [Figure 10-20-4] together and slide the window to the rear of the excavator.
10-20-2
TRANSPORTING THE EXCAVATOR 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 transport vehicle. Align the ramps with the center of the transport vehicle. Secure the ramps to the truck bed and be sure ramp angle does not exceed 15 degrees. Use metal loading ramps with a slip resistant surface. Use ramps that are the correct length and width, and can support the weight of the machine. 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).
Figure 10-30-2
P-32598
Figure 10-30-3
1 Figure 10-30-1
P-32603
P-32599
Fasten chains to the front corners of the blade (Item 1) [Figure 10-30-2] and to the tie down loop at the rear track frame (both sides) (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 tie the chain binder levers to prevent loosening.
Move the machine forward onto the transport vehicle [Figure 10-30-1]. Do not change direction of the machine while it is on the ramps. Lower the boom, arm and bucket to the transport vehicle. Stop the engine and remove the key. Put blocks at the front and rear of the tracks.
WARNING
Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.
W-2058-0494
10-30-1
10-30-2
REAR COVER Opening And Closing The Rear Cover
WARNING
AVOID INJURY OR DEATH Never service or adjust the machine when the engine is running unless instructed to do so in the manual.
W-2012-0497
WARNING
Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander.
W-2020-1285
Figure 10-40-1
P-56406
Push the latch (Item 1) [Figure 10-40-1] and raise the rear cover. Lower the rear cover and push down firmly to close the cover. NOTE: The start key can be used to lock the rear cover.
10-40-1
10-40-2
RIGHT SIDE COVER Opening And Closing The Right Side Cover Figure 10-41-2
P-56407
Push the latch (Item 1) [Figure 10-41-2] and raise the right side cover. Lower the right side cover and push down firmly to close the cover. NOTE: The start key can be used to lock the right side cover.
10-41-1
10-41-2
SERVICE SCHEDULE Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat Excavator.
SERVICE SCHEDULE
ITEM Engine Coolant Engine Oil SERVICE REQUIRED Check coolant level. Add coolant as needed. (Water cooled engines only) Check engine oil level and add as needed.
8-10 50
HOURS
100 250 500 1000
Hydraulic Fluid Hoses Tube lines and Check the hydraulic fluid level and add as needed. Check Reservoir Breather Cap for damage and leaks. Repair or replaced as needed. Track Tension Indicators and Lights Operator Cab/Canopy Seat Belt Safety Signs (Decals) Pivot Points Fuel Tank & Filter Control Console Swing Circle & Pinion Door Hinges Battery Belts Travel Motors Check and adjust track tension. Check for correct operation of indicators and lights. Check cab/canopy condition and hardware. Check seat belt condition and mounting hardware Check for damaged signs (decals). Replace as needed. Grease all machinery pivot points. Drain water and sediment from fuel tank and filter. Check control console lockout for proper operation. Grease swing circle and swing pinion. Grease door hinges. Check battery, cables and electrolyte level. Check and adjust bolts. Check oil level in both travel motors.
Hydraulic Oil Cooler, *Engine Oil Clean radiator/oil cooler fins. Clean A/C condenser. Cooler, *Radiator, A/C Condenser and Clean/replace cab filter. Cab Ventilation Filter Hydraulic Filter Engine Oil & Filter Air Filter Intake Alternator & Starter Fuel Filters Engine Valves Travel Motors Engine Cooling System Hydraulic System Replace hydraulic filter. Replace engine oil and filter. Check/clean air filter intake Check alternator and starter connections. Replace diesel fuel pre-filter and filter. Check and adjust engine valve clearance. Replace oil in both travel motors. Drain and flush cooling system. Replace coolant. (Water cooled engines only) Replace hydraulic fluid and filter. Clean reservoir.
If equipped Service at first 50 hours, then as scheduled Service at first 100 hours, then as scheduled 1000 hours or every six months
10-50-1
10-50-2
AIR CLEANER Daily Check See the Service Schedule for the correct service interval. (See SERVICE SCHEDULE on Page 10-50-1.) Figure 10-60-1
Replacing The Filters Outer Filter Unlatch the air filter cover latches (Item 2) [Figure 10-602]. Remove the air filter cover (Item 3) [Figure 10-60-2]. Figure 10-60-3 1
P-32713
If the air filter condition indicator (Item 1) [Figure 10-601] is illuminated, the filter element needs to be replaced. Open the right side cover. (See RIGHT SIDE COVER on Page 10-41-1.) Figure 10-60-2
P-32689
Remove the outer filter (Item 1) [Figure 10-60-3]. Check the housing for damage. Clean the housing and seal surface. Do not use compressed air. Install the outer filter. 2 Install the cover.
2 3 1
P-32688
Inspect the air intake (Item 1) [Figure 10-60-2] for damage or restrictions.
10-60-1
AIR CLEANER (CONTD) Replacing The Filters (Contd) Inner Filter S/N 522311001 & Above Replace the inner filter every third time the outer filter has been replaced. Replace the inner filter after the outer filter has been replaced and the air filter indicator is still illuminated. Remove the air cleaner cover and outer filter. Figure 10-60-4
Figure 10-60-5
P-32691
Install the new inner filter (Item 1) [Figure 10-60-5]. Install the outer filter and air cleaner cover.
P-32690
Pry up on the ends of the air filter (Item 1). Pull the air filter (Item 2) [Figure 10-60-4] out of the housing. Discard the inner air filter after it has been removed. Do not clean or reuse the filter. Make sure all sealing surfaces are free of dirt and debris.
10-60-2
AIR CLEANER (CONTD) Replacing The Filters (Contd) Inner Filter S/N 528911001 & Above and S/N 528611001 & Above Replace the inner filter every third time the outer filter has been replaced. Replace the inner filter after the outer filter has been replaced and the air filter indicator is still illuminated. Remove the air cleaner cover and outer filter. Figure 10-60-6
Figure 10-60-7
P-56409
Install the new inner filter (Item 1) [Figure 10-60-7]. Install the outer filter and air cleaner cover.
1
P-56408
Pull the air filter (Item 1) [Figure 10-60-6] out of the housing. Discard the inner air filter after it has been removed. Do not clean or reuse the filter. Make sure all sealing surfaces are free of dirt and debris.
10-60-3
10-60-4
FRESH AIR FILTER (S/N 522311001 & ABOVE) Removal And Installation See the Service Schedule for the correct service interval. (See SERVICE SCHEDULE on Page 10-50-1.) Figure 10-61-1
Figure 10-61-3
1 2
P-32910
Remove the bolts (Item 1) [Figure 10-61-3]. Remove the filter (Item 2) [Figure 10-61-3].
P-32912
Position the excavator as shown [Figure 10-61-1]. Figure 10-61-2
2 1
P-32911
Remove the eleven bolts (Item 1) [Figure 10-61-2] and washers. Installation: Tighten the bolts to 18-19 ft.-lb. (24-26 Nm) torque. Remove the cover (Item 2) [Figure 10-61-2].
10-61-1
10-61-2
FRESH AIR FILTER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Removal And Installation See the Service Schedule for the correct service interval. (See SERVICE SCHEDULE on Page 10-50-1.) Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 10-62-1
P-58101
Remove the screws (Item 1) and cover (Item 2) [Figure 10-62-1]. Figure 10-62-2
P-58100
Remove the filter (Item 1) [Figure 10-62-2].
10-62-1
10-62-2
COOLING SYSTEM
Figure 10-70-2
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. Engine is running. Tools are being used.
W-2019-1285
Check the cooling system every day to prevent overheating, loss of performance or engine damage. Cleaning The Cooling System Open the right side cover. Use air pressure or water pressure to clean the radiator oil cooler. Be careful not to damage the fins when cleaning. Checking Coolant Level (S/N 522311001 & Above)
P-32844
The surge tank (Item 1) [Figure 10-70-2] must be half full when the engine is cold.
IMPORTANT
AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze. To much antifreeze reduces cooling system efficiency and may cause serious premature engine damage. Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system. Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.
I-2124-0497
WARNING
Do not remove radiator cap when the engine is hot. You can be seriously burned.
W-2070-1285
Open the right side cover. Figure 10-70-1
P-32693
Check the coolant level in the surge tank (Item 1) [Figure 10-70-1].
10-70-1 442 Excavator Service Manual
COOLING SYSTEM (CONTD) Replacing The Coolant (S/N 522311001 & Above) See the Service Schedule for the correct service interval to replace the coolant. (See SERVICE SCHEDULE on Page 10-50-1.)
Figure 10-70-4
WARNING
Do not remove radiator cap when the engine is hot. You can be seriously burned.
W-2070-1285
P-32849
Figure 10-70-3 Remove the plug (Item 1) [Figure 10-70-4] from the back side of the engine block. 1 NOTE: The plug is located next to the alternator mount bracket. Drain the coolant from the engine.
P-32693
When the engine is cool, loosen and remove the radiator cap (Item 1) [Figure 10-70-3].
10-70-2
COOLING SYSTEM (CONT) Replacing The Coolant (S/N 522311001 & Above) (Contd) Figure 10-70-5
Figure 10-70-6
P-32844
Check the coolant level (COLD) in the surge tank (Item 1) [Figure 10-70-6] when cool.
P-32847
Add coolant to the tank as needed. Remove the lower radiator hose (Item 1) [Figure 10-705]. Drain the coolant from the engine. After the coolant is removed, install the plug (Item 1) [Figure 10-70-4 on Page 10-70-2] and lower radiator hose (Item 1) [Figure 10-70-5]. Recycle or dispose of the used coolant in an environmentally safe manner. Mix the coolant in a separate container. NOTE: The excavator is factory filled with ethylene glycol coolant. Add premixed coolant, 50% water and 50% ethylene glycol to the reservoir if the coolant level is low. One gallon (3,8 L) of ethylene glycol mixed with one gallon (3,8 L) of water is the correct mixture of coolant to provide a -34 F (-37 C) freeze protection. Use a refractometer to check the condition of ethylene glycol in your cooling system. Fill the radiator with the premixed coolant. Install the radiator cap. Run the engine until it is at operating temperature. Stop the engine.
10-70-3
10-70-4
FUEL SYSTEM Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1. The following is a suggested blending guideline which should prevent fuel gelling problems during feezing temperatures: Temp. F (C) +15 (9) Down to -20 (-29) Below -20 (-29) No. 2 No. 1
Figure 10-80-2
100% 50% 0%
0% 50% 100%
P-32698
See your fuel supplier for local recommendations. Filling The Fuel Tank NOTE: The fuel fill cap can be locked. Use the fuel fill cap key to lock and unlock the cap. Figure 10-80-1
Check the condition of the fill strainer screen (Item 1) [Figure 10-80-2]. Clean or replace as necessary. Use a clean, approved safety container to add fuel. Add fuel only in an area that has a free movement of air and no flames or sparks. NO SMOKING! Install and tighten the fuel fill cap. Close the tailgate. See the Service Schedule for the service interval when to remove water from the fuel pre-filter or replace the fuel pre-filter and fuel filter. (See SERVICE SCHEDULE on Page 10-50-1.)
WARNING
1
P-32697
Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.
W-2063-0887
Open the rear cover and remove the fuel fill cap (Item 1) [Figure 10-80-1].
10-80-1
FUEL SYSTEM (CONTD) Removing Water From The Pre-Filter (S/N 522311001 & Above) Open the rear cover. Figure 10-80-3
P-32699
Loosen the drain (Item 1) [Figure 10-80-3] at the bottom of the filter housing to drain water from the filter.
WARNING
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 which can result in injury or death.
W-2103-1285
10-80-2
FUEL SYSTEM (CONTD) Pre-Filter Removal (S/N 522311001 & Above) See the Service Schedule for the service interval when to replace the fuel pre-filter. (See SERVICE SCHEDULE on Page 10-50-1.) Clean the area around the fuel pre-filter housing. Figure 10-80-4
Figure 10-80-6
1
P-32859
Remove the gasket (Item 1) [Figure 10-80-6] from the filter head. Figure 10-80-7
P-32699
Loosen the drain (Item 1) [Figure 10-80-4] at the bottom of the filter housing and drain the fuel out of the housing. Figure 10-80-5
P-32860
2 1 Remove the filter (Item 1) [Figure 10-80-7] from the filter housing.
P-32858
Support the filter housing (Item 1) and remove the bolt (Item 2) [Figure 10-80-5] and washer. Remove the filter.
10-80-3
FUEL SYSTEM (CONTD) Pre-Filter Removal (S/N 522311001 & Above) (Contd) Figure 10-80-8
Figure 10-80-10
P-32860
Install the filter (Item 1) [Figure 10-80-10] in the housing.

P-32861
Apply clean engine oil on both sides of the filter gasket. Remove the spacer (Item 1) [Figure 10-80-8] from the filter housing. Pre-Filter Installation (S/N 522311001 & Above) Clean the filter housing in clean solvent and dry with compressed air. Figure 10-80-9 Figure 10-80-11
1 1
P-32859
Install the gasket (Item 1) [Figure 10-80-11] on the filter head.
P-32861
Install the spacer (Item 1) [Figure 10-80-9] in the filter housing.
10-80-4
FUEL SYSTEM (CONTD) Pre-Filter Installation (S/N 522311001 & Above) (Contd) Figure 10-80-12
Figure 10-80-14
1 2 1
P-32862
Remove the bolt (Item 1) and loosen the vent screw (Item 2) [Figure 10-80-14].
P-32858
Fill the filter through the bolt hole with clean fuel until fuel flows from the vent with no air bubbles. Install the filter housing (Item 1) and bolt (Item 2) [Figure 10-80-12]. Tighten the bolt to 15-18 ft.-lbs. (20-25 Nm) torque. Figure 10-80-13 Install the bolt (Item 1) [Figure 10-80-14]. Tighten the vent screw (Item 2) [Figure 10-80-14].
1
P-32699
Close the drain (Item 1) [Figure 10-80-13] on the bottom of the filter housing.
10-80-5
FUEL SYSTEM (CONTD) Pre-Filter Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above) Figure 10-80-15
P-56410
Loosen the clamp (Item 1) and remove the filter (Item 2) [Figure 10-80-15].
10-80-6
FUEL SYSTEM (CONTD) Fuel Filter Removal And Installation See the Service Schedule for the service interval when to replace the fuel filter. (See SERVICE SCHEDULE on Page 10-50-1.) Clean the area around the filter. Figure 10-80-16 S/N 522311001 & Above
P-32694
P-56411
Remove the filter (Item 1) [Figure 10-80-16] & [Figure 10-80-17]. Put clean oil on the seal of the new filter. Install the filter and hand tighten.
10-80-7
FUEL SYSTEM (CONTD) Draining The Fuel Tank See the Service Schedule for the correct service interval to drain the fuel tank. (See SERVICE SCHEDULE on Page 10-50-1.) Figure 10-80-18
Figure 10-80-20
P-32902
Open the drain (Item 1) [Figure 10-80-20] and drain the fuel into a container.
P-32901
WARNING
W-2103-1285
Position the excavator as shown [Figure 10-80-18]. Figure 10-80-19
P-32903
Remove the cap (Item 1) [Figure 10-80-19] from the drain.
10-80-8
ENGINE LUBRICATION SYSTEM Checking Engine Oil Check the engine oil every day before starting the engine for the work shift. Figure 10-90-1 S/N 522311001 & Above
Figure 10-90-3
P-32692
Figure 10-90-2 S/N 528911001 & Above S/N 528611001 & Above 1
Use a good quality motor oil that meets the correct API Service Classification [Figure 10-90-3].
P-56411
Open the right side cover and remove the dipstick (Item 1) [Figure 10-90-1] & [Figure 10-90-2]. Keep the oil level between the marks on the dipstick.
10-90-1
ENGINE LUBRICATION SYSTEM (CONTD) Replacing Oil And Filter See the Service Schedule for the service interval for replacing the engine oil and filter. (See SERVICE SCHEDULE on Page 10-50-1.) Figure 10-90-4
Figure 10-90-6
P-32886
Install the drain hose (Item 1) [Figure 10-90-6] on the oil pan. Tighten the hose until oil starts to drain from the oil pan. Drain the oil in a container.
P-32884
Recycle or dispose of used oil in an environmentally safe manner. Rotate the upperstructure so the right side is positioned between the tracks [Figure 10-90-4]. Run the engine until it is at operating temperature. Stop the engine. Open the right side cover. Figure 10-90-5
P-32885
Remove the cap (Item 1) [Figure 10-90-5].
10-90-2
ENGINE LUBRICATION SYSTEM (CONTD) Replacing Oil And Filter (Contd)
Put oil in the engine. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-70-1.) Install the fill cap.
Figure 10-90-7 S/N 522311001 & Above Start the engine and let it run for several minutes. Stop the engine. Check for leaks at the oil filter. Check the oil level. 2 Add oil as needed if it is not at the top mark on the dipstick.
P-32692
Figure 10-90-8 S/N 528911001 & Above S/N 528611001 & Above 2
1
P-56411
Remove the oil filter (Item 1) [Figure 10-90-7] & [Figure 10-90-8] and clean the filter housing surface. Use a genuine Bobcat replacement oil filter. Put clean engine oil on the filter gasket. Install the filter and hand tighten. Remove the drain hose and install the cap on the oil pan after the oil has been completely drained. Remove the fill cap (Item 2) [Figure 10-90-7] & [Figure 10-90-8].
10-90-3
10-90-4
HYDRAULIC SYSTEM Checking And Adding Hydraulic Oil Put the machine on a flat level surface. Retract the arm and bucket cylinders, put the bucket on the ground and raise the blade. Stop the engine. Open the rear cover. Figure 10-100-1
Figure 10-100-2
1
P-32851
Clean the surface around the reservoir (breather) cap and remove the cap from the reservoir (Item 1) [Figure 10-100-2] 1 Add the correct oil to the reservoir until it is visible in the sight gauge. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-70-1.)
P-32695
Check the breather cap and clean as necessary. Replace the cap if damaged. Install the reservoir cap. Close the rear cover.
Check the hydraulic oil level, it must be visible in the sight gauge (Item 1) [Figure 10-100-1].
10-100-1
HYDRAULIC SYSTEM (CONTD) Replacing The Hydraulic Oil See the Service Schedule for the correct service interval. (See SERVICE SCHEDULE on Page 10-50-1). Retract the arm and bucket cylinders, lower the bucket to the ground. Stop the engine. Open the rear cover. Figure 10-100-3
Remove the drain hose and install the cap on the hydraulic reservoir. Add fluid to the reservoir. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-70-1). Run the machine through the hydraulic functions. Stop the engine. Check the fluid level and add as needed.
WARNING
W-2103-1285
WARNING
P-32899
Remove the cap (Item 1) [Figure 10-100-3] from the hydraulic reservoir drain. Figure 10-100-4
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-2072-0496
P-32900
Install the drain hose (Item 1) [Figure 10-100-4] on the hydraulic reservoir. Tighten the hose until oil starts to drain from the reservoir. Drain the fluid into a container. Recycle or dispose of the fluid in an environmentally safe manner.
HYDRAULIC SYSTEM (CONTD) Hydraulic Filter Removal (S/N 522311001 & Above) See the Service Schedule for the correct service interval. (See SERVICE SCHEDULE on Page 10-50-1). Open the rear cover. Figure 10-100-5
Figure 10-100-7
P-32855
Remove the filter (Item 1) [Figure 10-100-7] from the filter bowl.
P-32696
Remove the filter cover (Item 1) [Figure 10-100-5] and spring. Figure 10-100-6
P-32853
Remove the filter and filter bowl (Item 1) [Figure 10-1006].
10-100-3
HYDRAULIC SYSTEM (CONTD) Hydraulic Filter Installation (S/N 522311001 & Above) Clean the filter bowl in clean solvent and dry with compressed air. Figure 10-100-8
Figure 10-100-10
1
P-32853
Install the filter and filter bowl (Item 1) [Figure 10-10010]. Figure 10-100-11
P-32977
Inspect the O-rings (Item 1) [Figure 10-100-8] on the outside and inside bottom of the filter bowl. Replace the O-rings if damaged. Figure 10-100-9
1 1
P-32852
Inspect the O-ring (Item 1) [Figure 10-100-11] Replace if damaged.
P-32855
Install a new filter (Item 1) [Figure 10-100-9] in the filter bowl.
10-100-4
HYDRAULIC SYSTEM (CONTD) Hydraulic Filter Installation (S/N 522311001 & Above) (Contd) Figure 10-100-12
P-32696
Install the spring and cover (Item 1) [Figure 10-100-12].
10-100-5
HYDRAULIC SYSTEM (CONTD) Hydraulic Filter Removal (S/N 528911001 & Above And S/N 528611001 & Above) See Service Schedule for the correct service interval. (See SERVICE SCHEDULE on Page 10-50-1). Open the rear cover. Figure 10-100-13
Figure 10-100-15
1
P-58143
Remove the filter (Item 1) [Figure 10-100-15] from the filter bowl.
P-58219
Remove the filter cover (Item 1) [Figure 10-100-13] and spring. Figure 10-100-14
P-58216
Remove the filter and filter bowl (Item 1) [Figure 10-10014].
10-100-6
HYDRAULIC SYSTEM (CONTD) Hydraulic Filter Installation (S/N 528911001 & Above And S/N 528611001 & Above) Clean the filter bowl in clean solvent and dry with compressed air. Figure 10-100-16
Figure 10-100-18
P-58143
Install the filter (Item 1) [Figure 10-100-18] in the filter bowl. Figure 10-100-19
P-58142
Inspect the O-ring (Item 1) [Figure 10-100-16] on the outside of the filter bowl. Replace the O-rings if damaged. Figure 10-100-17
P-58216
Install the filter and filter bowl (Item 1) [Figure 10-10019].
P-58217
Install the O-ring (Item 1) [Figure 10-100-17] in the bottom of the new filter.
10-100-7
HYDRAULIC SYSTEM (CONTD) Hydraulic Filter Installation (S/N 528911001 & Above And S/N 528611001 & Above) (Contd) Figure 10-100-20
1
P-58218
Inspect the O-ring (Item 1) [Figure 10-100-20]. Replace if damaged. Figure 10-100-21
P-58219
Install the spring and cover (Item 1) [Figure 10-100-21].
10-100-8
HYDRAULIC SYSTEM (CONTD) Diagnostic Couplers (S/N 522311001 & Above) Open the rear cover and right side cover.
Figure 10-100-24
1 Figure 10-100-22
P-33048
The four diagnostic couplers (item 1) [Figure 10-100-22], [Figure 10-100-23] & [Figure 10-100-24] are located on the hydraulic circuitry.
P-32843
The couplers can be used to check circuit pressures. (See Testing on Page 20-33-1.) Figure 10-100-23 1
1
P-32842
10-100-9
HYDRAULIC SYSTEM (CONTD) Diagnostic Couplers (S/N 528911001 & Above And S/N 528611001 & Above) Open the rear cover and right side cover. Figure 10-100-25
Figure 10-100-27
1 1
P-63745
The three diagnostic couplers (Item 1) [Figure 10-10025], [Figure 10-100-26] and [Figure 10-100-27] are located on the hydraulic circuitry.
P-58221
The couplers can be used to check circuit pressures.
Figure 10-100-26
P-58220
10-100-10
LUBRICATION OF THE EXCAVATOR Lubricate the excavator as specified in the Service Schedule for the best performance of the machine. (See SERVICE SCHEDULE on Page 10-50-1.) Always use a good quality lithium based multipurpose grease when lubricating the machine. Apply the lubricant until extra grease shows. Lubricate the following locations on the excavator EVERY 8-10 HOURS: Figure 10-110-1
Figure 10-110-3
P-32869
1 3 2
7. Boom pivot (1) [Figure 10-110-3] Figure 10-110-4
P-32866
1. Right blade cylinder rod end (1) [Figure 10-110-1] 2. Right blade cylinder base end (1) [Figure 10-110-1] 3. Right side blade pivot (1) [Figure 10-110-1] Figure 10-110-2
P-32868
8. Boom swing pivot (2) [Figure 10-110-4] 4
5
P-32867
4. Left blade cylinder rod end (1) [Figure 10-110-2] 5. Left blade cylinder base end (1) [Figure 10-110-2] 6. Left side blade pivot (1) [Figure 10-110-2]
10-110-1
LUBRICATION OF THE EXCAVATOR (CONTD) Figure 10-110-5
Figure 10-110-7
13 12 9
10
P-32876 P-32878
12. Boom cylinder base end (1) [Figure 10-110-7] 13. Arm cylinder base end (1) [Figure 10-110-7] 9. Boom swing cylinder base end (1) [Figure 10-110-5] 10. Boom swing cylinder rod end (1) [Figure 10-110-5] Figure 10-110-6 14 Figure 10-110-8
11
P-32875 P-32877
14. Arm cylinder rod end (1) [Figure 10-110-8] 11. Boom cylinder rod end (1) [Figure 10-110-6]
10-110-2
LUBRICATION OF THE EXCAVATOR (CONTD) Figure 10-110-9
Figure 10-110-11
17
15
P-32872 P-32874
17. Bucket cylinder rod end (1) [Figure 10-110-11] 15. Arm pivot (1) [Figure 10-110-9] Figure 10-110-10 18 Figure 10-110-12
16 19
20
P-32871 P-32873
16. Bucket cylinder base end (1) [Figure 10-110-10]
18. Bucket link pivot (1) [Figure 10-110-12] 19. Bucket pivot (1) [Figure 10-110-12] 20. Bucket link (2) [Figure 10-110-12]
10-110-3
LUBRICATION OF THE EXCAVATOR (CONTD) Lubricate the following locations on the excavator EVERY 50 HOURS: Figure 10-110-13
Figure 10-110-14
1 2
P-32870
3 1. Swing circle bearing (1) [Figure 10-110-13] 2. Swing circle pinion (1) [Figure 10-110-13]
P-32975
3. Door hinges (2) [Figure 10-110-14]
10-110-4
TRAVEL MOTOR Checking Oil Level Figure 10-120-1
Draining The Travel Motor See the Service Schedule for the correct service interval. (See SERVICE SCHEDULE on Page 10-50-1). Figure 10-120-2 2
1 2 1
P-32898 P-32897
Put the machine on a level surface with the plugs positioned as shown (Items 1 & 2) [Figure 10-120-1] Remove the plug (Item 1) [Figure 10-120-1]. The oil level should be at the bottom edge of the plug hole. Remove the plug (Item 2) [Figure 10-120-1] and add gear lube through the hole if the oil level is below the hole (Item 1) [Figure 10-120-1]. (See FUEL, COOLANT AND LUBRICANTS on Page SPEC-70-1.) Install both plugs. Repeat the procedure for the other side.
Put the machine on a level surface with the plugs positioned as shown (Items 1 & 2) [Figure 10-120-2] Remove both plugs (Items 1 & 2) [Figure 10-120-2] and drain into a container. Recycle or dispose of the oil in an environmentally safe manner. After all the gear lube is removed, rotate the travel motor to the position shown [Figure 10-120-1] Add gear lube to the plug hole (Item 2) until the oil level is at the bottom edge of the plug hole (Item 1) [Figure 10120-1]. Install and tighten the plugs. Repeat the procedure for the other side.
10-120-1
10-120-2
ALTERNATOR BELT Adjusting Belt Tension Check the alternator belt deflection at the mid span of the belt between the crankshaft pulley and alternator pulley. Apply approximately 33 lb. (15 Kg) force to the belt. The belt should deflect 0.40 inches (10 mm). Figure 10-130-1
Figure 10-130-2
1 1
B-16596
P-32846
Loosen the three alternator mount bolts (Item 1) [Figure 10-130-1] & (Item 1) [Figure 10-130-2] and rotate the alternator until the belt is correctly tensioned. Tighten the bolts.
10-130-1
10-130-2
FAN/FUEL PUMP BELT Adjusting Belt Tension (S/N 522311001 & Above) Figure 10-140-1
Figure 10-140-2
1 1 1
P-32845 B-16596
Check the fan/fuel pump belt deflection mid span of the belt between the crankshaft pulley and the fuel pump pulley (Item 1) [Figure 10-140-1]. Apply approximately 33 lb. (15 Kg) force to the belt. The belt should deflect 0.40 inches (10 mm).
Loosen the two bolts (Item 1) [Figure 10-140-2] on the fuel pump mount. Rotate the fuel pump until the belt is correctly tensioned. Tighten the bolts.
10-140-1
10-140-2
AIR CONDITIONING COMPRESSOR BELT (S/N 522311001 & ABOVE) Adjusting Belt Tension Figure 10-150-1
Figure 10-150-2
1
P-40475
1
P-40348
Loosen the two bolts (Item 1) [Figure 10-150-2] and nuts. Loosen the bracket bolt (Item 2) [Figure 10-150-2]. Rotate the compressor until the belt is correctly tensioned. Tighten the bolts.
Check the A/C belt deflection at the mid span of the belt (Item 1) [Figure 10-150-1]. Apply approximately 33 lb. (15 Kg) force to the belt. The belt should deflect 0.40 inches (10 mm).
10-150-1
10-150-2
AIR CONDITIONING COMPRESSOR BELT (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Adjusting Belt Tension Figure 10-151-3
P-56413
Check the air conditioning compressor belt deflection mid span of the belt between the crankshaft pulley and the compressor pulley (Item 1) [Figure 10-151-3]. Apply approximately 33 lb. (45 mm) force to the belt. The belt should deflect 0,40 inches (10 mm). Figure 10-151-4
1
P-58069
Loosen the bolts (Item 1) [Figure 10-151-4] and rotate the compressor until the belt is correctly tensioned. Tighten the bolts.
10-151-1
10-151-2
CAB TILT PROCEDURE Installing The Cab Tilt Hinges Figure 10-160-1
Figure 10-160-3
1 1 1
P-33034
P-33032
Install the bolts (Item 1) and washers (Item 2) [Figure 10160-3]. Do not tighten the bolts at this time. Figure 10-160-4
Remove the four bolts (Item 1) [Figure 10-160-1] from the front of the excavator. Figure 10-160-2
2 1 1
P-33035
P-33033
Install the bolts (Item 1)and washers (Item 2) [Figure 10160-4]. Tighten the bolts to 29-37 ft.-lb. (40-50 Nm) torque.
Install the hinge (Item 1) on the excavator frame. Install the washers (Item 2) [Figure 10-160-2] between the frame and the hinge.
Tighten the front bolts (Item 1) [Figure 10-160-3] to 2937 ft.-lb. (40-50 Nm) torque. Repeat the procedure for the right hinge.
10-160-1
CAB TILT PROCEDURE (CONTD) Installing The Cab Tilt Hinges (Contd) Figure 10-160-5
Figure 10-160-7
1 3
1
P-33030
2
P-33036
Figure 10-160-8
Install the bumpers (Item 1) on both hinges. Install the two bolts (Item 2) and washers (Item 3) [Figure 10-1605]. Tilting The Cab 1 Figure 10-160-6
P-33031
Remove the two storage compartment bolts (Item 1) [Figure 10-160-7] & [Figure 10-160-8] and washers. Remove the storage compartment. (If equipped)
P-33029
Remove the two bolts (Item 1) [Figure 10-160-6] and washers from the right arm rest. Remove the arm rest.
10-160-2
CAB TILT PROCEDURE (CONTD) Tilting The Cab (Contd) Figure 10-160-9
Figure 10-160-11 2
P-33042
P-33037
Remove the 11 bolts (Item 1) and washers. Remove the bottom cover (Item 2) [Figure 10-160-11] Installation: Tighten the bolts to 18-19 ft.-lb. (110-125 Nm) torque.
Figure 10-160-10
P-33038
Remove the rear cab mount nuts (Item 1) [Figure 10160-9] & [Figure 10-160-10] and washers. Installation: Tighten the nuts to 81-92 ft.-lb. (110-125 Nm) torque.
10-160-3
CAB TILT PROCEDURE (CONTD) Tilting The Cab (Contd) Early Models Figure 10-160-12
Later Models Figure 10-160-14
1
P-63545
Figure 10-160-15
P-33043
Figure 10-160-13 1
P-63544
P-33044
Remove the nuts (Item 1) [Figure 10-160-14] & [Figure 10-160-15] and washers.
Remove the front cab mount bolts (Item 1) [Figure 10160-12] & [Figure 10-160-13] washers and nuts. Installation: Tighten the bolts to 81-92 ft.-lb. (110-125 Nm) torque.
10-160-4
CAB TILT PROCEDURE (CONTD) Tilting The Cab (Contd) Later Models (Contd) Figure 10-160-16
All Models Figure 10-160-18
1 Figure 10-160-19
P-63542
P-33794
Figure 10-160-17
P-33793
P-63543
Do NOT remove the side bolts (Item 1) [Figure 10-16018] & [Figure 10-160-19].
Turn the bolts (Item 1) down flush with the plate (Item 2) [Figure 10-160-16] & [Figure 10-160-17].
10-160-5
Figure 10-160-22
1
P-33040
P-33039
Install a winch (Item 1) [Figure 10-160-22] to the clevis on the cab. Install the other end of the winch to the chain that was installed on the arm.
Install the clevis (Item 1) [Figure 10-160-20] on the right (as viewed from the operators seat) corner of the cab. Figure 10-160-21
IMPORTANT
When tilting the cab, use winches and chains that are in good condition and of proper weight ratings.
I-2215-0502
Lower the left console and close the cab door. Figure 10-160-23 1
P-33041
Install a chain (Item 1) around the arm between the bucket and the bucket link (Item 2) [Figure 10-160-21]. 2
P-33036
Winch the cab forward until the front of the cab (Item 1) contacts the bumpers (Item 2) [Figure 10-160-23].
10-160-6
Figure 10-160-25
P-33046
Reverse the direction of the winch and lower the cab until the approved cab support device (Item 1) [Figure 10160-25] fully engages the cab mount hole and the weight of the cab is resting on the support device. Figure 10-160-26
P-33045
Install an approved cab support device (Item 1) through the cab mount hole (Item 2) and over the rear cab mount stud (Item 3) [Figure 10-160-24].
P-33047
Install the nut (Item 1) [Figure 10-160-26] on the cab mount stud.
WARNING
Avoid injury or death. Never work under the excavator cab without installing an approved cab support device.
W-2435-0502
10-160-7
10-160-8
HYDRAULIC SYSTEM ACCUMULATOR (S/N 522311001 & ABOVE) . . . . . . . . . . . . . 20-60-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1 ACCUMULATOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1 ARM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21-11 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 AUXILIARY HYDRAULIC FLOW CONTROL/HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-171-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-171-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-171-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-171-1 AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/N 522311001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-170-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1 AUXILIARY HYDRAULICS SELECTOR VALVE . . . . . . . . . . . 20-220-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1 BLADE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-24-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-10 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-5 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-4 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-24-1 BLADE FLOAT VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-181-1 20-181-3 20-181-2 20-181-1
HYDRAULIC SAFETY & MAINTENANCE SYSTEM
DRIVE SYSTEM
SPECIFICATIONS
20-01
HYDRAULIC SYSTEM (CONTD) BLADE VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-180-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-180-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-180-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-180-1 BOOM CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-13 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-8 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-7 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1 BOOM OFFSET VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-190-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-190-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-190-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1 BOOM OFFSET CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-13 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-9 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-8 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-4 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-22-1 BOOM LOAD HOLDING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-200-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-200-10 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-200-3 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-200-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-200-1 BUCKET CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-23-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-23-10 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-23-6 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-23-5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-23-1 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-23-1
20-02
HYDRAULIC SYSTEM (CONTD) DUMP VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34-1 20-34-1 20-34-1 20-34-4 20-34-3 20-34-2 20-34-1
HYDRAULIC BREAKER APPLICATION VALVE (S/N 522311001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-160-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1 HYDRAULIC FILTER MOUNT . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1 HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) . . . . . 20-51-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-12 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-51-1 HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-53-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-53-7 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-53-4 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-53-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-53-1 HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) . . . . .20-50-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-48 Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . .20-50-18 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-39 Hydraulic Pump Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . .20-50-1 Initial Torque Limiter Valve Setting. . . . . . . . . . . . . . . . . . . .20-50-29 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-38 Pump Control Disassembly And Assembly . . . . . . . . . . . . .20-50-33 Pump Control Parts Identification . . . . . . . . . . . . . . . . . . . .20-50-31 Pump Control Removal And Installation . . . . . . . . . . . . . . .20-50-32 Pump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-6 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-15 Testing Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-4 Torque Limiter Valve Assembly . . . . . . . . . . . . . . . . . . . . . .20-50-25 Torque Limiter Valve Disassembly . . . . . . . . . . . . . . . . . . . .20-50-21 Torque Limiter Valve Parts Identification . . . . . . . . . . . . . . .20-50-19 Torque Limiter Valve Removal and Installation . . . . . . . . . .20-50-20 Continued On Next Page
20-03 442 Excavator Service Manual
HYDRAULIC SYSTEM (CONTD) HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52-45 Coupler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-52-15 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52-36 Hydraulic Pump Work Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52-1 Initial Torque Limiter Valve Setting . . . . . . . . . . . . . . . . . . . . . . . 20-52-26 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52-35 Pump Control Disassembly And Assembly . . . . . . . . . . . . . . . . 20-52-30 Pump Control Parts Identification . . . . . . . . . . . . . . . . . . . . . . . 20-52-28 Pump Control Removal And Installation . . . . . . . . . . . . . . . . . . 20-52-29 Pump Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52-5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52-13 Testing Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52-4 Torque Limiter Valve Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-52-22 Torque Limiter Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . 20-52-18 Torque Limiter Valve Parts Identification . . . . . . . . . . . . . . . . . . 20-52-16 Torque Limiter Valve Removal and Installation . . . . . . . . . . . . . 20-52-17 HYDRAULIC PISTON PUMP DRIVE COUPLER . . . . . . . . . . . . . . 20-230-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230-1 HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1 HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . 20-10-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1 JOYSTICK CONTROL PATTERN SELECTOR VALVE. . . . . . . . . . .20-100-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-100-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-100-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-100-1 JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE) 20101-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-101-1 JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102-4 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-102-1 Continued On Next Page
HYDRAULIC SYSTEM (CONTD) LEFT CONTROL LEVER (JOYSTICK) . . . . . . . . . . . . . . . . . . . 20-111-1 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-6 Handle Removal And Installation. . . . . . . . . . . . . . . . . . . . . 20-111-2 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-111-1 OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-140-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-140-1 OIL TEMPERATURE REGULATOR . . . . . . . . . . . . . . . . . . . . .20-210-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-210-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .20-210-1 PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-31-1 Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-31-1 PRESSURE REDUCING VALVE (S/N 522311001 & ABOVE) . .20-33-1 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-33-2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-33-1 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-33-1 PRESSURE REDUCING VALVE (S/N 528911001 & ABOVE AND 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-32-1 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-32-2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-32-1 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-32-1 RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-1 Adjusting The Three Spool Control Valve Main Relief Valve .20-30-2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-1 Testing The Three Spool Control Valve Main Relief Valve. . .20-30-2 RIGHT CONTROL LEVER (JOYSTICK). . . . . . . . . . . . . . . . . . 20-110-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . 20-110-6 Handle Removal And Installation. . . . . . . . . . . . . . . . . . . . . 20-110-2 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-3 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1 SECONDARY FRONT AUXILIARY VALVE . . . . . . . . . . . . . . .20-150-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . .20-150-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-150-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .20-150-1

HYDRAULIC SYSTEM (CONTD) SIX SPOOL HYDRAULIC CONTROL VALVE. . . . . . . . . . . . . . . . . . .20-40-1 Boom, Arm, Bucket And Auxiliary Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12 Control Valve Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-5 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-6 Inlet Valve Section Disassembly And Assembly . . . . . . . . . . . . . 20-40-17 Left Travel And Right Travel Valve Section Disassembly And Assembly . 20-40-9 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1 SWING BRAKE RELEASE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . .20-93-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-93-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-93-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-93-1 SWING BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-92-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-92-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-92-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-92-1 SWING MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-10 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-4 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-90-1 SWING MOTOR DRIVE CARRIER. . . . . . . . . . . . . . . . . . . . . . . . . . .20-91-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-91-13 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-91-4 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-91-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-91-1 SWIVEL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-4 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-80-1
20-06
HYDRAULIC SYSTEM (CONTD) THREE SPOOL HYDRAULIC CONTROL VALVE . . . . . . . . 20-41-1 Boom Offset And Blade Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-6 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 20-41-4 Inlet/Upperstructure Swing Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-10 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1 TRAVEL LEVER/FOOT PEDAL VALVE . . . . . . . . . . . . . . . 20-112-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . 20-112-5 Left Travel Lever/Foot Pedal Valve Removal And Installation .20112-1 Right Travel Lever/Foot Pedal Valve Removal And Installation. . 20-112-2 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-112-4 TRAVEL MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-20 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
20-07
20-08
HYDRAULIC/HYDROSTATIC SCHEMATIC 442 EXCAVATOR (S/N 522311001 AND ABOVE)

(PRINTED APRIL 2005) MS1422legend
LEGEND
1 2 3 4 5 6 7 8 9 BACK-UP RELIEF VALVE 4350 PSI (300 Bar) LOAD SENSE RELIEF VALVE 4060 PSI (280 Bar) PORT RELIEF VALVE - Boom Cyl. (Rod End) 4350 PSI (300 Bar) PORT RELIEF VALVE - Boom Cyl. (Base End) 2610 PSI (180 Bar) PORT RELIEF VALVE - Arm Cyl. (Rod End) 4350 PSI (300 Bar) PORT RELIEF VALVE - Arm Cyl. (Base End) 4350 PSI (300 Bar) PORT RELIEF VALVE - Bucket Cyl. (Rod End) 4350 PSI (300 Bar) PORT RELIEF VALVE - Bucket Cyl. (Base End) 4350 PSI (300 Bar) PORT RELIEF VALVE - Auxiliary 4350 PSI (300 Bar) NOTE: With clamp installed - Reset port relief valve to 3625 PSI (250 Bar) 10 PORT RELIEF VALVE - Auxiliary 4350 PSI (300 Bar) LOAD SENSE BLEED CARTRIDGE 28 12 13 14 15 16 MAIN RELIEF VALVE (Gear Pump) 3335 PSI (230 Bar) PILOTED OPERATED TWO POSITION VALVE CHECK VALVE ORIFICE PORT RELIEF VALVE 5075 PSI (350 Bar) 31 29 30 25 26 27 11 17 CROSS PORT RELIEF VALVE - 2 STAGE 1450 PSI (100 Bar) / 3625 PSI (250 Bar) ANTI-CAVITATION VALVE ORIFICE 0.06 inch (1,5 mm) 34 32 33 RETURN BLOCK With Check Valve 72.5 PSI (5 Bar) MAIN FILTER
18 19 20
ORIFICE - One Way Restrictor 0.0023 inch (0,6 mm) 35
PRESSURIZED BREATHER / FILL CAP 5 PSI (0,34 Bar) HYDRAULIC RESERVOIR - PRESSURIZED Reservoir Volume 29 gal (110 L) System Volume 37 gal (140 L) COMPENSATOR - Standard ( Boom, Arm, Bucket, Auxiliary, Left Travel and Right Travel) CROSS PORT RELIEF VALVE Travel Motor 4060 PSI (280 Bar) COUNTERBALANCE SPOOL (Travel Motor) TWO SPEED SHIFT SPOOL SHUTTLE VALVE - DRIVE PRESSURE BRAKE CONTROL SPOOL SELECTOR VALVE - MANUAL (Bucket Cylinder or Secondary Auxiliaries) CHECK VALVE - Accumulator LOAD CHECK VALVE - Boom Swing 334 PSI (23 Bar) ISO/STANDARD VALVE CHECK VALVE
21 PRESSURE REDUCING VALVE 508 PSI (35 Bar) 22 ACCUMULATOR 145 PSI (10 Bar) 23 DUMP VALVE - PUMP 2 1595 PSI (110 Bar) 24 HYDRAULIC PISTON PUMP Minimum Displacement 0.0 GPM (0.0 L/min) @ 2000 RPM Maximum Displacement 37.5 GPM (142 L/min) @ 2000 RPM Torque Limitor PUMP MARGIN SPOOL 365 PSI (25 Bar) TORQUE LIMITER SUPPLY SPOOL 290 PSI (20 Bar) OIL TEMPERATURE REGULATOR 131 degrees F. (55 degrees C.) OIL COOLER HYDRAULIC PUMP # 1 Gear Type 8.7 GPM (33 L/min.) at 2000 Engine RPM HYDRAULIC PUMP # 2 Gear Type 8.7 GPM (33 L/min.) at 2000 Engine RPM
36
37
38 39 40 41 42 43 44 45 46
NOTE: Unless otherwise specified springs have NO significant pressure value.
Printed in U.S.A.
MS1422legend (3-21-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC 442 (S/N 522311001 AND ABOVE)

(PRINTED APRIL 2005) MS-1422
T P T P
SWIVEL JOINT
T P
1 3
S
C2 E E
16 13
BOOM CYLINDER ARM CYLINDER BUCKET CYLINDER Left Side Auxiliary On Arm Right Side Auxiliary On Arm 2 TRAVEL CONTROL VALVE LEFT 1 2 TRAVEL CONTROL VALVE RIGHT 1 AUXILIARY PILOT PRESSURE REDUCING VALVE
Y4
BREAKER VALVE 2 1 DOZER BLADE CONTROL VALVE BOOM OFFSET CONTROL VALVE 4 5 6 7 8
2 1
15
3 2 1
1 2 3 4 5 6 7 8
LEFT TRAVEL LEFT TRAVEL RIGHT TRAVEL RIGHT TRAVEL TWO SPEED BLADE - BASE END BLADE - ROD END CASE DRAIN
14
Y18
Y19 P
AUXILIARY CONTROL VALVE
SWIVEL JOINT
T
BOOM SWING CYLINDER
Pil T V2
Pil T V2 LOAD HOLDING VALVE
42
42
Y11
BLADE CYLINDER FLOAT POSITION VALVE
Under carriage
36 36 36 36 36 36
LS P
B1
B2
A2
B3
A3
B4
A4
B5
A5
B6
A6
P M
A1
B1
A2
B2
A3
B3
11
2 44
39
X1 T
1 12
MA T1
SWING RELIEF PRESSURE CONTROL VALVE
37
MB
6 SPOOL VALVE
T3
T B A T T B A T T B A T T B A T
37
BOOM SWING
BOOM T1 a
3 4
ARM a
5 6
BUCKET a
7 8
AUXILIARY a
9 10
LEFT TRAVEL a a
RIGHT TRAVEL 3 SPOOL VALVE
SWING b
BLADE
46 38
b
46
45
Y12
40
a b
p t
41
TRAVEL MOTOR
Y
45
a b
p t
X
2 1
4 5 6 7 8
27
SWIVEL JOINT
X
2 4 1 3 2 4 3 1
TRAVEL MOTOR
BLADE CYLINDER
25
T LEFT JOYSTICK
26
T RIGHT JOYSTICK
41
28
T
29
K
40 17
24
SWING MOTOR T
38
A
T M
R
46
S
L1
variable displacement pump

32
S1
P
23
18
37
46
B C G
A E D F
30
31
P B S
Z
19
MA T X1
20 39
37
M B
MAIN FILTER
34
17
S1
S2 R
A P
SWING BRAKE RELEASE VALVE
T
22 33
Y3
2 Y5
21
P T
JOYSTICK LOCKOUT AND TWO SPEED VALVE
35
S
43
MS-1422 (3-21-05)
HYDRAULIC/HYDROSTATIC SCHEMATIC 442 EXCAVATOR (S/N 528611001 AND ABOVE) (S/N 528911001 AND ABOVE)
(PRINTED NOVEMBER 2007) V-0621legend
LEGEND
1 2 3 4 5 6 7 8 9 BACK-UP RELIEF VALVE 4350 PSI (300 bar) LOAD SENSE RELIEF VALVE 4060 PSI (280 bar) PORT RELIEF VALVE - Boom Cyl. (Rod End) 4350 PSI (300 bar) PORT RELIEF VALVE - Boom Cyl. (Base End) 2610 PSI (180 bar) PORT RELIEF VALVE - Arm Cyl. (Rod End) 4350 PSI (300 bar) PORT RELIEF VALVE - Arm Cyl. (Base End) 4350 PSI (300 bar) PORT RELIEF VALVE - Bucket Cyl. (Rod End) 4350 PSI (300 bar) PORT RELIEF VALVE - Bucket Cyl. (Base End) 4350 PSI (300 bar) PORT RELIEF VALVE - Auxiliary 4350 PSI (300 bar) NOTE: With clamp installed - Reset port relief valve to 3625 PSI (250 bar) 10 PORT RELIEF VALVE - Auxiliary 4350 PSI (300 bar) LOAD SENSE BLEED CARTRIDGE 28 12 13 14 15 16 MAIN RELIEF VALVE (Gear Pump) 3335 PSI (230 bar) PILOTED OPERATED TWO POSITION VALVE (2) CHECK VALVE (2) ORIFICE (2) PORT RELIEF VALVE (2): 5075 PSI (350 bar) 31 29 30 25 26 27 11 17 CROSS PORT RELIEF VALVE - 2 STAGE 1450 PSI (100 bar) / 3625 PSI (250 bar) ANTI-CAVITATION VALVE ORIFICE 0.003 inch (0,8 mm) 35 HYDRAULIC RESERVOIR - PRESSURIZED Reservoir Volume 29 gal (110 L) System Volume 37 gal (140 L) COMPENSATOR - Standard ( Boom, Arm, Bucket, Auxiliary, Left Travel and Right Travel) CROSS PORT RELIEF VALVE Travel Motor 4060 PSI (280 bar) COUNTERBALANCE SPOOL (Travel Motor) TWO SPEED SHIFT SPOOL SHUTTLE VALVE - DRIVE PRESSURE BRAKE CONTROL SPOOL SELECTOR VALVE - MANUAL (Bucket Cylinder or Secondary Auxiliaries) CHECK VALVE (8) LOAD CHECK VALVE - Boom Swing 334 PSI (23 bar) ISO/STANDARD VALVE SLEW BRAKE SOLENOID VALVE CHECK VALVE 43.5 PSI (3 bar) NOTE: Unless otherwise specified springs have NO significant pressure value. 33 MAIN FILTER With 43.5 PSI (3 bar) Filter By-Pass Valve PRESSURIZED BREATHER / FILL CAP 5 PSI (0,34 bar)
18 19 20
34
ORIFICE - One Way Restrictor 0.0023 inch (0,6 mm)
21 PRESSURE REDUCING VALVE 508 PSI (35 bar) 22 ACCUMULATOR 145 PSI (10 bar) 23 CHECK VALVE 24 HYDRAULIC PISTON PUMP Minimum Displacement 0.0 GPM (0.0 L/min) @ 2200 RPM Maximum Displacement 41.2 GPM (156 L/min) @ 2200 RPM TORQUE LIMITOR PUMP MARGIN SPOOL 365 PSI (25 bar) TORQUE LIMITER SUPPLY SPOOL 290 PSI (20 bar) OIL COOLER BY-PASS VALVE 43.5 PSI (3 bar) OIL COOLER HYDRAULIC PUMP Gear Type 17.9 GPM (68 L/min.) at 2200 Engine RPM CONSOLE/JOYSTICK SHUT-OFF SOLENOID VALVE TWO SPEED SOLENOID VALVE
36
37
38 39 40 41 42 43 44 45 46 47
32
Printed in U.S.A.
V-0621legend (10-15-07)
HYDRAULIC/HYDROSTATIC SCHEMATIC 442 (S/N 528611001 AND ABOVE) (S/N 528911001 AND ABOVE) LOAD HOLDING
(PRINTED NOVEMBER 2007) V-0621
13
2 1
VALVE
C2 E E E
LOAD HOLDING VALVE

C2 E
AUX. COUPLER, DIRECT TO TANK

P T P T P T P T
16
13
2 1
16
14
Pil T V2
15
Pil T V2
14
Pil T V2
15
Pil T V2 1 2 1 2
PVL
Y4
RIGHT LEFT SIDE SIDE AUX. ON AUX. ON ARM ARM
TRAVEL CONTROL VALVE LEFT
TRAVEL CONTROL VALVE RIGHT
DOZER BLADE CONTROL VALVE
BOOM OFFSET CONTROL VALVE
4 5 6 7 8
SWIVEL JOINT 1. LEFT TRAVEL 2. LEFT TRAVEL 3. RIGHT TRAVEL 4. RIGHT TRAVEL 5. TWO SPEED 6. BLADE - BASE END 7. BLADE - ROD END 8. CASE DRAIN
2 1
DDF
SWIVEL JOINT (TOP PORTS)
BOOM CYLINDER
ARM CYLINDER
BUCKET CYLINDER
BREAKER VALVE
T P
B A
Y11
42 42
BLADE CYLINDER FLOAT POSITION VALVE
BOOM OFFSET CYLINDER TRAVEL MOTOR
39
LS P M M b B1 A1
36
b B2
A2
36
b B3
A3
36
b B4
A4
36
B5
A5
36
B6
A6
A1
B1
A2
B2
A3
B3
X1 T MA
11
37 37
2 1
T3 T
T T B A T B A T T B A T T B A T
12 43
44 38
6 SPOOL VALVE
T1 a
T1
SWING
BLADE
BOOM OFFSET
44
M
BOOM
3 4
a
ARM
5 6
a 7
BUCKET
AUX.
a
10
LEFT TRAVEL
RIGHT TRAVEL
45
40
41
p
a b
Y25
a b p t
P T
P T
3 2 1
4 5 6 7 8
AUXILIARY CONTROL VALVE

Y18
45
A B
X Y26
DDF
SWIVEL JOINT (BOTTOM PORTS) LEFT JOYSTICK RIGHT JOYSTICK
A B
BLADE CYLINDERS
Y19
P T
17
A
MA
41
47
19
Pst S
40 44 38 43 44
18 S1
SWING MOTOR
P T
B
Pst
FR1
27
37 17
MB
20
MA T
S1 A
37
FR2
26
MB
28
29 25
P2
LR
X1
24
30
P M
31
1
32
2
46
R P
S2
SWING BRAKE RELEASE VALVE
39
Y3
Y5
Y12
34
21
23
SBO
22
MAIN FILTER
33
VARIABLE DISPLACEMENT PUMP
L1
TRAVEL MOTOR
35
T
V-0621 (10-15-07)
ACCUMULATOR
HYDRAULIC SYSTEM INFORMATION Troubleshooting Chart TROUBLESHOOTING THE HYDRAULIC CIRCUIT PROBLEM CAUSE Replace Repair or replace. Readjust or replace. Readjust or replace. CORRECTION Refill with correct oil.
No hydraulic operation at one or more Hydraulic oil level low. circuits. Hydraulic pump drive coupling damaged. Hydraulic pump defective. Pump pressure too low. Hydraulic power insufficient to one or more circuits. All hydraulic speed too slow. Pump pressure setting incorrect.
Torque limiter supply spool set too low. Readjust. Hydraulic oil level or viscosity incorrect. Fill to correct level. Use correct viscosity oil. Pump margin too low. Engine RPM reduced. Torque limiter set too low/high. Hydraulic pump volume low. Test and adjust. Readjust or replace. Test and adjust. Check repair or replace. Clean oil cooler external surface. Fill to correct level. Replace. Use proper operating procedures. Readjust or replace.
Oil temperature too high.
Oil cooler or radiator fins plugged. Hydraulic oil level low. Non recommended hydraulic oil. Auxiliary in detent mode. One or more port relief valves not set correctly. Extreme operating conditions. High ambient temperature. (IE: Enclosed structure). Fan belt loose. Piston pump margin too high.
Tighten fan belt. Readjust.
Pump (Piston) response slow.
Pump minimum displacement set too low.
20-10-1
HYDRAULIC SYSTEM INFORMATION (CONTD) Troubleshooting Chart (Contd) TROUBLESHOOTING THE CYLINDER CIRCUIT PROBLEM Cylinder inoperable. CAUSE Pump torque limiter supply spool not shifting. Control console raised. Loose fittings or broken hoses. Low PSI at joystick. Control console lockout switch. Cylinder internal leakage excessive. Joystick pressure reducing valve defective. Joystick internal leakage excessive. Pump margin spool not shifting. Load sense relief valve set too low. Cylinder force insufficient. . Lever linkage incorrectly adjusted. Pump pressure too low. Pump torque limiter too low. Cylinder speed too slow. Engine RPM low. Cylinder internal leakage excessive. CORRECTION Repair or replace. Lower control console. Repair or replace. Check, repair or replace pressure reducing valve. Readjust or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Readjust. Readjust or replace. Readjust or replace. Check RPM or increase engine speed. Repair or replace.
Main relief valve malfunctioning. (Three Readjust or replace. spool valve) Joystick pressure reducing valve defective. Control valve internal leakage excessive. Joystick internal leakage excessive. Low or dirty fluid. Repair or replace. Repair or replace. Repair or replace. Add or replace the hydraulic fluid.
Load sense relief valve malfunctioning. Readjust or replace. (Six spool valve) Pump margin too low. Pump torque limiter too low. Repair or replace. Readjust or replace.
20-10-2
HYDRAULIC SYSTEM INFORMATION (CONTD) Troubleshooting Chart (Contd) TROUBLESHOOTING THE SWING (SLEW) CIRCUIT PROBLEM Swing not operating. CAUSE Swing brake not releasing. Lower control console. Control console lockout switch incorrectly adjusted or defective. Swing motor gear defective. Joystick internal leakage excessive. Swing motor defective. Swing force. Pump pressure set too low. Swing motor relief valve pressure too low. Swing speed too slow. Swing brake not releasing. Engine RPM low. Pump flow low. (Gear pump) Blocked or restricted line to swing motor. Joystick internal leakage excessive. Control valve internal leakage excessive. (Three spool valve) Swing motor internal leakage excessive. Swing over run excessive. Control valve spool sticking. Joystick spool sticking. Swing motor relief valve set too low. Swing motor internal leakage excessive. Swing motor seal leakage. Swing stop/start too harsh. Return line filter plugged. Sequence valve shifting too early. CORRECTION Repair or replace. Lower control console. Readjust or replace. Repair or replace. Repair or replace. Repair or replace. Readjust or replace. Readjust or replace. Repair, replace or adjust. Adjust. Check, repair or adjust. Replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Inspect, clean or replace. Repair, replace or adjust.
20-10-3
HYDRAULIC SYSTEM INFORMATION (CONTD) Troubleshooting Chart (Contd) TROUBLESHOOTING THE TRAVEL CIRCUIT PROBLEM Travel system inoperable. CAUSE Pilot pressure too low. Console switch not closed. Lever linkage incorrectly adjusted. Track tension too tight. Defective pump. (Piston pump) Travel motor counter balance spool sticking. Travel motor internal leakage excessive. Travel motor defective. Travel motor gears defective. Swivel joint defective. Pump pressure too low. Travel power. Track tension too tight. Travel motor check valve leaking. Pump pressure too low. Torque limiter. Swivel joint leaking. Travel motor counterbalance spool sticking. Travel speed too slow. Engine RPM low. Pilot pressure low. Pump margin too low. Lever linkage incorrectly adjusted. Control valve internal leakage excessive. Low pump pressure. Travel motor internal leakage excessive. Travel motor seal leakage. Return line filter plugged. CORRECTION Repair or readjust. Repair or replace. Readjust. Readjust. Check, repair or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Readjust. Readjust. Readjust or replace. Readjust. Readjust. Repair or replace. Repair or replace. Readjust. Readjust. Readjust. Readjust. Repair or replace. Check, repair or replace. Repair or replace. Inspect, clean or replace.
Swivel joint internal leakage excessive. Repair or replace.
20-10-4
HYDRAULIC SYSTEM INFORMATION (CONTD) Troubleshooting Chart (Contd) TROUBLESHOOTING THE TRAVEL CIRCUIT (CONTD) PROBLEM Machine not running straight. CAUSE Straight travel orifice plugged. Lever linkage incorrectly adjusted. Track tension not equal. Travel motor counter balance spool sticking. Pump pressure set too low. Control valve internal leakage not equal. Machine will not hold on slope or while Valve compensators not equal. digging. Track motor counterbalance valve leakage excessive. Blade drops while machine is moving. Cylinder internal leakage excessive. Control valve internal leakage excessive. (Three spool valve) Readjust. Readjust. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. Repair or replace. CORRECTION Repair or replace.
Travel motor internal leakage not equal. Repair or replace.
Swivel joint internal leakage excessive. Repair or replace.
Swivel joint internal leakage from travel Repair or replace. motor pressure circuit into blade cylinder circuit. High/low gear switch inoperative (2speed). Control valve defective. Torque limiter set too low. Pump pressure set too low. Switch defective. Faulty pressure reducing valve. Bad solenoid. Replace. Readjust. Readjust. Replace. Repair or replace. Replace.
20-10-5
HYDRAULIC SYSTEM INFORMATION (CONTD) Description
Figure 20-10-2
IMPORTANT
When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
I-2003-0888
1
P-32843
The hydraulic system has two separate hydraulic circuits. The piston pump circuit supplies fluid to the six spool hydraulic control valve. The six spool control valve contains the boom, arm, bucket auxiliary, left and right travel valve sections. Figure 20-10-1 The three spool control valve contains the upperstructure swing, blade and boom swing valve sections. Figure 20-10-3 1 The coupler (Item 2) [Figure 20-10-2] is used to check the load sense relief valve, safety relief valve and piston pump torque limiter supply adjustment. The gear pump circuit supplies fluid to the three spool hydraulic control valve.
P-33367
A load sense relief valve (Item 1) [Figure 20-10-1] and safety relief valve (Item 1) [Figure 20-10-2] protect the valve from high pressure.
P-33373
A main relief valve (Item 1) [Figure 20-10-3] protects the valve from high pressure.
20-10-6
HYDRAULIC SYSTEM INFORMATION (CONTD) Description (Contd) Figure 20-10-4
Figure 20-10-6
1 1
P-33048
P-32842
The coupler (Item 1) [Figure 20-10-6] is used to check the hydraulic controls (joysticks) pilot pressure.
The coupler (Item 1) [Figure 20-10-4] is used to check the main relief valve located on the three spool valve. Figure 20-10-5
P-32842
The coupler (item 1) [Figure 20-10-5] is used to check the pressure cutoff valve.
20-10-7
20-10-8
BOOM CYLINDER Testing Fully retract the bucket and arm cylinders. Lower the boom to the ground. With the engine off and the key in the run position, move the joysticks to relieve hydraulic pressure.
Figure 20-20-3
1 Figure 20-20-1
P-33401
Remove the pin (Item 1) [Figure 20-20-3]. Figure 20-20-4 1
1
P-33396
Remove the bolt (Item 1) [Figure 20-20-1] from the rod end retaining pin. Figure 20-20-2
P-33403
Raise the cylinder and remove the shims (Item 1) [Figure 20-20-4] from both sides of the rod end.
P-33399
Remove the spacer (Item 1) [Figure 20-20-2].
20-20-1
BOOM CYLINDER (CONTD) Testing (Contd) Figure 20-20-5
Figure 20-20-7
P-33395
P-36024
Remove the hose (Item 1) [Figure 20-20-7] from the base end of the boom cylinder. Figure 20-20-8
Install a block (Item 1) [Figure 20-20-5] under the cylinder housing. Figure 20-20-6 2
P-36026
Install a plug (Item 1) [Figure 20-20-8] on the hose.

P-36025
Start the engine and retract the boom cylinder. Start the engine and retract the boom cylinder (Item 1) [Figure 20-20-6]. Stop the engine. With the engine off and the key in the run position, move the joysticks to relieve hydraulic pressure. If there is any oil leakage from the base end fitting (Item 2) [Figure 20-20-8] on the boom cylinder, remove the cylinder for repair or replacement.
20-20-2
BOOM CYLINDER (CONTD) Removal And Installation Fully retract the bucket and arm cylinders. Lower the boom to the ground. With the engine off and the key in the run position, move the joysticks to relieve hydraulic pressure.
Figure 20-20-10
IMPORTANT
I-2003-0888
P-33394
Disconnect the hose (Item 1) [Figure 20-20-10] from the rod end. Figure 20-20-11
Figure 20-20-9
1 2
1
P-33395
P-33391
Disconnect the hose (Item 1) [Figure 20-20-11] from the base end.
Remove the load sense line (Item 1) and two pilot hoses (Item 2) [Figure 20-20-9].
20-20-3
BOOM CYLINDER (CONTD) Removal And Installation (Contd) Figure 20-20-12 1
Figure 20-20-14
P-33400
Remove the spacer (item 1) [Figure 20-20-14].

P-33397
Figure 20-20-15 Install a sling (Item 1) [Figure 20-20-12] on the cylinder. Figure 20-20-13
1 1
P-33402
Remove the pin (Item 1) [Figure 20-20-15].

P-33398
Remove the bolt (Item 1) [Figure 20-20-13] from the base end retaining pin.
20-20-4
BOOM CYLINDER (CONTD) Removal And Installation (Contd) Figure 20-20-16
Figure 20-20-18
P-33401

P-33396
P-33399
20-20-5
BOOM CYLINDER (CONTD) Removal And Installation (Contd) Figure 20-20-19
Figure 20-20-21
P-33405
Remove the cylinder [Figure 20-20-21].

P-33403
Figure 20-20-20
P-33404
Raise the hoist and remove the shims (Item 1) [Figure 20-20-19] & [Figure 20-20-20] from both sides of the rod end and base end of the cylinder.
20-20-6
BOOM CYLINDER (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9.
Snap Ring Bearing Grease Fitting Housing Ring Seal Seal O-ring Backup Ring
10. 11. 12. 13. 14. 15. 16. 17. 18.
Head Bolt Seal Wiper Seal Nut Piston Seals Steel Ring Piston Rod
1 2 3
8 9 10 11
5 15 16 17 16
14
12 13 3 18
1 2
B-16949
20-20-7
BOOM CYLINDER (CONTD) Disassembly Use the following tools to disassemble the cylinder. MEL1074-O-Ring Seal Hook Clamp the base end of the cylinder in a vise. Figure 20-20-22
Figure 20-20-24
P-36056
Remove the tubeline (Item 1) and blocks (Item 2) [Figure 20-20-24]. Figure 20-20-25 1
P-36053
Install a block (Item 1) [Figure 20-20-22] under the end of the cylinder housing. Use care not to damage the cylinder housing. Figure 20-20-23
1
P-36057
Remove the 4 bolts (Item 1) [Figure 20-20-25] and remove the boom load holding valve. For boom load holding valve disassembly. (See Disassembly on Page 20-200-3.)
P-36054
Remove the clamps (Item 1) [Figure 20-20-23].
20-20-8
BOOM CYLINDER (CONTD) Disassembly (Contd) Figure 20-20-26
Figure 20-20-28
1
P-36068
P-36058
Remove the snap ring (Item 1) [Figure 20-20-28] from the base end of the cylinder. Figure 20-20-29
Remove the 12 bolts (Item 1) [Figure 20-20-26] from the head. Figure 20-20-27
P-36067
Remove the bearing (Item 1) [Figure 20-20-29].

P-36060
NOTE: The bearing can only be removed through the snap ring side of the housing. Install a drain pan (Item 1) under the housing and remove the rod assembly (Item 2) [Figure 20-20-27]. Remove the cylinder from the vise.
20-20-9
Figure 20-20-32
P-36076
P-36069
Remove the piston (Item 1) and head (Item 2) [Figure 20-20-32]. Figure 20-20-33
Clamp the rod end in a vise, support the end of the rod with a wood block (Item 1) [Figure 20-20-30]. Use care not to damage the rod. Figure 20-20-31 1
1
P-36074
Remove the steel rings (Item 1) [Figure 20-20-33] from the piston.
P-36070
Apply moderate heat to the nut (Item 1) [Figure 20-2031]. Remove the nut.
20-20-10
BOOM CYLINDER (CONTD) Disassembly (Contd) Figure 20-20-34 1
Figure 20-20-36 1
P-36071
Remove the seal (Item 1) [Figure 20-20-36].

P-36073
Figure 20-20-37 Remove the wear rings (Item 1) [Figure 20-20-34]. 2 Figure 20-20-35 1 1
P-36078
P-36072
Remove the O-ring (Item 1) and back-up ring (Item 2) [Figure 20-20-37] from the head.
Remove the back-up rings (Item 1) [Figure 20-20-35].
20-20-11
Figure 20-20-40
P-36085
P-36079
Remove the rod from the vise. Remove the snap ring (Item 1) [Figure 20-20-40]. Figure 20-20-41
Remove the two wear rings (Item 1) [Figure 20-20-38]. Figure 20-20-39
1 1
3 4
P-36086
P-36080
Remove the bearing (Item 1) [Figure 20-20-41]. NOTE: The bearing can only be removed through the snap ring side of the housing.
Remove the wiper (Item 1), wear ring (Item 2), seal (Item 3) and back-up ring (Item 4) [Figure 20-20-39].
20-20-12
BOOM CYLINDER (CONTD) Assembly
Figure 20-20-43 1
Use the following tools to assemble the cylinder. MEL1396-Universal Seal Expander MEL1033-Rod Seal Installation Tool Piston Ring Compressor Wash the cylinder parts in clean solvent and dry them with compressed air. Inspect the cylinder parts for nicks, scratches or other damage. replace any damaged parts. Always install new O-rings and seals during assembly. Lubricate all O-rings and seals with hydraulic oil during installation. Figure 20-20-42 Figure 20-20-44
P-36085
1 1
P-36086
P-36084
Make sure the bearing is fully seated in the housing (Item 1) [Figure 20-20-43] and install the snap ring (Item 1) [Figure 20-20-44].
Install the bearing (Item 1) [Figure 20-20-42] in the rod end. NOTE: The bearing can only be installed from the snap ring side of the housing.
20-20-13
BOOM CYLINDER (CONTD) Assembly (Contd) Figure 20-20-45
Figure 20-20-47
2 1
P-36080
P7427
Install the wiper (Item 1), wear ring (Item 2) and backup ring (Item 3) [Figure 20-20-47]. Figure 20-20-48
Install the rod seal on the rod seal tool [Figure 20-20-45]. 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 2020-45]. Figure 20-20-46 1
P-36079
Install the two wear rings (Item 1) [Figure 20-20-48].
P-36081
Install the rod seal in the head [Figure 20-20-46].
20-20-14
Figure 20-20-51
1
P-36071
Install the seal (Item 1) [Figure 20-20-51] on the piston.

P-36078
Figure 20-20-52 Install the O-ring (Item 1) and back-up ring (Item 2) [Figure 20-20-49] on the head. Figure 20-20-50
1
P-36072
Install the back-up rings (Item 1) [Figure 20-20-52].

P-35979
Install the new seal on the tool and slowly stretch it until it fits the piston [Figure 20-20-50]. Allow the seal to stretch for thirty seconds before installing it on the piston.
20-20-15
Figure 20-20-55
1
P-36082
P-36073
Clamp the rod end in a vise. Support the end of the rod with a wood block (Item 1) [Figure 20-20-55]. Use care not to damage the rod. Figure 20-20-56
Install the wear rings (Item 1) [Figure 20-20-53]. Figure 20-20-54
1 1 2
P-36076 P-36074
Install the head (Item 1) and piston (Item 2) [Figure 2020-56]. Install the steel rings (Item 1) [Figure 20-20-54].
20-20-16
Figure 20-20-59
1 1
P-36066
P-36070
Install the bearing (Item 1) [Figure 20-20-59] into the base end of the cylinder housing. NOTE: The bearing can only be installed thru the snap ring side of the housing. Figure 20-20-60
Apply thread lock adhesive (Loctite 270) to the threads and install the nut (Item 1) [Figure 20-20-57]. Tighten the nut to 1512 ft.-lb. (2050 Nm) torque. Figure 20-20-58
P-36068
P-36083
Fully seat the bearing and install the snap ring (Item 1) [Figure 20-20-60].
Install a ring compressor on the piston (Item 1) [Figure 20-20-58] and compress the seal to the correct size. Leave the piston in the compressor for about three minutes. Remove the rod and head assembly from the vise.
20-20-17
Figure 20-20-63 1
2 1
P-36155
P-36064
Install the twelve bolts (Item 1) [Figure 20-20-63]. Tighten the bolts to 107 ft.-lb. (145 Nm) torque. Figure 20-20-64
Clamp the base end of the cylinder in a vise and support the end of the housing with a block (Item 1) [Figure 2020-61]. Use care not to damage the cylinder housing. Support the rod assembly with wood blocks (Item 2) [Figure 20-20-61]. Install a ring compressor (Item 3) [Figure 20-20-61] on the piston to compress the steel rings to the correct size. Push the piston into the housing. 3 Figure 20-20-62 4 4
P-36053
1 2
To allow the cylinder rod to be moved during installation do not install the boom load holding valve (Item 1) [Figure 20-20-64] until the cylinder has been installed on the excavator. For boom load holding valve installation on the excavator. (See Removal And Installation on Page 20200-1). Install the tubeline (Item 2) blocks (Item 3) and clamps (Item 4) [Figure 20-20-64].
P-36065
Install the head (Item 1) [Figure 20-20-62] in the housing.
20-20-18
ARM CYLINDER Testing Fully retract the bucket and arm cylinders. Lower the boom to the ground. With the engine off and the key in the run position, move the joysticks to relieve hydraulic pressure. Figure 20-21-1
Removal And Installation Fully retract the bucket and arm cylinders. Lower the boom to the ground. With the engine off and the key in the run position, move the joysticks to relieve hydraulic pressure.
IMPORTANT
1 When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
I-2003-0888
Figure 20-21-3
P-33406
Remove the hydraulic hose (Item 1) [Figure 20-21-1] from the base end of the arm cylinder. 2 Figure 20-21-2
P-33406
2 1
Remove the hose (Item 1) [Figure 20-21-3] from the base end. Remove the hose (Item 2) [Figure 20-21-3] from the rod end.
P-36023
Install a plug (Item 1) [Figure 20-21-2] on the hose. Start the engine and retract the arm cylinder. If there is any oil leakage from the base end fitting (Item 2) [Figure 20-21-2] on the arm cylinder, remove the cylinder for repair or replacement.
20-21-1
ARM CYLINDER (CONTD) Removal And Installation (Contd) Figure 20-21-4
Figure 20-21-6
P-33408
P-33407
Remove the auxiliary hydraulic hose (Item 1) [Figure 2021-6]. Figure 20-21-7
Install a sling (Item 1) [Figure 20-21-4] on the cylinder. Figure 20-21-5
1 1
P-33409
P-33415
Remove the bolt (Item 1) [Figure 20-21-7] from the rod end retaining pin.
Install a chain hoist (Item 1) [Figure 20-21-5] on the boom.
20-21-2
Figure 20-21-10
P-33413
P-33410
Remove the bolt (Item 1) [Figure 20-21-10] from the base end retaining pin. Figure 20-21-11
Remove the spacer (Item 1) [Figure 20-21-8]. Figure 20-21-9
1 1
P-33414
P-33411
Raise the chain hoist attached to the boom and remove the pin (Item 1) [Figure 20-21-9].
20-21-3
Figure 20-21-14
1
P-33416
P-33412
Raise the hoist and remove the shims (Item 1) [Figure 20-21-13] & [Figure 20-21-14] from both sides of the rod end and base end of the cylinder. Figure 20-21-15
Remove the pin (Item 1) [Figure 20-21-12]. Figure 20-21-13
1
P-33418 P-33417
20-21-4
ARM CYLINDER (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9.
Snap Ring Bearing Grease Fitting Housing Ring Seal Seal O-Ring Backup Ring
10. 11. 12. 13. 14. 15. 16. 17. 18.
Head Bolt Seal Wiper Seal Nut Piston Seals Steel Ring Piston Rod
1 2 3
5 8 9 10 11 13 12 3 18 1 2 16 17 7 6 15 16
14
B-16948
20-21-5
ARM CYLINDER (CONTD) Disassembly Use the following tools to disassemble the cylinder. MEL1074-O-ring Seal Hook. Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder. Clamp the base end of the cylinder in a vise. Be careful not to damage the cylinder housing. Figure 20-21-16
Figure 20-21-18
P-36063
Remove the block (Item 1) and tube line (Item 2) [Figure 20-21-18]. Figure 20-21-19 1
1
P-36061
Support the cylinder with a block (Item 1) [Figure 20-2116]. Figure 20-21-17
P-36064
Remove the 12 bolts (Item 1) [Figure 20-21-19].
P-36062
Remove the clamp (Item 1) [Figure 20-21-17].
20-21-6
ARM CYLINDER (CONTD) Disassembly (Contd) Figure 20-21-20
Figure 20-21-22
P-36067

P-36065
NOTE: The bearing can only be removed through the snap ring side of the housing. Remove the rod assembly (Item 1) [Figure 20-21-20]. Figure 20-21-23 Remove the cylinder housing from the vise. Figure 20-21-21
1
P-36068
P-36069
Clamp the rod end in a vise. Support the end of the rod with a wood block (Item 1) [Figure 20-21-23]. Use care not to damage the rod.
Remove the snap ring (Item 1) [Figure 20-21-21] from the base end of the cylinder.
20-21-7
ARM CYLINDER (CONTD) Disassembly (Contd)
Figure 20-21-26
1 Figure 20-21-24
P-36074
P-36070
Remove the steel rings (Item 1) [Figure 20-21-26] from the piston. Figure 20-21-27
Apply moderate heat to the nut (Item 1) [Figure 20-2124]. Remove the nut. Figure 20-21-25
P-36073
Remove the wear rings (Item 1) [Figure 20-21-27].

P-36076
Remove the piston (Item 1) and head (Item 2) [Figure 20-21-25].
20-21-8
ARM CYLINDER (CONTD) Disassembly (Contd)
Figure 20-21-30 2
Figure 20-21-28 1
P-36078
P-36072
Remove the O-ring (Item 1) and back-up ring (Item 2) [Figure 20-21-30] from the head. Figure 20-21-31
Remove the back-up rings (Item 1) [Figure 20-21-28]. Figure 20-21-29 1 1
P-36079
P-36071
Remove the two wear rings (Item 1) [Figure 20-21-31].
20-21-9
ARM CYLINDER (CONTD) Disassembly (Contd) Figure 20-21-32
Figure 20-21-34
1 1
4 3
P-36086

P-36080
NOTE: The bearing can only be removed through the snap ring side of the housing. Remove the wiper (Item 1), wear ring (Item 2) seal, (Item 3) and back-up ring (Item 4) [Figure 20-21-32]. Figure 20-21-33
P-36085
Remove the rod from the vise. Remove the snap ring (Item 1) [Figure 20-21-33].
20-21-10
ARM CYLINDER (CONTD) Assembly Use the following tools to assemble the cylinder: MEl1396-Universal Seal Expander MEL1033-Rod seal Installation Tool Piston Ring Compressor Wash the cylinder parts in clean solvent and dry them with compressed air. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts. Always install new O-rings and seals during assembly. Lubricate all O-rings and seals with hydraulic oil during installation. Figure 20-21-35
Figure 20-21-36
P-36085
Figure 20-21-37
1 1
P-36086
P-36084
Make sure the bearing is fully seated in the housing [Figure 20-21-36] and install the snap ring (Item 1) [Figure 20-21-37].
20-21-11
ARM CYLINDER (CONTD) Assembly (Contd) Figure 20-21-38
Figure 20-21-40
2 3
P-36080
P7427
Install the wiper (Item 1), wear ring (Item 2) and back-up ring (Item 3) [Figure 20-21-40]. Figure 20-21-41
Install the rod seal on the rod seal tool [Figure 20-21-38]. 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 2021-38]. Figure 20-21-39
P-36079
P-36081
20-21-12
ARM CYLINDER (CONTD) Assembly (Contd) Figure 20-21-42 1 2
Figure 20-21-44
1
P-36071
Install the seal (Item 1) [Figure 20-21-44] on the piston.

P-36078
Figure 20-21-45 Install the back-up ring (Item 1) and O- ring (Item 2) [Figure 20-21-42] on the head. Figure 20-21-43
P-36072

P-35979
Figure 20-21-46
Install the new seal on the tool and slowly stretch it until it fits the piston [Figure 20-21-43]. Allow the seal to stretch for 30 seconds before installing it on the piston.
1
P-36073
Install the wear rings (Item 1) [Figure 20-21-46].

Figure 20-21-49
P-36076
P-36074
Install the head (Item 1) and piston (Item 2) [Figure 2021-49]. Figure 20-21-50
Install the steel rings (Item 1) [Figure 20-21-47]. Figure 20-21-48 1
1
P-36082
P-36070
Apply thread lock adhesive (Loctite 270) to the threads and install the nut (Item 1) [Figure 20-21-50]. Tighten the nut to 1364 ft.-lb. (1850 Nm) torque.
20-21-14
Figure 20-21-53
P-36068
P-36083
Fully seat the bearing and install the snap ring (Item 1) [Figure 20-21-53]. Figure 20-21-54
Install a ring compressor on the piston (Item 1) [Figure 20-21-51] and compress the seal to the correct size. Leave the piston in the compressor for three minutes. Remove the rod and head assembly from the vise. Figure 20-21-52 3
1 2
P-36155
Clamp the base end of the cylinder in a vise and support the end of the housing with a block (Item 1) [Figure 2021-54]. Use care not to damage the cylinder housing.
P-36066
Support the rod assembly with wood blocks (Item 2) [Figure 20-21-54]. Install the bearing (Item 1) [Figure 20-21-52] into the base end of the cylinder housing. NOTE: The bearing can only be installed through the snap ring side of the housing. Install a ring compressor (Item 3) [Figure 20-21-54] on the piston to compress the steel rings to the correct size. Push the piston into the housing.
20-21-15
Figure 20-21-57
P-36063
P-36065
Install the tubeline (Item 1) and block (Item 2) [Figure 2021-57]. Figure 20-21-58
Install the head (Item 1) [Figure 20-21-55] in the housing. Figure 20-21-56 1 1
P-36062
Install the clamp (Item 1) [Figure 20-21-58].

P-36064
Install the 12 bolts (Item 1) [Figure 20-21-56] and tighten to 114 ft.-lb. (155 Nm) torque.
20-21-16
BOOM OFFSET CYLINDER Testing Swing the boom to the right, fully extending the boom offset cylinder. Lower the boom/bucket to the ground. Stop the engine. Figure 20-22-1
Figure 20-22-3
P-33701
Remove the pin (Item 1) [Figure 20-22-3]. 1 Figure 20-22-4
P-33699
Remove the bolt (Item 1) [Figure 20-22-1]. Installation: Tighten the bolt to 48-55 ft.-lb. (65-75 Nm) torque. Figure 20-22-2
P-33702
Place a board (Item 1) [Figure 20-22-4] between the cylinder and excavator frame.
P-33700
20-22-1
BOOM OFFSET CYLINDER (CONTD) Testing (Contd) Figure 20-22-5 When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
I-2003-0888
IMPORTANT
Figure 20-22-7
P-33703
Start the excavator and fully retract the boom offset cylinder (Item 1) [Figure 20-22-5]. Figure 20-22-6
1 Loosen the clamp (Item 1) [Figure 20-22-7]. Remove the block (Item 2) [Figure 20-22-7]. Figure 20-22-8
P-33706
P-33704
1 To test the cylinder, the cab must be tilted. Use the blade (Item 1) [Figure 20-22-6] as an attaching point for the hand winch and tilt the cab. (See Tilting The Cab on Page 10-160-2). NOTE: Make sure the blade is not in the float position (if equipped) before tilting the cab.
P-33707
Reposition the rod end hose (Item 1) [Figure 20-22-8] from the clamp.
20-22-2
BOOM OFFSET CYLINDER (CONTD) Testing (Contd) Figure 20-22-9
P-33708
Remove the base end hose (Item 1) [Figure 20-22-9]. Install a plug on the hose. Start the engine. Retract the cylinder. If there is any oil leakage from the base end fitting (Item 2) [Figure 20-22-9] on the boom offset cylinder, remove the cylinder for repair or replacement.
20-22-3
BOOM OFFSET CYLINDER Removal And Installation Swing the boom to the right, fully extending the boom offset cylinder. Lower the boom/bucket to the ground. Stop the engine. Figure 20-22-10
Figure 20-22-12
P-33701
P-33699
Remove the bolt (Item 1) [Figure 20-22-10]. Installation: Tighten the bolt to 48-55 ft.-lb. (65-75 Nm) torque. Figure 20-22-11
P-33702
Place a board (Item 1) [Figure 20-22-13] between the cylinder and excavator frame.
P-33700
20-22-4
BOOM OFFSET CYLINDER (CONTD) Removal And Installation (Contd) Figure 20-22-14 When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
I-2003-0888
IMPORTANT
Figure 20-22-16
1
P-33703
Start the excavator and fully retract the boom offset cylinder (Item 1) [Figure 20-22-14]. Figure 20-22-15
P-33705
Remove the rod end hose (Item 1) [Figure 20-22-16]. Figure 20-22-17
P-33704
2 To remove the cylinder, the cab must be tilted. Use the blade (Item 1) [Figure 20-22-15] as an attaching point for the hand winch and tilt the cab. (SSee Tilting The Cab on Page 10-160-2). NOTE: Make sure the blade is not in the float position (if equipped) before tilting the cab. Loosen the clamp (Item 1) [Figure 20-22-17]. Remove the block (Item 2) [Figure 20-22-17].
P-33706
20-22-5
BOOM OFFSET CYLINDER (CONTD) Removal And Installation (Contd) Figure 20-22-18
Figure 20-22-20
P-33709
Remove the bolt (Item 1) [Figure 20-22-20].

P-33707
Installation: Tighten the bolt to 48-55 ft.-lb. (65-75 Nm) torque. Remove the rod end hose (Item 1) [Figure 20-22-18] from the clamp. Figure 20-22-19 Figure 20-22-21
1 1 2
P-33710 P-33708
Remove the spacer (Item 1) [Figure 20-22-21]. Remove the base end hose (Item 1) [Figure 20-22-19]. Remove the remote grease hose (Item 2) [Figure 20-2219].
20-22-6
BOOM OFFSET CYLINDER (CONTD) Removal And Installation (Contd) Figure 20-22-22
P-33711
Remove the pin (item 1) [Figure 20-22-22]. Figure 20-22-23
P-33712
Slide the cylinder (Item 1) [Figure 20-22-23] out the front of the excavator.
20-22-7
BOOM OFFSET CYLINDER (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.
Snap Ring Bearing Housing O-Ring Backup Ring Ring Seal Seal Head Bolt Wiper Seal Nut Steel Ring Piston Seals Piston Cylinder Rod Grease Fitting 6 8 9 10 7 7
2 1 3
4 5
11
12 13 14 15 13 17 16
B-16942
20-22-8
BOOM OFFSET CYLINDER (CONTD) Disassembly Use the following tools to disassemble the cylinder: MEL1074-O-ring Seal Hook Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder. Clamp the base end of the cylinder in a vise. Figure 20-22-24
Figure 20-22-26
P-36065
Remove the rod assembly (Item 1) [Figure 20-22-26]. Remove the cylinder housing from the vise. Figure 20-22-27
P-36182
Support the cylinder with a block (Item 1) [Figure 20-2224]. Use care not to damage the cylinder housing. Figure 20-22-25 1
P-36068
Remove the snap ring (Item 1) [Figure 20-22-27] from the base end of the cylinder.
P-36064
20-22-9
BOOM OFFSET CYLINDER (CONTD) Disassembly (Contd) Figure 20-22-28
Figure 20-22-30
P-36070
P-36067
Apply moderate heat to the nut (Item 1) [Figure 20-2230]. Remove the nut. Figure 20-22-31
Remove the bearing (Item 1) [Figure 20-22-28]. NOTE: The bearing can only be removed through the snap ring side of the housing. Figure 20-22-29 2 1
P-36076
Remove the piston (Item 1) and head (Item 2) [Figure 20-22-31].

P-36069
20-22-10
BOOM OFFSET CYLINDER (CONTD) Disassembly (Contd) Figure 20-22-32 1
Figure 20-22-34
1
P-36072

P-36074
Figure 20-22-35 Remove the steel rings (Item 1) [Figure 20-22-32] from the piston. Figure 20-22-33
1
P-36071
Remove the seal (Item 1) [Figure 20-22-35]. 1

P-36073
Remove the wear rings (Item 1) [Figure 20-22-33].
20-22-11
Figure 20-22-38
1 2 2 1 3 4
P-36080
P-36078
Remove the wiper (Item 1) wear ring (Item 2), seal (Item 3) and back-up ring (Item 4) [Figure 20-22-38]. Figure 20-22-39
Remove the O-ring (Item 1) and back-up ring (Item 2) [Figure 20-22-36] from the head. Figure 20-22-37 1 1
P-36085
P-36079
20-22-12
Assembly Use the following tools to assemble the cylinder. MEL1396-Universal Seal Expander MEL1033-Rod Seal Installation Tool Piston Ring Compressor Wash the cylinder parts in clean solvent and dry with compressed air. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts. Always install new O-rings and seals during assembly. Lubricate all O-rings and seals with hydraulic oil during assembly.
P-36086
Figure 20-22-41
Remove the bearing (Item 1) [Figure 20-22-40]. NOTE: The bearing can only be removed through the snap ring side of the housing.
P-36084
20-22-13
BOOM OFFSET CYLINDER (CONTD) Assembly (Contd) Figure 20-22-42
Figure 20-22-44
P7427
Install the rod seal on the rod seal tool [Figure 20-22-44].
P-36085
NOTE: During installation the spring side of the seal must be toward the inside of the cylinder. Figure 20-22-43 Rotate the handles to collapse the rod seal [Figure 2022-44]. Figure 20-22-45
P-36086
P-36081
20-22-14
BOOM OFFSET CYLINDER (CONTD) Assembly (Contd)
Figure 20-22-48
2 Figure 20-22-46 1
P-36078
P-36080
Install the O-ring (Item 1) and back-up ring (Item 2) [Figure 20-22-48] on the head. Figure 20-22-49
P-35979
P-36079
20-22-15
Figure 20-22-52
1 1
P-36071
P-36073
Install the wear rings (Item 1) [Figure 20-22-52]. Figure 20-22-53
Install the seal (Item 1) [Figure 20-22-50] on the piston. Figure 20-22-51 1
P-36074
1
P-36072
Install the steel rings (Item 1) [Figure 20-22-53].
20-22-16
Figure 20-22-56
P-36070
1
P-36082
Apply thread lock adhesive (Loctite 270) to the threads and install the nut (Item 1) [Figure 20-22-56]. Tighten the nut to 1143 ft.-lb. (1550 Nm) torque.
Clamp the rod end in a vise and support the end of the rod with a wood block (Item 1) [Figure 20-22-54]. Use care not to damage the rod. Figure 20-22-55
Figure 20-22-57
P-36083
P-36076
Install a ring compressor on the piston (Item 1) [Figure 20-22-57] and compress the seal to the correct size. Leave the piston in the compressor for three minutes. Remove the rod and head assembly from the vise.
Install the head (Item 1) and piston (Item 2) [Figure 2022-55].
20-22-17
Figure 20-22-60
2 1
P-36155
1 Clamp the base end of the cylinder in a vise and support the end of the housing with a block (Item 1) [Figure 2022-60]. Use care not to damage the cylinder housing. Support the rod assembly with wood blocks (item 2) [Figure 20-22-60]. Install a ring compressor (Item 3) [Figure 20-22-60] on the piston to compress the steel rings to the correct size. Push the piston into the housing. Remove the ring compressor. Figure 20-22-61
P-36066
Install the bearing (Item 1) [Figure 20-22-58] in to the base end of the cylinder housing. NOTE: The bearing can only be installed through the snap ring side of the housing. Figure 20-22-59
P-36068
P-36065
20-22-18
BOOM OFFSET CYLINDER (CONTD) Assembly (Contd) Figure 20-22-62 1
P-36064
Install the 12 bolts (Item 1) [Figure 20-22-62] and tighten to 114 ft.-lb. (155 Nm) torque.
20-22-19
20-22-20
BUCKET CYLINDER Testing Fully retract the bucket and arm cylinders. Lower the boom to the ground.
Removal And Installation Fully retract the bucket cylinder. Fully retract the arm cylinder and lower the boom until the bucket is on the ground. Figure 20-23-65
With the engine off and the key in the run position, move the joysticks to relieve hydraulic pressure. Figure 20-23-63 1
P-33713
P-33714
Support the arm with a chain hoist (Item 1) [Figure 2023-65]. With the engine off and the key in the run position, move the joysticks to relieve hydraulic pressure.
Remove the hydraulic hose (Item 1) [Figure 20-23-63] from the base end of the bucket cylinder. Figure 20-23-64
IMPORTANT
1 2 When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
I-2003-0888
P-36030
Install a plug (Item 1) [Figure 20-23-64] on the hose. Start the engine and retract the bucket cylinder. If there is any oil leakage from the base end fitting (Item 2) [Figure 20-23-64] on the bucket cylinder, remove the cylinder for repair or replacement.
20-23-1
BUCKET CYLINDER (CONTD) Removal And Installation (Contd) Figure 20-23-66
Figure 20-23-68
1 1
P-33716
P-33714
Remove the snap ring (Item 1) [Figure 20-23-68] and two washers from the cylinder rod end pin. Figure 20-23-69
Remove the hose (Item 1) [Figure 20-23-66] from the base end. Remove the hose (Item 2) [Figure 20-23-66] from the rod end. Figure 20-23-67
P-33717
P-33715
Install a hoist on the cylinder [Figure 20-23-67].
20-23-2
Figure 20-23-72
P-33720

P-33718
Figure 20-23-73 Raise the cylinder [Figure 20-23-70]. Figure 20-23-71
1 1
P-33721

P-33719
Remove the bolt (Item 1) [Figure 20-23-71] and washer.
20-23-3
P-33722
Raise the hoist and remove the spacers (Item 1) [Figure 20-23-74] from both sides of the base end. Figure 20-23-75
P-33723
20-23-4
BUCKET CYLINDER (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9.
Snap Ring Bearing Grease Fitting Housing Ring Seal Seal O-Ring Backup Ring
10. 11. 12. 13. 14. 15. 16. 17. 18.
Head Bolt Seal Wiper Seal Nut Piston Seals Piston Steel Ring Rod
1 2 3
5 6 8 10 11 13 16 17 9 15 7 14
12
3 18
1 2
B-16947
20-23-5
BUCKET CYLINDER (CONTD) Disassembly Use the following tools to disassemble the cylinder. MEL1074 - O-ring Seal Hook Hold the hydraulic cylinder over a drain pan and move the rod in and out slowly to remove the fluid from the cylinder. Clamp the base end of the cylinder in a vise. Be careful not to damage the cylinder housing. Figure 20-23-76
Figure 20-23-78
P-36184
Remove the 12 bolts (Item 1) [Figure 20-23-78]. Figure 20-23-79
1 1
P-36182
Support the cylinder with a block (Item 1) [Figure 20-2376]. Figure 20-23-77
P-36185
Remove the rod assembly (Item 1) [Figure 20-23-79]. Remove the cylinder housing from the vise.
1 3
P-36183
Remove the clamp (Item 1), block (Item 2) and tubeline (Item 3) [Figure 20-23-77]
20-23-6
BUCKET CYLINDER (CONTD) Disassembly (Contd) Figure 20-23-80
Figure 20-23-82
1 1
P-36190
P-36067
Remove the snap ring (Item 1) [Figure 20-23-80] from the base end of the cylinder. Figure 20-23-81
Figure 20-23-83
1
P-36068
P-36191
Apply moderate heat to the nut (Item 1) [Figure 20-2383]. Remove the bearing (Item 1) [Figure 20-23-81]. NOTE: The bearing can only be removed through the snap ring side of the housing.
20-23-7
BUCKET CYLINDER (CONTD) Disassembly (Contd)
Figure 20-23-86 1
Figure 20-23-84
P-36194

P-36190
Figure 20-23-87 Remove the nut (Item 1), piston (Item 2) and head (Item 3) [Figure 20-23-84]. 1 Figure 20-23-85 1
P-36193

P-36195
Figure 20-23-88
Remove the wear rings (Item 1) [Figure 20-23-85] from the piston.
P-36192
Remove the steel ring (Item 1) [Figure 20-23-88].

BUCKET CYLINDER (CONTD) Disassembly (Contd) Figure 20-23-89 2 1
Figure 20-23-91
P-36080
P-36078
Remove the wiper (Item 1), wear ring (Item 2), seal (Item 3) and back-up ring (Item 4) [Figure 20-23-91]. Figure 20-23-92
Remove the O-ring (Item 1) and back-up ring (Item 2) [Figure 20-23-89] from the head. Figure 20-23-90 1
P-36085
P-36079
20-23-9
BUCKET CYLINDER (CONTD) Disassembly (Contd) Figure 20-23-93
Assembly Use the following tools to assemble the cylinder. MEL1396-Universal Seal Expander MEL1033-Rod Seal Installation Tool Piston Ring Compressor Wash the cylinder parts in clean solvent and dry them with compressed air. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts. 1 Always install new O-rings and seals during assembly. Lubricate all O-ring and seals with hydraulic oil during installation.
P-36086
Figure 20-23-94
Remove the bearing (Item 1) [Figure 20-23-93]. 1 NOTE: The bearing can only be removed through the snap ring side of the housing.
P-36084
20-23-10
BUCKET CYLINDER (CONTD) Assembly (Contd) Figure 20-23-95
Figure 20-23-97
P7427
Install the rod seal on the rod seal tool [Figure 20-23-97].
P-36085
NOTE: During installation the spring side of the seal must be toward the inside of the cylinder. Figure 20-23-96 Rotate the handles to collapse the rod seal [Figure 2023-97]. Figure 20-23-98
P-36086
P-36081
20-23-11
Figure 20-23-101 1 2
P-36078
P-36080
Install the back-up ring (Item 1) and O-ring (Item 2) [Figure 20-23-101] on the head. Figure 20-23-102
P-35979
P-36079
20-23-12
Figure 20-23-105
P-36194

P-36192
Figure 20-23-106 Install the steel ring (Item 1) [Figure 20-23-103] on the piston. Figure 20-23-104
P-36195

P-36193
Install the seal (Item 1) [Figure 20-23-104].
20-23-13
Figure 20-23-109
P-36191
P-36196
Tighten the nut (Item 1) [Figure 20-23-109] to 1364 ft.-lb. (1850 Nm) torque. Figure 20-23-110
Clamp the rod end in a vise. Support the end of the rod with a wood block (Item 1) [Figure 20-23-107]. Use care not to damage the rod. 1 Figure 20-23-108
P-36197
Install a ring compressor on the piston (Item 1) [Figure 20-23-110] and compress the seal to the correct size.
P-36190
Leave the piston in the compressor for three minutes. Install the head (Item 1) and piston (Item 2) [Figure 2023-108]. Apply thread lock adhesive (Loctite 270) to the rod threads and install the nut (Item 3) [Figure 20-23-108]. Remove the rod assembly from the vise.
20-23-14
Figure 20-23-113
1 1
P-36155
P-36067
Clamp the base end of the cylinder in a vise and support the end of the housing with a block (Item 1) [Figure 2023-113]. Use care not to damage the cylinder housing. Support the rod assembly with wood blocks (Item 2) [Figure 20-23-113]. Install a ring compressor (Item 3) [Figure 20-23-113] on the piston to compress the steel rings to the correct size. Push the piston into the housing. Figure 20-23-114
Install the bearing (Item 1) [Figure 20-23-111] into the base end of the cylinder housing. NOTE: The bearing can only be installed through the snap ring side of the housing. Figure 20-23-112
1
P-36068
P-36065
20-23-15
BUCKET CYLINDER (CONTD) Assembly (Contd) Figure 20-23-115 1
P-36064
Install the 12 bolts (Item 1) [Figure 20-23-115] and tighten to 53 ft.-lb. (72 Nm) torque Figure 20-23-116
3 1
P-36183
Install the tubeline (Item 1), block (Item 2) and clamp (Item 3) [Figure 20-23-116].
20-23-16
BLADE CYLINDER Testing Put the bucket on the ground. Figure 20-24-1
Figure 20-24-3
1
P-36029
Install a plug (Item 1) [Figure 20-24-3] on the hose. Start the engine and retract the blade cylinders.
P-36027
Raise the blade, and support with jack stands [Figure 20-24-1]. Stop the engine. With the engine off and the key in the run position, move the blade lever to relieve hydraulic pressure. Figure 20-24-2
If there is any oil leakage from the base end fitting (Item 2) [Figure 20-24-3] on the blade cylinders, remove the cylinders for repair or replacement.
P-36028
Remove the hydraulic hose (Item 1) [Figure 20-24-2] from the base end of the blade cylinders.
20-24-1
BLADE CYLINDER (CONTD) Removal And Installation NOTE: The right blade cylinder is shown. The procedure is the same for the left blade cylinder. Put the blade on the floor. With the engine off and the key in the run position, move the blade lever to relieve hydraulic pressure.
Figure 20-24-5
IMPORTANT
I-2003-0888
P-33449
Remove the bolt (Item 1) [Figure 20-24-5] and nut from the base end retaining pin. Installation: Tighten the bolt to 48-55 ft.-lb. (65-75 Nm) torque. Figure 20-24-6
Figure 20-24-4 1 2
1
P-35918
P-33450
Remove the hose (Item 1) [Figure 20-24-4] from the base end of the cylinder. Remove the hose (Item 2) [Figure 20-24-4] from the rod end of the cylinder.
Remove the bolt (Item 1) [Figure 20-24-6] and nut from the rod end retaining pin. Installation: Tighten the bolt to 48-55 ft.-lb. (65-75 Nm) torque.
20-24-2
BLADE CYLINDER (CONTD) Removal And Installation (Contd) Figure 20-24-7
Figure 20-24-9
2
P-33447
Figure 20-24-10
P-33448
Figure 20-24-8
1 1
2
P-33445
P-33446
Raise the hoist and remove the shims (Item 1) [Figure 20-24-9] & [Figure 20-24-10] from both sides of the rod end and base end of the cylinder. Figure 20-24-11
Install a sling (Item 1) [Figure 20-24-7] & [Figure 20-248] on the rod end and base end of the cylinder. Remove the pins (Item 2) [Figure 20-24-7] & [Figure 2024-8].
P-33443
Remove the cylinder [Figure 20-24-11]

BLADE CYLINDER (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9.
Snap Ring Bearing Grease Fitting Housing O-Ring Backup Ring Seal Seal Seal
10. 11. 12 13. 14. 15. 16. 17.
Wear Ring Head Bolt Wiper Seal Nut Piston Piston Seals Rod
2 4 1
5 6 7 9 11 12 10 8 8 3
14 13 3 16 15
17
B-16946
20-24-4
BLADE CYLINDER (CONTD) Disassembly
Figure 20-24-13
IMPORTANT
When making repairs on hydraulic system, clean the work area before disassemble and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
I-2056-0793
P-35994
1 2
Use the following tools to disassemble the cylinder. MEL1074-O-Ring Seal Hook Hold the cylinder over a drain pan and slowly move the rod in and out to remove the oil from the cylinder. NOTE: The blade cylinder on the right side of the excavator has a check valve installed in the base end port which will prevent the hydraulic oil from being drained from the base end of the cylinder. Figure 20-24-12 Remove the bolt (Item 1) and seal carrier (Item 2) [Figure 20-24-13] from the fittings. Figure 20-24-14
P-35996
2 Remove the O-ring (Item 1) [Figure 20-24-14] from the bolt. 1
P-35993
Clamp the base end of the cylinder housing in a vise [Figure 20-24-12]. Be careful not to damage the cylinder housing. Install a block (Item 1) [Figure 20-24-12] to support the cylinder. Remove the fittings (Item 2) [Figure 20-24-12].
20-24-5
BLADE CYLINDER (CONTD) Disassembly (Contd) Figure 20-24-15
Figure 20-24-17 1
P-35991
P-35995
Remove the cover (Item 1) and clamps (Item 2) [Figure 20-24-17]. Figure 20-24-18
Remove the seal (Item 1) [Figure 20-24-15] from the seal carrier. Figure 20-24-16 2 2
1
P-35990
P-35992
Remove the blocks (Item 1) and clamps (Item 2) [Figure 20-24-18] from the cover.
Loosen the hose clamps (Item 1) [Figure 20-24-16] until they are fully disconnected.
20-24-6
BLADE CYLINDER (CONTD) Disassembly (Contd) Figure 20-24-19
Figure 20-24-21
P-35986
Remove the check valve (Item 1) [Figure 20-24-21].

P-35989
Remove the cylinder housing from the vise. Remove the 10 bolts (Item 1) [Figure 20-24-19]. Figure 20-24-20 Figure 20-24-22
1 2 1
P-35985 P-35988
Remove the snap ring (Item 1) and bearing (Item 2) [Figure 20-24-22]. Remove the rod assembly (Item 1) [Figure 20-24-20] from the housing. NOTE: Place a drain pan under the end of the cylinder housing to catch any undrained hydraulic oil from the base end of the right hand cylinder. (with check valve)
20-24-7
BLADE CYLINDER (CONTD) Disassembly (Contd) Figure 20-24-23 2 3 1
Figure 20-24-25
P-35974
P-35984
Remove the wear rings (Item 1) and seal (Item 2) [Figure 20-24-25] from the head. Figure 20-24-26
Clamp the rod end in a vise and install a wood block to support the end of the rod [Figure 20-24-23]. Use care not to damage the rod. Apply moderate heat to the nut (Item 1) [Figure 20-2423] and loosen the nut. Remove the nut (Item 1), piston (Item 2) and head (Item 3) [Figure 20-24-23] Figure 20-24-24 3 2 1
3
P-35977
1 1
Remove the wiper (Item 1), seal (Item 2) and wear ring (Item 3) [Figure 20-24-26].
2
P-35982
Remove the wear rings (Item 1), back-up rings (Item 2) and seal (Item 3) [Figure 20-24-24] from the piston.
20-24-8
BLADE CYLINDER (CONTD) Disassembly (Contd) Figure 20-24-27 2 1
P-35973
Remove the O-ring (Item 1) and back-up ring (Item 2) [Figure 20-24-27]. Remove the rod from the vise. Figure 20-24-28
P-35972
Remove the snap ring (Item 1) and bearing (Item 2) [Figure 20-24-28] from the rod.
20-24-9
BLADE CYLINDER (CONTD) Assembly Use the following tools to assemble the cylinder. MEL1396 - Universal Seal Expander MEL1033 - Rod Seal Installation Tool Piston Ring Compressor Wash the cylinder parts in clean solvent and dry with compressed air. Inspect the cylinder parts for nicks, scratches or other damage. Replace any damaged parts. Always install new O-rings and seals during assembly. Lubricate all O-rings and seals with hydraulic oil during assembly. Figure 20-24-29
Figure 20-24-30
P7427
Install the rod seal on the rod seal tool [Figure 20-24-30]. 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 2024-30]. Figure 20-24-31
2 1
P-35972
Install the bearing (Item 1) and snap ring (Item 2) [Figure 20-24-29] in the rod.
P-35976
Install the two rod seals in the head [Figure 20-24-31].
20-24-10
BLADE CYLINDER (CONTD) Assembly (Contd) Figure 20-24-32
Figure 20-24-34 1 2 2
P-35973
P-35977
Install the back-up ring (Item 1) and O-ring (Item 2) [Figure 20-24-34]. Figure 20-24-35
Install the wear ring (Item 1) and wiper (Item 2) [Figure 20-24-32]. Figure 20-24-33
P-35979
P-35974
20-24-11
Figure 20-24-38
1 1
P-35982

P-35980
Figure 20-24-39 Install the seal (Item 1) [Figure 20-24-36] on the piston. Figure 20-24-37
P-35978
1
P-35981
Clamp the rod end in a vise [Figure 20-24-39]. Use care not to damage the rod.
20-24-12
Figure 20-24-42
2 2
P-35985
3 Install the bearing (Item 1) and snap ring (Item 2) [Figure 20-24-42] in the base end of the cylinder. Figure 20-24-43 Install the head (Item 1) and piston (Item 2) [Figure 2024-40]. Apply thread lock adhesive (Loctite 270) to the threads of the rod and install the nut (Item 3) [Figure 20-24-40]. Support the rod with a wood block and tighten the nut to 1143 ft.-lb. (1550 Nm) torque. Figure 20-24-41 1
P-35984
P-35986
Install the check valve (Item 1) [Figure 20-24-43].
P-35983
Use a ring compressor to compress the seal to the correct size. Leave the piston in the compressor for three minutes [Figure 20-24-41]. Remove the rod assembly from the vise.
20-24-13
Figure 20-24-46
P-35989
P-35987
Install the ten bolts (Item 1) [Figure 20-24-46] and tighten to 114 ft.-lb. (155 Nm) torque. Figure 20-24-47
Clamp the base end of the cylinder housing in a vise [Figure 20-24-44]. Use care not to damage the cylinder housing. Figure 20-24-45 3 2 2 1
P-35990
Install the clamps (Item 1) and blocks (Item 2) [Figure 20-24-47] on the cover.
P-35988
Support the end of the housing with a block (Item 1) and install the rod assembly (Item 2) until the head (Item 3) [Figure 20-24-45] is fully seated in the housing.
20-24-14
BLADE CYLINDER (CONTD) Assembly (Contd) Figure 20-24-48 1 2
Figure 20-24-50 3 1
2 4 2
P-35997
P-35991
Install the seal (Item 1) with the lips (Item 2) in the grooves (Item 3) of the seal carrier (Item 4) [Figure 2024-50]. Figure 20-24-51
Install the cover (Item 1) on the cylinder housing with the hole (Item 3) over the base end port (Item 2) [Figure 2024-48]. Figure 20-24-49
P-35996
Install the O-ring (Item 1) [Figure 20-24-51] on the bolt.

P-35992
Connect the ends of the clamps (Item 1) [Figure 20-2449] and tighten.
20-24-15
Figure 20-24-54
1 1 3 2
P-35993
P-35994
Install the fittings (Item 1) [Figure 20-24-54] in the cylinder housing.
Install the bolt (Item 1) and seal carrier (Item 2) into the fitting (Item 3) [Figure 20-24-52]. Figure 20-24-53
1
P-35998
NOTE: The groove (Item 1) on the seal carrier fits into the groove (Item 2) [Figure 20-24-53] in the fitting.
20-24-16
RELIEF VALVES Description Figure 20-30-1
Figure 20-30-3
1
P-32843
P-33373
The backup relief valve (Item 1) [Figure 20-30-3] is set at 4350 PSI (300 bar), 290 PSI (20 bar) higher than the load sense relief. The backup relief valve and load sense relief valve are tested and adjusted during the piston pump testing and adjusting. (See Pump Testing on Page 20-50-6 or See Pump Testing on Page 20-52-5.)
The gear pump circuit has one main relief valve (Item 1) [Figure 20-30-1] located on the three spool valve. The relief valve is factory set at 3335 PSI (230 bar). Figure 20-30-2
P-33367
The piston pump circuit has one load sense relief valve (Item 1) [Figure 20-30-2] and one backup relief valve (Item 1) [Figure 20-30-3] located on the six spool valve. The load sense relief valve (Item 1) [Figure 20-30-2] is factory set at 4060 PSI (280 bar).
20-30-1
RELIEF VALVES (CONTD) Testing The Three Spool Control Valve Main Relief Valve Open the right side cover. Figure 20-30-4
Adjusting The Three Spool Control Valve Main Relief Valve Stop the engine. Open the rear cover. Figure 20-30- 5
1 1 2
P-33371
P-33373
Install a 5000 PSI (345 bar) pressure gauge on the front test coupler (Item 1) [Figure 20-30-4] of the gear pump. Start the excavator and warm the hydraulic oil to operating temperature. Move the engine speed control to the high speed position. Raise the blade until the hydraulic cylinders are fully retracted and the relief valve opens. Record the pressure. The pressure at the gauge (Item 2) [Figure 20-30-4] should be 3335 PSI (230 bar).
Figure 20-30- 6
P-33374
Loosen the lock nut (Item 1) [Figure 20-30- 5] & [Figure 20-30- 6]. Turn the adjustment screw (Item 2) [Figure 20-30- 6] in to increase pressure and out to decrease pressure. NOTE: One quarter turn is approximately 700 psi (48 bar). Tighten the lock nut and retest the main relief valve.
20-30-2
PORT RELIEF VALVES Adjustment Procedure
Figure 20-31-2
IMPORTANT
I-2003-0888
1
P-35504
A portable hydraulic hand pump will be used to test the work port relief valves. The hand pump must have clean hydraulic fluid that is compatible with the Bobcat hydraulic fluid. NOTE: The valve is shown removed from the excavator for photo clarity. Figure 20-31-1
Remove the protective end cap (Item 1) [Figure 20-312]. Figure 20-31-3
2
P-35503
P-35502
Loosen the lock nut (Item 1) [Figure 20-31-3]. Turn the adjusting screw (Item 2) [Figure 20-31-3] clockwise to increase the pressure and counterclockwise to reduce the pressure. NOTE: One-quarter turn is approximately 1000 PSI (69 bar). When the correct pressure setting is obtained, tighten the locknut while holding the adjustment screw from turning. Adjust the port relief valve until the correct setting is obtained. Install the end cap.
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 20-31-1]. Pressurize this section with the hand pump until the port relief valve opens and record the pressure reading. If the port relief pressure setting needs to be adjusted, release the hand pump pressure valve.
20-31-1
20-31-2
PRESSURE REDUCING VALVE (S/N 528911001 & ABOVE AND 528611001 & ABOVE) Description The pressure reducing valve lowers system pressure to 508 PSI (35 bar) for joystick operation. Testing Remove the battery access cover. NOTE: It is not necessary to tilt the cab for this procedure. The cab is shown tilted for photo clarity. Figure 20-32-1
Figure 20-32-2
P-63749
The pressure at the gauge (Item 1) [Figure 20-32-2] should be 508 PSI (35 bar).
P-63747
Install a 1000 PSI (69 bar) pressure gauge on the test coupler (Item 1) [Figure 20-32-1]. Start the engine. Move the speed control lever to the high speed position. Lower the left console. Raise the boom and fully extend the bucket cylinder. Record the pressure.
20-32-1
PRESSURE REDUCING VALVE (S/N 528911001 & ABOVE AND 528611001 & ABOVE) (CONTD) Adjustment Stop the engine. With the engine off and the key in the run position, move the joysticks to relieve hydraulic pressure. Figure 20-32-3
P-63748
The pressure reducing valve (Item 1) [Figure 20-32-3] is located under the battery access cover. Figure 20-32-4
2 1
P-63750
Loosen the lock nut (Item 1) [Figure 20-32-4]. Turn the adjustment screw (Item 2) [Figure 20-32-4] in to increase the pressure and out to decrease the pressure. Tighten the lock nut and retest the valve.
20-32-2
PRESSURE REDUCING VALVE (S/N 522311001 & ABOVE) Description The pressure reducing valve lowers system pressure to 508 PSI (35 bar) for joystick operation. Testing Open the rear cover. Figure 20-33-1
Figure 20-33-2
P-33376
1 The pressure at the gauge (Item 1) [Figure 20-33-2] should be 508 PSI (35 bar).
P-33048
Install a 1000 PSI (69 bar) pressure gauge on the test coupler (Item 1) [Figure 20-33-1]. Start the engine. Move the speed control lever to the high speed position. Lower the left console. Raise the boom and fully extend the bucket cylinder. Record the pressure.
20-33-1
PRESSURE REDUCING VALVE (S/N 522311001 & ABOVE) (CONTD) Adjustment Stop the engine. With the engine off and the key in the run position, move the joysticks to relieve hydraulic pressure. Figure 20-33-3
P-33378
The pressure reducing valve (Item 1) [Figure 20-33-3] is located to the right of the hydraulic reservoir. Figure 20-33-4
1 3
P-33377
Cut and remove the wire (Item 1) [Figure 20-33-4]. Loosen the lock nut (Item 2) [Figure 20-33-4]. Turn the adjustment screw (Item 3) [Figure 20-33-4] in to increase the pressure and out to decrease the pressure. Tighten the lock nut and retest the valve.
20-33-2
DUMP VALVE Description Hydraulic oil from the gear pumps supply the three spool valve. When pressure rises in the valve the dump valve opens and allows oil from one of the gear pumps to flow directly to tank. Testing Figure 20-34-1
Adjustment Stop the engine. Figure 20-34-2
P-33375
Loosen the lock nut (Item 1) [Figure 20-34-2]. 1 Turn the adjustment screw (Item 2) [Figure 20-34-2] in to increase the pressure or out to decrease the pressure.
P-33372
NOTE: One turn is approximately 150 PSI (10 bar). Install a 5000 PSI (345 bar) gauge on the test port (Item 1) [Figure 20-34-1] of the rear gear pump. Start the excavator and warm the hydraulic oil to operating temperature. Move the speed control lever to the high speed position. Lower the left console. Slowly engage the blade raise circuit. Once the blade is fully raised continue to slowly engage the blade raise circuit. The pressure will build to 1595 psi (110 bar) and then drop to zero when the unloading valve opens. Record the pressure. NOTE: Repeat the above procedure several times to verify when the unloading valve is opening. Wear safety glasses to prevent eye injury when any of the following conditions exist: When fluids are under pressure. Flying debris or loose material is present. Engine is running. Tools are being used.
W-2019-1285
Tighten the lock nut and retest the dump valve.
WARNING
20-34-1
DUMP VALVE (CONTD) Removal And Installation
Figure 20-34-4
IMPORTANT
I-2003-0888
P-33383
Figure 20-34-3 Remove the bolts (Item 1) [Figure 20-34-4]. Installation: Tighten the bolts to 15-18 ft.-lb. (20-25 Nm) torque. Remove the valve.
1 1
P-33382
Remove the hoses (Item 1) and tee fitting (Item 2) [Figure 20-34-3].
20-34-2
DUMP VALVE (CONTD) Parts Identification
1 2 3 4 5 6 7 8 9
Valve O-Ring Spring Spool Fitting Plug Spring Spring Seat Valve Body
2 5 2 9 4
2 2 5 5
2 6
8 7 2 6
MS1533
20-34-3
DUMP VALVE (CONTD) Disassembly And Assembly Figure 20-34-5
Figure 20-34-7
P-36126
1 Remove the spring (Item 1) [Figure 20-34-7].

P-36124
Figure 20-34-8 Remove the valve (Item 1) [Figure 20-34-5]. Figure 20-34-6
1 Remove the spool (Item 1) [Figure 20-34-8].

P-36125
P-36127
Remove the O-ring (Item 1) [Figure 20-34-6].
20-34-4
DUMP VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-34-9
Figure 20-34-11
P-36130
1 Remove the fitting (Item 1) [Figure 20-34-11].

P-36128
Figure 20-34-12 Remove the fitting (Item 1) [Figure 20-34-9]. Figure 20-34-10 1
P-36129

P-36129
20-34-5
Figure 20-34-15
2 1
P-36133
Remove the spring (Item 1) [Figure 20-34-15].

P-36131
Remove the spring seat (Item 2) [Figure 20-34-15]. Remove the plug (Item 1) [Figure 20-34-13]. Figure 20-34-14 Figure 20-34-16
1 1
P-36134 P-36132
Remove the plug (Item 1) [Figure 20-34-16]. Remove the O-ring (Item 1) [Figure 20-34-14].
20-34-6
Figure 20-34-19
P-36129

P-36135
Remove the O-ring (Item 1) [Figure 20-34-17]. Figure 20-34-18
1
P-36136
Remove the fitting (Item 1) [Figure 20-34-18].
20-34-7
20-34-8
SIX SPOOL HYDRAULIC CONTROL VALVE Removal And Installation Remove the right side cover. (See RIGHT SIDE COVER on Page 40-160-1.) Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Figure 20-40-1
Figure 20-40-3 1
1
P-35162
Remove the shield (Item 1) [Figure 20-40-3]. Figure 20-40-4
1
P-35160
Figure 20-40-2
1
P-35163
Remove the 2 bolts (Item 1) [Figure 20-40-4]. Remove the gas strut mount (Item 2) [Figure 20-40-4].
P-35161
Remove the 4 bolts (Item 1) [Figure 20-40-1] & [Figure 20-40-2] from the shield.
20-40-1
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Removal And Installation (Contd)
Figure 20-40-7
IMPORTANT
I-2003-0888
P-35166
1 1
Figure 20-40-5 1 Remove the 3 hoses (Item 1) [Figure 20-40-7]. Figure 20-40-8 1
1 1
1 2
P-35164
Remove the hoses (Item 1) [Figure 20-40-5] from the front of the valve. Figure 20-40-6 Remove the 2 hoses (Item 1) [Figure 20-40-8]. Remove the fitting (Item 2) [Figure 20-40-8].
P-35167
1 1
P-35165
Remove the hoses (Item 1) [Figure 20-40-6] from the rear of the valve.
20-40-2
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Removal And Installation (Contd) Figure 20-40-9
Figure 20-40-11
1 1
P-35171
P-35169
Install a hoist (Item 1) [Figure 20-40-11] on the valve mount. Figure 20-40-12
Remove the 7 hoses (Item 1) [Figure 20-40-9] from the A ports of the valve. Figure 20-40-10
P-35172
1
P-35170
Remove the 4 bolts (Item 1) [Figure 20-40-12] and washers. Installation: Tighten the bolts to 48-55 ft.-lb. (65-75 Nm) torque.
Remove the 6 hoses (Item 1) [Figure 20-40-10] from the B ports of the valve.
20-40-3
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Removal And Installation (Contd) Figure 20-40-13
P-35173
Remove the valve (Item 1) [Figure 20-40-13].
20-40-4
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Control Valve Identification
ITEM 1 2 3 4 5 6 7 8 9 10
DESCRIPTION Inlet Section Boom Section Arm Section Bucket Section Auxiliary Section Left Travel Right Travel Outlet Port Relief 4350 psi (300 bar) Port Relief 2610 psi (180 bar)
8 2 3 4 5 6 7
10
B-16827
20-40-5
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Disassembly And Assembly Clean the outside of the valve with clean solvent. Figure 20-40-14 1 2
Figure 20-40-16
1 1
P-35238
Remove the tie rod nuts (Item 1) [Figure 20-40-16]. Installation: Tighten the nuts to 18 ft.-lb. (25 Nm) torque. Figure 20-40-17 Remove the 3 bolts (Item 1) [Figure 20-40-14]. Remove the mount (Item 2) [Figure 20-40-14]. Figure 20-40-15 1
P-35236
P-35239
1 Remove the outlet section (Item 1) [Figure 20-40-17].

P-35237
Installation: Install the washers (Item 1) [Figure 20-4015] between the valve and mount. Tighten the bolts to 111-129 ft.-lb. (150-175 Nm) torque.
20-40-6
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-40-18
Figure 20-40-20
1 1 1 2
P-35242
1 2 Remove the O-rings (Item 1) [Figure 20-40-20] from the auxiliary valve section. Remove the valve section (Item 2) [Figure 20-40-20]. Remove the O-rings (Item 1) [Figure 20-40-18] from the right travel valve section. Remove the valve section (Item 2) [Figure 20-40-18]. Figure 20-40-19 1 1 1 1 2 1 2
P-35241 P-35243
P-35240
Figure 20-40-21
Remove the O-rings (Item 1) [Figure 20-40-21] from the bucket valve section. Remove the valve section (Item 2) [Figure 20-40-21].
Remove the O-rings (Item 1) [Figure 20-40-19] from the left travel valve section. Remove the valve section (Item 2) [Figure 20-40-19].
20-40-7
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-40-22
Figure 20-40-24
1 1 1 1 1 1
P-35246
2
P-35244
Remove the O-rings (Item 1) [Figure 20-40-24] from the inlet section. Figure 20-40-25
Remove the O-rings (Item 1) [Figure 20-40-22] from the arm valve section. Remove the valve section (Item 2) [Figure 20-40-22]. Figure 20-40-23 1
1 1
P-35247
Remove the rods (Item 1) [Figure 20-40-25] from the inlet section. 2
P-35245
Installation: Tighten the rods to 18 ft.-lb. (25 Nm) torque.
Remove the O-rings (Item 1) [Figure 20-40-23] from the boom valve section. Remove the valve section (Item 2) [Figure 20-40-23].
20-40-8
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Left Travel And Right Travel Valve Section Disassembly And Assembly NOTE: The disassembly and assembly procedure is shown on the right travel valve section. The procedure is the same on the left travel valve section. Figure 20-40-26
Figure 20-40-28
1
P-35251
Remove the plastic plug (Item 1) [Figure 20-40-28]. Figure 20-40-29
P-35249
Remove the plug (Item 1) [Figure 20-40-26]. (Both ends) Installation: Tighten the plug to 52 ft.-lbs (70 Nm). Figure 20-40-27
P-35252
Remove the plug (Item 1) [Figure 20-40-29].
1 2 1
P-35250
Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-40-27].
20-40-9
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Left Travel And Right Travel Valve Section Disassembly And Assembly (Contd) Figure 20-40-30
Figure 20-40-32
1 1
2
P-35254
Remove the 4 screws (Item 1) [Figure 20-40-32] from both ends.

P-35253
Installation: Tighten the screws to 18 ft.-lb. (25 Nm) torque. Remove the O-ring (Item 1) [Figure 20-40-30]. Figure 20-40-31 Remove the valve end cover (Item 2) [Figure 20-40-32] from both ends. Figure 20-40-33 1
1
P-35258
Remove the pressure compensator (Item 1) [Figure 2040-31]. Remove the O-ring (Item 1) [Figure 20-40-33].
P-35255
20-40-10
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Left Travel and Right Travel Valve Section Disassembly And Assembly (Contd) Figure 20-40-34
Figure 20-40-36
1 2 1
P-35259
1 Remove the plugs (Item 1) [Figure 20-40-36].

P-35256
Figure 20-40-37
Remove the centering spring (Item 1) [Figure 20-40-34] from both ends. 1 Remove the spring seat (Item 2) [Figure 20-40-34] from both ends. Figure 20-40-35
P-35253
Remove the O-ring (Item 1) [Figure 20-40-37]. 1
P-35257
Remove the spool (Item 1) [Figure 20-40-35].
20-40-11
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Boom, Arm, Bucket And Auxiliary Valve Section Disassembly And Assembly NOTE: The disassembly and assembly procedure is shown on the auxiliary valve section. The procedure is the same for all valve sections, except where noted. Figure 20-40-38 1
Figure 20-40-40
P-35262
1 Remove the plastic plug (Item 1) [Figure 20-40-40]. Figure 20-40-41
P-35261
Remove the relief valves (Item 1) [Figure 20-40-38]. Installation: Tighten the valves to 52 ft.-lb. (70 Nm) torque. Figure 20-40-39
P-35263
1 1
P-35260
20-40-12
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Boom, Arm, Bucket And Auxiliary Valve Section Disassembly And Assembly (Contd) Figure 20-40-42
Figure 20-40-44
1 1 1
P-35264
Remove the fittings (Item 1) [Figure 20-40-44] from both ends of the valve section. (Auxiliary Valve Section only)
P-35253
Figure 20-40-45 Remove the O-ring (Item 1) [Figure 20-40-42]. Figure 20-40-43 2 1 1
P-35281
P-35265
Hold the spool stroke limitation adjustment screw (Item 1) and remove the fitting (Item 2) [Figure 20-40-45]. (Auxiliary Valve Section only)
Remove the compensator (Item 1) [Figure 20-40-43].
20-40-13
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Boom. Arm, Bucket and Auxiliary Valve Section Disassembly And Assembly (Contd) Figure 20-40-46
Figure 20-40-48
1 2 2 1 1
P-35282
Remove the 4 screws (Item 1) [Figure 20-40-48] from both ends.

P-35283
Installation: Tighten the screws to 18 ft.-lb. (25 Nm) torque. Remove the O-ring (Item 1) [Figure 20-40-46]. Figure 20-40-47 Remove the valve end cover (Item 2) [Figure 20-40-48] from both ends. Figure 20-40-49
P-35280
Record the distance of spool stroke limitation adjustment screw (Item 1) [Figure 20-40-47] for correct installation. (Auxiliary Valve Section only)
P-35279
20-40-14
Figure 20-40-52
1 1 1
P-35268
2 Remove the check valves (Item 1) [Figure 20-40-52].

P-35266
Figure 20-40-53
Remove the centering spring (Item 1) [Figure 20-40-50] from both ends. Remove the spring seat (Item 2) [Figure 20-40-50] from both ends. Figure 20-40-51
1 1
P-35269
Remove the poppet (Item 1) and spring (Item 2) [Figure 20-40-53] from the plug.
P-35267
20-40-15
1
P-35270
20-40-16
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Inlet Valve Section Disassembly And Assembly Figure 20-40-55
Figure 20-40-57
1 2
P-35273
P-35271
Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-40-57] from the backup relief valve. Figure 20-40-58
Remove the load sense relief valve (Item 1) [Figure 2040-55]. Installation: Tighten the load sense valve to 18 ft.-lb. (25 Nm) torque. Remove the backup relief valve (Item 2) [Figure 20-4055]. Installation: Tighten the backup relief valve to 52 ft.-lb. (70 Nm) torque. Figure 20-40-56
P-35274
Remove the load sense bleed cartridge (Item 1) [Figure 20-40-58] Installation: Tighten the cartridge to 15 ft.-lbs. (20 Nm) torque.
1
P-35272
Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-40-56] from the load sense relief valve.
20-40-17
SIX SPOOL HYDRAULIC CONTROL VALVE (CONTD) Inlet Valve Section Disassembly And Assembly (Contd) Figure 20-40-59
Figure 20-40-61
P-35277
1 Remove the O-ring (Item 1) [Figure 20-40-61].

P-35275
Figure 20-40-62
Remove the O-rings (Item 1) and back-up ring (Item 2) [Figure 20-40-59]. Figure 20-40-60
P-35278
P-35276
20-40-18
THREE SPOOL HYDRAULIC CONTROL VALVE Removal And Installation
Figure 20-41-3 1
IMPORTANT
I-2003-0888
P-33800
2 1
Figure 20-41- 1 Remove the 4 hoses (Item 1) [Figure 20-41-3]. Remove the tee fitting (Item 2) [Figure 20-41-3]. Figure 20-41-4
1 1 1 1 1
P-33802
Remove the 3 hoses (Item 1) [Figure 20-41- 1]. Figure 20-41-2
1
P-33799
Remove the 3 hoses (Item 1) [Figure 20-41-4].
1 2 1
P-33801
Remove the 2 hoses (Item 1) [Figure 20-41-2]. Remove the 2 tee fittings (Item 2) [Figure 20-41-2].
20-41-1
THREE SPOOL HYDRAULIC CONTROL VALVE (CONTD) Removal And Installation (Contd) Figure 20-41-5
P-33798
Remove the front 2 bolts (Item 1) [Figure 20-41-5]. Figure 20-41-6
P-33797
Remove the rear bolt (Item 1) [Figure 20-41-6]. Remove the valve.
20-41-2
THREE SPOOL HYDRAULIC CONTROL VALVE (CONTD) Parts Identification
1. 2. 3. 4. 5. 6.
Swing/Inlet Section Blade Section Boom Offset Section Outlet Section Load Check Valve Main Relief Valve
6 5
B-16941
20-41-3
THREE SPOOL HYDRAULIC CONTROL VALVE (CONTD) Disassembly And Assembly Figure 20-41-7
Figure 20-41-9
1 1
2
P-35764
Remove the3 O-rings (Item 1) [Figure 20-41-9] from the boom offset valve section.
P-35762
Remove the valve section (Item 2) [Figure 20-41-9]. Remove the 4 tie rod nuts (Item 1) [Figure 20-41-7]. Installation: Tighten the nuts to 16-19 ft.-lb. (22-26 Nm) torque. Figure 20-41-8 Figure 20-41-10
2
P-35765
Remove the 3 O-rings (Item 1) [Figure 20-41-10] from the blade valve section.
P-35763
Remove the valve section (Item 2) [Figure 20-41-10]. Remove the outlet section (Item 1) [Figure 20-41-8].
20-41-4
THREE SPOOL HYDRAULIC CONTROL VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-41-11
IMPORTANT
Do not use parts from one assembly to repair another assembly. Hydraulic and hydrostatic parts develop specific wear patterns. Used parts must be installed in the exact location that they were removed from.
I-2009-0284
P-35766
Remove the 3 O-rings (Item 1) [Figure 20-41-11] from the upperstructure swing/inlet section. Figure 20-41-12 Cut
0.5625 dia.
2.0
1.500
0.750
B-14674
To remove the spring retaining bolt from the spool, a holding fixture will have to be made from a 0.750 inch thick x 1.500 inches wide x 2.0 inches long (19 mm thick x 38 mm wide x 50 mm long) piece of hardwood. Drill a 0.5625 inch (14 mm) hole in the center of the hardwood block. Cut the block lengthwise [Figure 20-41-12]. NOTE: Do not use anything other than hardwood blocks to grip the spool, or the spool will be damaged.
20-41-5
THREE SPOOL HYDRAULIC CONTROL VALVE (CONTD) Boom Offset And Blade Valve Section Disassembly And Assembly NOTE: The disassembly and assembly procedure is shown on the boom offset valve section. The procedure is the same on the blade valve section except where noted. Figure 20-41-13
Figure 20-41-15
1 1
1
P-35769
Remove the load check valves (Item 1) [Figure 20-4115]. NOTE: The blade valve section is equipped with plugs. Figure 20-41-16
P-35767
Remove the plug (Item 1) [Figure 20-41-13]. Installation: Tighten the plug to 46-57 ft.-lb. (63-77 Nm) torque. Figure 20-41-14 1 3 2
3
P-35771
Remove the plug (Item 1), spring (Item 2) and poppet (Item 3) [Figure 20-41-16] from the valve body.
2
P-35768
Remove the seat (Item 1) and spring (Item 2) [Figure 2041-14] from the plug. Remove the O-ring (Item 3) [Figure 20-41-14].
20-41-6
THREE SPOOL HYDRAULIC CONTROL VALVE (CONTD) Boom Offset And Blade Valve Section Disassembly And Assembly (Contd) Figure 20-41-17
Figure 20-41-19
2 1
1
P-35774
2
P-35772
Remove the two screws (Item 1) [Figure 20-41-19] from both ends. Installation: Tighten the screws to 48-58 in.-lb. (5,4-6,6 Nm) torque. Remove the valve end cover (Item 2) [Figure 20-41-19] from both ends. Figure 20-41-20 2
Remove the O-ring (Item 1) and seal ring (Item 2) [Figure 20-41-17]. Figure 20-41-18
1 1 1
P-35773 P-35775
20-41-7
Figure 20-41-23
1
P-35778
Remove the spool (Item 1) [Figure 20-41-23] from the valve.

P-35776
Place the spool in the hardwood blocks. Place the spool/blocks in a vise. NOTE: Do not use anything other than hardwood blocks to grip the spool, or the spool will be damaged. Figure 20-41-24
Install a wrench (Item 1) [Figure 20-41-21] on both ends of the spool. Remove the bolt. Installation: Tighten the bolt to 80-97 in.-lb. (9-11 Nm) torque. Figure 20-41-22
1 1
2 1
P-35779 P-35777
Remove the spring seats (Item 1) and spring (Item 2) [Figure 20-41-22].
Remove the bolt (Item 1) [Figure 20-41-24]. Installation: Tighten the bolt to 80-97 in.-lb. (9-11 Nm) torque.
20-41-8
P-35780
Remove the spring seats (Item 1) and spring (Item 2) [Figure 20-41-25] from the spool.
20-41-9
THREE SPOOL HYDRAULIC CONTROL VALVE (CONTD) Inlet/Upperstructure Swing Valve Section Disassembly And Assembly Figure 20-41-26
Figure 20-41-28
1 1
P-35782
Remove the two screws (Item 1) [Figure 20-41-28] from both ends.
P-35781
Installation: Tighten the screws to 48-58 in.-lb. (5,4-6,6 Nm) torque. Remove the valve end cover (Item 2) [Figure 20-41-28] from both ends. Figure 20-41-29
Remove the plug (Item 1) [Figure 20-41-26]. Installation: Tighten the plug to 46-57 ft.-lb. (63-77 Nm) torque. Figure 20-41-27
1 1 2
P-35775 P-35768
Remove the O-ring (Item 1) [Figure 20-41-29]. Remove the seat (Item 1) and spring (Item 2) [Figure 2041-27] from the plug. Remove the O-ring (Item 3) [Figure 20-41-27].
20-41-10
THREE SPOOL HYDRAULIC CONTROL VALVE (CONTD) Inlet/Upperstructure Swing Valve Section Disassembly And Assembly (Contd) Figure 20-41-30
Figure 20-41-32
1 1
P-35785
Remove the spool (item 1) [Figure 20-41-32] from the valve.

P-35783
Place the spool in the hardwood blocks. Place the spool/blocks in a vise. NOTE: Do not use anything other than hardwood blocks to grip the spool, or the spool will be damaged. Figure 20-41-33
Install a wrench (Item 1) [Figure 20-41-30] on both ends of the spool. Remove the bolt. Installation: Tighten the bolt to 80-97 in.-lb. (9-11 Nm) torque. Figure 20-41-31
1 1 1
P-35779 P-35784
Remove the spring seats (Item 1) and spring (Item 2) [Figure 20-41-31].
Remove the bolt (Item 1) [Figure 20-41-33]. Installation: Tighten the bolt to 80-97 in.-lb. (9-11 Nm) torque.
20-41-11
THREE SPOOL HYDRAULIC CONTROL VALVE (CONTD) Inlet/Upperstructure Swing Valve Section Disassembly And Assembly (Contd)
Figure 20-41-36
2 Figure 20-41-34
2 1 1
P-35787
Remove the O-rings (Item 1) [Figure 20-41-36]. Remove the back-up ring (Item 2) [Figure 20-41-36].
P-35780
Figure 20-41-37 Remove the spring seats (Item 1) and spring (Item 2) [Figure 20-41-34] from the spool. Figure 20-41-35
1 1
P-35788

P-35786
Remove the main relief valve (Item 1) [Figure 20-41-35]. Installation: Tighten the main relief valve to 46-57 ft.-lb. (63-77 Nm) torque.
20-41-12
THREE SPOOL HYDRAULIC CONTROL VALVE (CONTD) Inlet/Upperstructure Swing Valve Section Disassembly And Assembly (Contd) Figure 20-41-38
P-35789
20-41-13
20-41-14
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) Hydraulic Pump Work Sheet (Please review pump procedure as illustrated in Pump Testing on page 6) If any of the following adjustments are not obtainable, pump repair is required. The outline listed below, gives the four adjustments for setting the hydraulic pump. The adjustments are listed in the order in which they MUST be performed. Below each adjustment is a list of the steps. Behind each adjustment is the page location within the Service Manual for the complete adjustment procedure. I. Torque Limiter Supply Pressure Adjustment on page 6 4. Bottom Out Pump Margin Spool (Approximately 6 Turns In.) 5. Remove the plug and install fitting and hose from the Torque Limit Supply Spool to a drain pan. 6. Install a 725 PSI (50 bar) pressure gauge on the test port on the six spool control valve. 7. Warm hydraulic fluid to 122 - 144 F (50 - 60 C). 8. Run Engine at High Idle 9. Adjust as Necessary to get 290 20 PSI (20 1,38 bar). 10. Record Pressure __________ TLS PRESSURE 11. Remove the Hose and Fitting from the Torque Limiter Supply Spool and Plug the Port 12. Reset Pump Margin Spool (Approximately 6 Turns Out.) II. Pump Margin Pressure Adjustment on page 7 13. Run Engine at High Idle 14. Adjust as Necessary to get 363 20 PSI (25 1,38 bar). 15. Record Pressure __________ PM PRESSURE 16. Remove 725 PSI (50 bar) pressure gauge. III. Back-up Relief Valve Adjustment on page 8 17. Install 5000 PSI (345 bar) gauge ont he test port on the six spool valve. 18. Turn the load sense relief valve in 3/4 turn. 19. Run engine at high idle and curl the bucket until the bucket cylinder is fully extended and the relief valve opens. 20. Adjust back-up relief valve as necessary to get 4350 50 PSI (300 3,45 bar).
20-50-1
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Hydraulic Pump Work Sheet (Contd) 21. Record Pressure __________ PM PRESSURE IV. Load Sense Relief Valve Adjustment on page 9 22. Install 5000 PSI (345 bar) Gauge on the test port on the six spool control valve. 23. Run Engine at High Idle and curl the bucket until the bucket cylinder is fully extended and the relief valve opens. 24. Adjust Load Sense Relief Valve as Necessary to get 4060 50 PSI (280 3,45 bar). 25. Record Pressure __________ PRESSURE 26. Remove the 5000 PSI Gauge, from the Pump Diagnostic Coupler at the Control Valve. V. Torque Limiter Adjustment on page 10 27. Remove the inlet hose from the six spool hydraulic control valve, install a cap on the valve and install the inlet hose on the inlet side of the hydraulic tester. 28. Route the outlet hose of the hydraulic tester to the hydraulic reservoir. 29. Bottom out the pump margin spool (approximately six turns in) 30. Run engine at high idle. 31. Free flow on the hydraulic tester is 40 GPM (152 L/min) 32. Adjust the hydraulic tester to 1450 PSI (100 bar) 33. Adjust torque limiter to 37 GPM (140 L/min). 34. Record Flow and Engine RPM. __________ FLOW 35. Adjust the Hydraulic Tester to 3480 PSI (240 bar). 36. Adjust the Torque Limiter to obtain 13 GPM (50 L/min) 37. Record Flow and Engine RPM. __________ FLOW
20-50-2
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Hydraulic Pump Work Sheet (Contd) 38. Remove the Hydraulic Tester 39. Install the pump outlet hose on the six spool hydraulic control valve. 40. Reset pump margin spool to 363 20 PSI (25 1,38 bar). ALL PUMP ADJUSTMENTS ARE NOW COMPLETED
20-50-3
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Testing Information The testing of the piston pump must be done in the following order:
Figure 1 2
1 Torque limiter supply pressure Pump margin pressure Load sense relief valve Torque Limiter All testing is done with the hydraulic oil at 122 to 140 F (50 to 60 C). Check and adjust as needed the engine high idle before any hydraulic testing. The hydraulic hoses, tubelines and fittings on the 442 Excavator are 24 DIN cone metric fittings. To test the torque limiter, order the following parts to adapt the metric fittings to 37 JIC flare fittings: 4 5 6
P-40568
Order the following parts from your Bobcat dealer: Item 1 [Figure 1]: Female 24 DIN to male 37 JIC flare Bobcat P/N 6698092. Item 2 [Figure 1]: Male 24 DIN to male 37 JIC flare Bobcat P/N 6698093. Item 3 [Figure 1]: Female 37 JIC flare cap Bobcat P/
N 36K-8.
Item 4 [Figure 1]: 37 JIC flare union, Bobcat P/N 45KN8. Item 5 [Figure 1]: Nut Bobcat P/N 86F-8. Item 6 [Figure 1]: Hydraulic reservoir cover, Bobcat P/N 5 380 660 846. MEL1610 Hose Kit (not shown).
20-50-4
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Testing Information (Contd) Figure 20-50-2
Figure 20-50-4
1 1
P-40571
Turn the cover over and install the nut (Item 1) [Figure 20-50-4].
P-40569
Drill a 1.0625 inch (26 mm) hole in the center of the cover (Item 1) [Figure 20-50-2]. Figure 20-50-3
P-40570
Install the union (Item 1) [Figure 20-50-3] in the cover. (This is (Item 4) [Figure 1].)
20-50-5
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Testing Torque Limiter Supply Pressure Adjustment Figure 20-50-5
Figure 20-50-7 4 5
3 1 2
P-40566
1 Install a fitting and drain hose (Item 1) [Figure 20-50-7]. Place the other end of the hose in a drain pan. NOTE: To adjust the Torque Limiter Supply Pressure, the Pump Margin Spool must be temporarily bottomed out. Loosen the nut (Item 2) [Figure 20-50-7]. Turn the pump margin spool (bottom spool) (Item 3) [Figure 20-50-7] all the way in (approximately 6 turns). Start the engine and run at high idle. Loosen the nut (Item 4) and adjust the torque limiter supply pressure spool (Item 5) [Figure 20-50-7] until the pressure gauge reads 290 PSI (20 bar). Turn the adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure. NOTE: 1/4 turn is approximately 35 PSI (2,41 bar). Tighten the nut (Item 4) [Figure 20-50-7].
P-40560
P-33366
Install a 725 PSI (500 bar) pressure gauge on the test coupler (Item 1) [Figure 20-50-5]. Figure 20-50-6
Stop the engine. Repeat the procedure listed above until the pressure is set. Turn the pump margin spool (bottom spool) (Item 3) [Figure 20-50-7] back to its original position (approximately 6 turns). Tighten the nut (Item 2) [Figure 20-50-7]. Remove the hose (Item 1) [Figure 20-50-7] and install the plug. Install the cap on the torque limiter supply pressure adjustment spool (top spool).
Remove caps (Item 1) [Figure 20-50-6]. Remove the plug (Item 2) [Figure 20-50-6].
20-50-6
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Testing (Contd) Pump Margin Pressure Adjustment Figure 20-50-8
Figure 20-50-9
P-40560
1
P-40562
Install the cap (Item 1) [Figure 20-50-9] on the pump margin pressure adjustment spool (bottom spool). Remove the gauge from the test coupler.
Start the engine and run at high idle. Loosen the nut (Item 1) and adjust the pump margin pressure adjustment spool (Item 2) [Figure 20-50-8] until the pressure gauge reads 363 PSI (25 bar). Turn the adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure. NOTE: 1/4 turn is 50 PSI (3,45 bar). Tighten the nut (Item 1) [Figure 20-50-8]. Stop the engine.
20-50-7
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Testing (Contd) Back-up Relief Valve Adjustment Figure 20-50-10
Curl the bucket until the bucket cylinder is fully extended and the relief valve opens. Record the pressure. The pressure at the gauge (Item 2) [Figure 20-50-11] should be 4350 PSI (300 bar). Stop the engine. Figure 20-50-12
1
P-33368
Turn the load sense adjustment screw (Item 1) [Figure 20-50-10] in 3/4 of a turn, increasing the relief pressure approximately 600 PSI (41,4 bar) to 4660 PSI (321 bar).The load sense relief is now set to a higher pressure than the back-up relief. Figure 20-50-11
P-33369
Remove the plastic cap (Item 1) [Figure 20-50-12]. Figure 20-50-13
1 2 2
1
P-33370 P-33366
Install a 5000 PSI (345 bar) pressure gauge on the test coupler (Item 1) [Figure 20-50-11]. Start the excavator and warm the hydraulic oil to operating temperature. Move the engine speed control to the high speed position.
Loosen the lock nut (Item 1) [Figure 20-50-13]. Turn the adjustment screw (Item 2) [Figure 20-50-13] in to increase pressure and out to decrease pressure. NOTE: One quarter turn is approximately 200 PSI (13,8 bar). Tighten the nut and retest the back-up relief valve.
20-50-8
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Testing (Contd) Load Sense Relief Valve Adjustment Figure 20-50-14
Figure 20-50-15
P-33367

P-33366
Install a 5000 PSI (345 bar) pressure gauge on the test coupler (Item 1) [Figure 20-50-14]. Move the engine speed control to the high idle position. Curl the bucket until the bucket cylinder is fully extended and the relief valve opens. Record the pressure. The pressure at the gauge (Item 2) [Figure 20-50-14] should be 4060 PSI (280 bar). Stop the engine. Loosen the lock nut (Item 1) [Figure 20-50-16]. Turn the adjustment screw (Item 2) [Figure 20-50-16] in to increase pressure and out to decrease pressure. NOTE: One quarter turn is approximately 200 PSI (13,8 bar). Tighten the lock nut and retest the load sense relief valve.
P-33368
20-50-9
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Testing (Contd) Torque Limiter Adjustment Figure 20-50-17
Figure 20-50-19
P-40577
Install the adapter (Gates P/N 87945) (Item 1) [Figure 20-50-19] on the inlet hose. Figure 20-50-20
P-40567
Remove the inlet hose (Item 1) [Figure 20-50-17] from the hydraulic control valve. Figure 20-50-18
P-40578
Connect the inlet hose to the INLET side of the hydraulic tester (Item 1) [Figure 20-50-20].
P-40576
Install the adapter (Gates P/N 87957) (Item 1) and cap (Bobcat P/N 36K-8) (Item 2) [Figure 20-50-18].
20-50-10
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Testing (Contd)
Figure 20-50-23
1 Figure 20-50-21
P-40574
Install the spring (Item 1) [Figure 20-50-23] on the modified cover.

P-32851
Figure 20-50-24 Remove the hydraulic reservoir cover (Item 1) [Figure 20-50-21]. Figure 20-50-22 1
P-40575
Install the modified cover (Item 1) [Figure 20-50-24] on the hydraulic reservoir.
P-40573
20-50-11
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Testing (Contd) Figure 20-50-25
Figure 20-50-27
P-40560
Remove the cap (Item 1) [Figure 20-50-27] from the pump margin spool (bottom spool).
P-40579
Figure 20-50-28 Connect the OUTLET side of the hydraulic tester (Item 1) [Figure 20-50-25] to the reservoir cover. Figure 20-50-26
2 1 1
P-40562
P-40580
Loosen the nut (Item 1) and turn the adjustment screw (Item 2) [Figure 20-50-28] all the way in (approximately 6 turns). Start the engine and run at high idle.
Fully open the hydraulic tester flow control (Item 1) [Figure 20-50-26].
20-50-12
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Testing (Contd) Figure 20-50-29
Figure 20-50-31
1 2 3
1
P-40583
2
P-40580
Check the 13 mm nut (Item 1) [Figure 20-50-31] to be sure it is locked in place. Adjust the flow at the hydraulic pump torque limiter by loosening the 27 mm nut (Item 2) [Figure 20-50-31] With an Allen wrench adjust the flow at low pressure. When the proper flow is obtained, 37 GPM (140 L/min) at 1450 PSI (100 bar), lock the 27 mm nut (Item 2) [Figure 20-50-31]. NOTE: Changing the flow at low pressure (27 mm nut) will affect flow at high pressure (13 mm nut). Turn the hydraulic tester flow control (Item 2) clockwise until the gauge (Item 3) [Figure 20-50-29] reads 3480 PSI (240 bar). NOTE: Do not exceed 4350 PSI (300 bar) with the hydraulic tester or the pump will be damaged. The gauge should show 13 GPM (50 L/min) which is flow at high pressure. Adjust the flow at the hydraulic pump torque limiter. Loosen the 13 mm nut (Item 1) [Figure 20-50-31] and with an Allen wrench adjust the flow at high pressure. When the proper flow is obtained, 13 GPM (50 L/min) at 3480 PSI (240 bar), lock the 13 mm nut (Item 1) [Figure 20-50-31]. NOTE: If adjustments were made to flow at high pressure verify the flow at low pressure. Install the protective cap on the hydraulic pump torque limiter.
The flow should be 40 GPM (152 L/mm) on the flow tester (Item 1) [Figure 20-50-29]. Turn the hydraulic tester flow control (Item 2) clockwise until the gauge (Item 3) [Figure 20-50-29] shows 1450 PSI (100 bar). The gauge (Item 1) [Figure 20-50-29] should show 37 GPM (140 L/min) which is flow at low pressure. Figure 20-50-30
P-40582
Remove the dust cover (Item 1) [Figure 20-50-30].
20-50-13
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Testing (Contd) Remove the hydraulic tester, fittings and hydraulic reservoir cover. Install the original reservoir cover. Install the supply hose on the hydraulic control valve. Figure 20-50-32
P-40562
Adjust the pump margin spool (Item 1) [Figure 20-50-32] back to the original position (approximately 6 turns out). Retest and adjust the pump margin spool as needed. See Pump Margin Pressure Adjustment on page 7. ALL PUMP ADJUSTMENTS ARE NOW COMPLETED
20-50-14
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Removal And Installation
Figure 20-50-34
IMPORTANT
I-2003-0888
P-33806
Open the rear cover. (See Opening And Closing The Rear Cover on Page 10-40-1.) Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Figure 20-50-33
Remove the hoses (Item 1) [Figure 20-50-33] & [Figure 20-50-34] from the gear pump. Figure 20-50-35
1 1
P-33805 P-35228
Reposition the hoses (Item 1) [Figure 20-50-35] to gain access to the piston pump.
20-50-15
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 20-50-36
Figure 20-50-38
1 1
P-35231
Loosen the clamp (Item 1) [Figure 20-50-38]. Rotate the clamp to provide clearance to the suction fitting bolts.
P-35229
Figure 20-50-39 Remove the hoses (Item 1) [Figure 20-50-36] from the pump. Figure 20-50-37 1
1 2
1
P-35232
1 Remove the 4 bolts (Item 1) [Figure 20-50-39].

P-35230
Remove the 4 bolts (Item 1) and remove the hose (Item 2) [Figure 20-50-37].
20-50-16
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Removal And Installation (Contd)
Figure 20-50-42
1 Figure 20-50-40
1
P-35235
Install a sling (Item 1) [Figure 20-50-42] on the pump.

P-35233
Separate the pump from the engine and remove the pump.
Figure 20-50-41
P-35234
Remove the bolts (Item 1) [Figure 20-50-40] & [Figure 20-50-41] and washers. Installation: Tighten the bolts to 125-140 ft.-lb. (170-190 Nm) torque.
20-50-17
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Coupler Removal And Installation
Figure 20-50-45
1 Figure 20-50-43
P-35316
P-35315
Installation: Slide the coupler on the pump shaft (Item 1) [Figure 20-50-44] until the coupler snap ring (Item 1) [Figure 20-50-45] is tight against the shaft.
Remove the bolt (Item 1) [Figure 20-50-43] from the coupler. Slide the coupler off the pump shaft. Installation: Tighten the bolt to 63 ft.-lb. (86 Nm) torque. Figure 20-50-44
1
P-35318
20-50-18
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Torque Limiter Valve Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Plug O-Ring Spring Spring Seat Spool Assembly Spool Bolt O-Ring Spring Seat Spring Spring O-Ring Body Locknut Washer Screw Nut Cap Housing 4
19
6 5 3
18 17 16 14 13 12 10 9 11 15
B-15929
20-50-19
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Torque Limiter Valve Removal and Installation Clean the outside of the pump with clean solvent and dry with compressed air before removing any components from the pump. Figure 20-50-46 1
P-35319
Remove the tubeline (Item 1) [Figure 20-50-46] from the pump control and torque limiter vale. NOTE: Mark the tubeline for correct installation. Loosen and remove the two mount bolts (Item 2) [Figure 20-50-46] from the torque limiter valve. Installation: Tighten the mount bolts to 7.0-7.5 ft.-lb. (9,5-10,5 Nm) torque. Figure 20-50-47
P-35330
Remove the torque limiter (Item 1) [Figure 20-50-47] from the pump.
20-50-20
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Torque Limiter Valve Disassembly Figure 20-50-48
Figure 20-50-50
1 2 2
N-23329
Remove the spring (Item 1) and spring seat (Item 2) [Figure 20-50-50].
N-23327
Figure 20-50-51 Remove the O-ring (Item 1) [Figure 20-50-48] from the torque limiter valve. NOTE: Do not scratch or damage the mounting surface on the valve body. Remove the plug (Item 2) [Figure 20-50-48]. NOTE: The plug (Item 2) [Figure 20-50-48] is under spring pressure. 1 Figure 20-50-49
P-35320
Remove the control spool assembly (Item 1) [Figure 2050-51]. 1 NOTE: Use care not to scratch or damage the spool. Scratches in the spool can cause internal leakage.
N-23328
20-50-21
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Torque Limiter Valve Disassembly (Contd) Figure 20-50-52
Figure 20-50-54
2 1
N-23333
2
P-35321
Remove the two springs (Items 1 & 2) [Figure 20-50-54]. Figure 20-50-55
Remove the metering spool (Item 1) from the control spool (Item 2) [Figure 20-50-52]. Figure 20-50-53
1
P-35322
N-23332
Remove the spring retainer (Item 1) [Figure 20-50-53] from the torque limiter valve.
20-50-22
Figure 20-50-58
2
P-35325
1
P-35323
Loosen the large nut (Item 1) [Figure 20-50-58]. Turn the small nut (Item 2) [Figure 20-50-58] to remove the adjustment body. Figure 20-50-59
Remove the O-ring (Item 1) [Figure 20-50-56]. The following procedures are only used if the adjustment assembly is removed. NOTE: If the adjustment assembly is removed and/or disassembled, the torque limiter must be tested and adjusted after the pump assembly is installed in the machine. See Initial Torque Limiter Valve Setting on page 29. for torque limiter adjustment) Figure 20-50-57
2
P-35326
With an Allen wrench hold the adjustment bolt (Item 1) and loosen the nut (Item 2) [Figure 20-50-59].
1
P-35324
Remove the dust cap (Item 1) [Figure 20-50-57].
20-50-23
3 2 1 4
P-35327
Remove the adjustment screw (Item 1), O-ring washer (Item 2) and large nut (Item 3) from the adjustment body (Item 4) [Figure 20-50-60]. Figure 20-50-61
P-35328
Remove the O-ring (Item 1) [Figure 20-50-61] from the torque limiter valve body.
20-50-24
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Torque Limiter Valve Assembly Clean all the parts in solvent and dry with compressed air. Inspect seats and spools for wear. Apply clean oil to new O-rings and spools. The following procedures are only used if the adjustment assembly is removed. Figure 20-50-62
Figure 20-50-63 3 4 1 2
P-35327
Install the O-ring washer (Item 1) on the adjustment screw (Item 2) [Figure 20-50-63]. Install the adjustment screw (Item 2) in the adjustment body (Item 3) [Figure 20-50-63]. Install the nut (Item 4) [Figure 20-50-63] on the adjustment body. Figure 20-50-64
P-35328
Install the O-ring (Item 1) [Figure 20-50-62] in the torque motor valve body. 1
P-35325
Install the adjustment screw/adjustment body (Item 1) [Figure 20-50-64] assembly into the valve body.
20-50-25
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Torque Limiter Valve Assembly (Contd) Figure 20-50-65
Figure 20-50-67
N-23332
1
P-35324
Install the spring seat (Item 1) [Figure 20-50-67] in the valve body with the ball side facing toward the control spool. Figure 20-50-68
Install the dust cap (Item 1) [Figure 20-50-65]. NOTE: After the pump assembly is installed in the machine, the torque motor must be tested and adjusted. See Initial Torque Limiter Valve Setting on page 29. for torque limiter adjustment) Figure 20-50-66
1 2 1
2
P-35321
Put oil on the metering spool (Item 1) and install in the control spool (Item 2) [Figure 20-50-68]. NOTE: The end of the metering spool with the three rings enters the control spool first.
N-23333
Install the two springs (Items 1 & 2) [Figure 20-50-66] in the valve body. NOTE: Install the big spring first and the small spring second.
20-50-26
Figure 20-50-71
2 1
N-23328
1 Install the O-ring (Item 1) on the plug. Install the plug (Item 2) [Figure 20-50-71].
P-35320
Figure 20-50-72 Install the control spool assembly (Item 1) [Figure 20-5069] in the valve body. NOTE: Use care not to scratch or damage the spool (Item 1) [Figure 20-50-69]. Scratches in the spool can cause internal leakage. Figure 20-50-70 1
N-23327
2 Install the O-ring (Item 1) [Figure 20-50-72].
1
N-23329
Install the spring seat (Item 1) [Figure 20-50-70] in the valve body, with the smaller diameter end toward the spring. Install the spring (Item 2) [Figure 20-50-70] in the valve body.
20-50-27
1
P-35323
Install the O-ring (Item 1) [Figure 20-50-73] on the plug. Figure 20-50-74
1
P-35322
Install the plug (Item 1) [Figure 20-50-74].
20-50-28
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Initial Torque Limiter Valve Setting The following procedures are only used if the adjustment assembly is removed. Figure 20-50-75
Figure 20-50-77
4.21 (107 mm)
P-40592
Measure from the cap to the top of the small adjusting screw [Figure 20-50-77]. Set the small adjustment screw to 4.21 inches (107 mm). Figure 20-50-78
N-23336
Remove the dust cap (Item 1) [Figure 20-50-75]. Figure 20-50-76
P-35330
3.78 (96 mm)
Align the linkage pin (Item 1) on the hydraulic piston pump into the hole (Item 1) [Figure 20-50-78] in the torque limiter valve.
P-40592
Measure from the cap to the top of the large adjustment screw. Set the large adjustment screw to 3.78 inches (96 mm) [Figure 20-50-76].
Turn the valve slightly to align the dowel pin (Item 2) on the hydraulic piston pump into the hole (Item 2) [Figure 20-50-78] in the torque limiter valve. NOTE: Care should be taken not to scratch or damage the valve spool. NOTE: Before tightening the bolts, make sure the dowel pin is aligned with the housing.
20-50-29
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Initial Torque Limiter Valve Setting (Contd) Figure 20-50-79 2
P-35319
Tighten the mount bolts (Item 1) [Figure 20-50-79] to 7.0-7.5 ft.-lb. (9,5-10,5 Nm) torque. Install the tubeline (Item 2) [Figure 20-50-79] and tighten.
20-50-30
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Control Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Cap O-Ring Nut Adjusting Screw Adjustment Screw Body Spring Seat Spring Spring Spring Seat Spool Plug Valve Body Bolt Fitting Elbow
1 1 2 3 2 2 4 4 5 5 2 6 7 8 9 10 2 6 7 8 9 10 2 2 2 2 2 14 13 12 2 11 2 3
11
15 14
2 2 2
11
11
MS1540
20-50-31
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Control Removal And Installation Clean the outside of the pump with clean solvent and dry with compressed air before removing any components from the pump. Figure 20-50-80
P-35319
Mark the tubeline (Item 1) [Figure 20-50-80] for correct assembly. Loosen and remove the tubeline (Item 1) [Figure 20-5080] from the pump control and torque limiter valve. Figure 20-50-81
P-35331
Loosen and remove the 4 bolts (Item 1) and remove the pump control (Item 2) [Figure 20-50-81] from the hydraulic piston pump. Installation: Tighten the bolts to 10 ft.-lb. (13 Nm) torque.
20-50-32
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Control Disassembly And Assembly Figure 20-50-82
Figure 20-50-84
4 3 1 2
1
P-35335
P-35332
Remove the adjustment screw (Item 1), nut (Item 2), and O-ring washer (Item 3) from the adjustment assembly (Item 4) [Figure 20-50-84]. Remove the adjustment assembly (Item 4) [Figure 2050-84]. Figure 20-50-85
Remove the three O-rings (Item 1) [Figure 20-50-82] from the valve. Pump Margin Control Figure 20-50-83
3 1
4
P-35344
P-35333
Before disassembling the pump margin control, remove the cap (Item 1) and O-ring washer (Item 2) [Figure 2050-83] from the adjustment assembly. Measure the adjustment screw (Item 3) [Figure 20-5083] thread length for the correct initial adjustment.
Remove the adjustment seat (Item 1), large spring (Item 2), and the small spring (Item 3) [Figure 20-50-85] from the adjustment assembly. Remove the O-ring (Item 4) [Figure 20-50-85].
20-50-33
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Control Disassembly And Assembly (Contd) Figure 20-50-86
Figure 20-50-88
1
N-23380
1
P-35336
Check the spool for scratches and be sure the orifice (Item 1) [Figure 20-50-88] is not plugged. Figure 20-50-89
Remove the spring seat (Item 1) [Figure 20-50-86]. Figure 20-50-87
1 1
P-35338

P-35337
20-50-34
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Control Disassembly And Assembly (Contd) Figure 20-50-90
Figure 20-50-92
2 1
P-35341
P-35339
Before disassembling the torque limiter supply control, remove the O-ring washer (Item 1) [Figure 20-50-92] from the adjustment assembly. Measure the adjustment screw (Item 2) [Figure 20-5092], thread length for the correct initial adjustment. Figure 20-50-93
Remove the O-ring washer (Item 1) [Figure 20-50-90]. Torque Limiter Supply Control Figure 20-50-91
P-35342 P-35340
Loosen the nut (Item 1) [Figure 20-50-93]. Remove the cap (Item 1) [Figure 20-50-91] from the torque limiter supply control.
20-50-35
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Control Disassembly And Assembly (Contd) Torque Limiter Supply Control (Contd) Figure 20-50-94
Figure 20-50-96
3 1
P-35345
4 2
P-35343
Remove the adjustment screw (Item 1) nut (Item 2), and O-ring washer (Item 3) from the adjustment assembly (Item 4) [Figure 20-50-94]. Remove the adjustment assembly (Item 4) [Figure 2050-94]. Figure 20-50-95
P-35346
4 Remove the spool (Item 1) [Figure 20-50-97].
P-35344
Remove the adjustment seat (Item 1) large spring (Item 2) [Figure 20-50-95] and small spring (Item 3) from the adjustment assembly. Remove the O-ring (Item 4) [Figure 20-50-95].
20-50-36
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Pump Control Disassembly And Assembly (Contd) Torque Limiter Supply Control (Contd) Figure 20-50-98
Figure 20-50-100
2 1
P-35348
Remove the O-ring washer (Item 1) [Figure 20-50-100].
N-23379
Check the spool for scratches and be sure the orifice (Items 1 & 2) [Figure 20-50-98] are not plugged. Figure 20-50-99
P-35347
20-50-37
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Parts Identification
1. 2. 3. 4. 5. 6.
Seal Shaft Bolt Bearing Plug Piston
6 4
5 4
B-19529
20-50-38
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Disassembly
Figure 20-50-102
IMPORTANT
I-2003-0888
1 2
N-23355
Clean the outside of the hydraulic piston pump with solvent and dry with compressed air. Remove the torque limiter valve.(See Torque Limiter Valve Removal and Installation on page 20. Remove the pump control assembly. See Pump Control Removal And Installation on page 32. Remove the pump coupler. See Coupler Removal And Installation on page 18. Figure 20-50-101
Remove the pin assembly (Item 1) [Figure 20-50-102]. NOTE: The position of the dowel pin (Item 2) on the pin assembly, with the locating hole on the swash plate cradle (Item 3) [Figure 20-50-102]. Figure 20-50-103
P-35350
Remove the plug (Item 1) [Figure 20-50-103] from the pump housing and drain the oil.
N-23354
Remove the screw (Item 1) [Figure 20-50-101] from the pin assembly.
20-50-39
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Disassembly (Contd) Figure 20-50-104
Figure 20-50-106 1 3
N-23386

P-35349
Remove the destroking piston (Item 2) [Figure 20-50106]. Remove the stroking piston/spring assembly (Item 3) [Figure 20-50-106]. Figure 20-50-107
Remove the O-ring (Item 1) [Figure 20-50-104] from the plug. Mark the pump housing for proper installation. Figure 20-50-105
1 2 1
1
P-35351
N-23387
Loosen and remove the four bolts (Item 1) [Figure 20-50105]. Remove the port block assembly (Item 2) [Figure 20-50105] from the pump.
Inspect the destroking piston (Item 1) [Figure 20-50-107] for scratches and replace as needed.
20-50-40
Figure 20-50-110
1 1 2
N-23390
Remove the adjustment spacer(s) (Item 1) [Figure 2050-110] from the pump shaft.
N-23388
Figure 20-50-111 Remove the spring (Item 1) from the stroking piston (Item 2) [Figure 20-50-108]. Inspect all parts and replace as needed. Figure 20-50-109
N-23391
Lay the pump assembly on its side and remove the rotary group, swash plate, and shaft (Item 1) [Figure 20-50111] from the housing.
N-23389
20-50-41
Figure 20-50-114 1
2 1
P-35354
Remove the retaining ball (Item 1) [Figure 20-50-114].

N-23392
Figure 20-50-115 1
Slide the rotary group (Item 1) and swash plate (Item 2) from the shaft assembly (Item 3) [Figure 20-50-112]. NOTE: It is NOT important that the pistons are installed in their original positions. NOTE: Check that there are no scratches or metal deposits on the sliding surface. (Pistons must be replaced in sets.) Figure 20-50-113 1
P-35355
Inspect the 3 pins (Item 1) [Figure 20-50-115] for wear and/or damage. NOTE: The following procedure shown is to disassemble the rotating group for inspection only. The rotating group parts can not be ordered separately and must be ordered as an assembly.
P-35361
Remove the retainer plate and pistons (Item 1) [Figure 20-50-113].
20-50-42
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Disassembly (Contd)
Figure 20-50-118
1 Figure 20-50-116 4 3 3 2 1 2 3 4 2 4
N-15289
N-15299
Install the second trimmed washer (Item 1) over the threaded rod (Item 2) install the nut (Item 3) [Figure 2050-118]. NOTE: The modified washer (Item 1) must fit between the 3 pins (Item 4) [Figure 20-50-118]. Figure 20-50-119
To remove the spring from inside the cylinder block, use a threaded rod (or bolt) (Item 1) 2 trimmed washers (Item 2) and 2 nuts (Item 3) [Figure 20-50-116]. Figure 20-50-117
2 1 2
3
N-15288
N-15290
Install the threaded rod and nut (Item 1) through the trimmed washer (Item 2) and through the block assembly (Item 3) [Figure 20-50-117]. NOTE: The modified washer (Item 2) must fit over the spring but must also fit inside the snap ring (Item 4) [Figure 20-50-117].
Tighten the nut (Item 1) until the spring is compressed enough to remove the snap ring (Item 2) [Figure 20-50119]. Loosen the nut to release the tension on the spring and remove the bolts and washers.
20-50-43
Figure 20-50-122
1 2 3 3 1 3 2
N-23395
Loosen and remove the bolt (Item 1) and remove the torque limiter plate (Item 2) [Figure 20-50-122].
N-15291
Remove the spring (Item 1), washer (Item 2) and the three pins (Item 3) [Figure 20-50-120] from the cylinder block. Figure 20-50-121
NOTE: The caps (Item 3) [Figure 20-50-122] cannot be replaced, a new cradle must be ordered. Figure 20-50-123
N-15284
N-23393
Press the bearing (Item 1) [Figure 20-50-123] off of the shaft.
Remove the swash plate (Item 1) from the shaft (Item 2) [Figure 20-50-121].
20-50-44
Figure 20-50-126
1 1
N-15277
Remove the 2 brass bearings (Item 1) [Figure 20-50126] from the housing.
P-35356
Figure 20-50-127 Remove the snap ring (Item 1 [Figure 20-50-124] from the housing. Figure 20-50-125
N-15280
Remove the race (Item 1) [Figure 20-50-127] from the housing.

P-35357
Remove the seal (Item 1) [Figure 20-50-125] from the housing. NOTE: The shaft seal can be removed without removing the shaft.
20-50-45
Figure 20-50-130
1 1 1
N-23415
1
N-23397
With a bearing puller (Item 1) [Figure 20-50-130] remove the bearing race from the port block assembly. Figure 20-50-131
Remove the 4 O-rings (Item 1) [Figure 20-50-128]. Figure 20-50-129 1
N-23418
N-23398
Remove the stroking piston (Item 1) [Figure 20-50-131]. (Spring Side)
Remove the valve plate (Item 1) [Figure 20-50-129].
20-50-46
Figure 20-50-134
1 1
P-35353
Remove the O-ring (Item 1) [Figure 20-50-134] from both plugs.

N-23419
Remove the destroking piston (Item 1) [Figure 20-50132]. Figure 20-50-133
P-35352
Remove the plugs (Item 1) [Figure 20-50-133].
20-50-47
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Assembly
Figure 20-50-136
IMPORTANT
I-2003-0888
N-23418
Clean parts in solvent and dry with compressed air. Replace any worn or damaged parts. Figure 20-50-135 Figure 20-50-137 Apply Loctite 241 on the threads and install the stroking piston (Item 1) [Figure 20-50-136] in the hole and tighten.
1 2
N-23419 N-23417
Apply Loctite 241 on the threads and install the destroking piston (Item 1) in the hole next to the alignment pin (Item 2) [Figure 20-50-135] and tighten.
Install the bearing race (Item 1) [Figure 20-50-137] in the port block assembly.
20-50-48
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Assembly (Contd) Figure 20-50-138
Figure 20-50-140
P-35356
Install the snap ring (Item 1) [Figure 20-50-140].

N-15296
Figure 20-50-141
Press the race into the housing [Figure 20-50-138]. Figure 20-50-139 2 1 1
N-15285
Press the bearing (Item 1) on the shaft (Item 2) [Figure 20-50-141].

P-35357
Install the shaft seal (Item 1) [Figure 20-50-139].
20-50-49
HYDRAULIC PISTON PUMP (S/N 522311001 & ABOVE) (CONTD) Assembly (Contd)
Figure 20-50-144
2 Figure 20-50-142
2
P-35358
Install the port block (Item 1) [Figure 20-50-144].

N-23423
Install and tighten the bolts (Item 2) [Figure 20-50-144]. Figure 20-50-145
To find the correct shim washer thickness for bearing end play, the shaft/bearing assembly (Item 1) [Figure 20-50142] must be installed in the housing. Figure 20-50-143
P-35360
Turn the pump assembly over [Figure 20-50-145].

N-23425
Install the bearing (Item 1) [Figure 20-50-143] on the shaft.
20-50-50
Figure 20-50-147
N-15277
Install the two brass bearings (Item 1) [Figure 20-50147].

P-35359
Figure 20-50-148 Install a dial indicator on the housing as shown [Figure 20-50-146] and set it to zero. Pull the shaft up as far as it will go and record the reading on the dial indicator. Repeat the procedure several times. The reading must be the same each time. Add the nominal pre-load of 0.001 inch (0,025 mm), the actual pre-load is 0.000 inch (0,000 mm) to 0.002 inch (0,050 mm) to the reading found on the dial indicator [Figure 20-50-146]. Example: (In Inches) 0.150 Measured movement of shaft 0.001 Nominal Pre-load = 0.151 thickness of the spacer needed. (See Assembly (Contd) on Page 20-50-50.) When the proper thickness of shim washer is determined, remove the dial indicator from the pump housing. Remove the two mounting bolts. Remove the port block. Remove the bearing and shaft from the pump housing.
N-15283
Apply Loctite 241 and install the torque limiter plate (Item 1) and bolt (Item 2) on the swash plate (Item 3) [Figure 20-50-148].
20-50-51
Figure 20-50-151 1
P-35354
Install the retaining ball (Item 1) [Figure 20-50-151] on the three pins.
N-23393
Figure 20-50-152 Install the swash plate (Item 1) on the shaft (Item 2) [Figure 20-50-149]. Figure 20-50-150 1
1 2
P-35361
Install the retainer and piston assembly (Item 1) in the cylinder block (Item 2) [Figure 20-50-152].
N-15291
Apply clean grease to the three pins (Item 1) [Figure 2050-150] and install them in the appropriate groove. Install the washer (Item 2) and the spring (Item 3) [Figure 20-50-150]. NOTE: If the rotating group is damaged, the parts can not be order separately and must be ordered as an assembly.
NOTE: It is NOT important that the pistons are installed in their original positions.
20-50-52
Figure 20-50-155
N-15299
P-35362
To compress the spring inside the cylinder block, use a threaded rod (or bolt) (Item 1), 2 trimmed washers (Item 2) and 2 nuts (Item 3) [Figure 20-50-155]. Figure 20-50-156
Install the shaft/swash plate assembly (Item 1) [Figure 20-50-153] in the cylinder block. Figure 20-50-154
2 1
N-15289
N-15276
Install the threaded rod and nut (Item 1) through the modified washer (Item 2) and the block assembly (Item 3) [Figure 20-50-156].
Lay the pump housing on its side and install the rotary group assembly, swash plate, and shaft in the housing [Figure 20-50-154].
20-50-53
Figure 20-50-159
2 1
3
N-23390
N-15288
Install the shim washer (Item 1) [Figure 20-50-159] See Assembly on page 48. for procedure to determine shim washer thickness.) Figure 20-50-160
NOTE: The modified washer (Item 1) must fit over the spring, but must also fit inside the snap ring (Item 2) [Figure 20-50-157]. Figure 20-50-158
N-23386

N-15290
Install a new O-ring (Item 2) [Figure 20-50-160]. Tighten the nut (Item 1) until the spring is compressed enough to install the snap ring (Item 2) [Figure 20-50158]. Remove the threaded rod/washer assembly. Set the pump housing in the up-right position.
20-50-54
Figure 20-50-163
1 2
N-23431
1 3
N-23399
Grease the inside of the control piston (Item 1) [Figure 20-50-163]. Install the control piston on the control piston shaft (Item 2) [Figure 20-50-163]. Figure 20-50-164
Install the valve plate (Item 1) on the port block assembly. The valve plate can only be installed one way by aligning the groove (Item 2) with the pin (Item 3) [Figure 20-50161]. Figure 20-50-162
1 1 1
P-35363
1
N-23397
Install the stroking piston (Item 1) [Figure 20-50-164].
Install the O-rings (Item 1) [Figure 20-50-162].
20-50-55
Figure 20-50-167
P-35366
Align the marks and install the port block assembly (Item 1) [Figure 20-50-167] on the pump housing.
P-35364
Figure 20-50-168 Install the spring (Item 1) [Figure 20-50-165] on the piston. 2 Figure 20-50-166 1 1 1
1
P-35367
Install the 4 mounting bolts (Item 1) [Figure 20-50-168] and tighten to 88 ft.-lbs. (119 Nm) torque.
P-35365
Install a 0.1835 inch (4,76 mm) rod (Item 1) [Figure 2050-166] through the spring and into the hole of the piston.
Remove the aligning rod (Item 2) [Figure 20-50-168] from the pump housing.
20-50-56
Figure 20-50-171
1 2
N-23355
Install the pin assembly (Item 1) [Figure 20-50-171].

P-35349
Make sure the dowel pin (Item 2) is fully seated in the hole (Item 3) [Figure 20-50-171] on the swash plate. Figure 20-50-172
Install the O-ring (Item 1) [Figure 20-50-169] on the plug. Figure 20-50-170
1 1
N-23354 P-35368
Install the plugs (Item 1) [Figure 20-50-170].
Apply Loctite 241 on the bolt (Item 1) [Figure 20-50172]. Tighten the bolt to 10 ft.-lbs. (13 Nm) torque. Install the torque limiter valve. See Torque Limiter Valve Removal and Installation on page 20. Install the pump control assembly. See Pump Control Removal And Installation on page 32.
20-50-57
P-35349
Install the O-ring (Item 1) [Figure 20-50-173] on the plug. Place the pump on its side and fill approximately half full with clean hydraulic fluid. Figure 20-50-174
P-35350
Install the plug (Item 1) [Figure 20-50-174] in the pump and tighten.
20-50-58
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) Removal And Installation
Figure 20-51- 2
IMPORTANT
I-2003-0888
2 Open the rear cover. (See Opening And Closing The Rear Cover on Page 10-40-1.)
P-33806
Remove the supply hose (Item 1) [Figure 20-51- 2]. Open the right side cover. (See Opening And Closing The Right Side Cover on Page 10-41-1.) Figure 20-51-1 Remove the hose (Item 2) [Figure 20-51- 2]. Figure 20-51- 3
1
P-33805
2
P-33807
Remove the hose (Item 1) [Figure 20-51-1].
Remove the tee fitting (Item 1) [Figure 20-51- 3]. Remove the three mount bolts (Item 2) [Figure 20-51- 3] Installation: Tighten the bolts to 22-26 ft.-lb. (30-35 Nm) torque. Remove the pump.
20-51-1
442 Excavator Service Manuall
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) (CONTD) Parts Identification
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Nut Gear Key Plate Mount Gasket Snap Ring Seal Plate Dowel Pin Bolt Fitting O-Ring Housing O-Ring Load Seal Load Seal Backup Ring Plug Bearing Gear End Cap Washer Bolt Tee Fitting Diagnostic Coupler Cap
2 3 4 5 6 7 8 9 13 14 18 19 10 17 18 17 16 19 18 17 15 9 8 15 16 7 18 9 13 11
17
15
16
17 9 12 10 11 9
18
14
10 10 12 9 18
19
11 10 12 9 14 10 23 24 18
18 16 15 9 20 21 17
17 19
22
25
MS1544
20-51-2
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) (CONTD) Disassembly Figure 20-51- 4
Figure 20-51- 5
1 2
1
P-33811
1 2
1
P-33808
Figure 20-51- 6
Mark and remove the bolts (Item 1) and remove the fittings (Item 2) [Figure 20-51- 4]. NOTE: Two different bolt lengths are used. Mark the bolts before removal for correct installation.
P-33812
Remove the O-ring (Item 1) [Figure 20-51- 5] & [Figure 20-51- 6].
20-51-3
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) (CONTD) Disassembly (Contd) Figure 20-51- 7
Figure 20-51- 9
1 1
1
P-33813
Remove the O-ring (Item 1) [Figure 20-51- 9] from the pump.

P-33809
Figure 20-51- 10 Mark and remove the bolts (Item 1) and remove the supply line fitting (Item 2) [Figure 20-51- 7]. 1 NOTE: Two different bolt lengths are used. Mark the bolts before removal for correct installation. Figure 20-51- 8 2
P-33987
1 Place the pump coupler (Item 1) [Figure 20-51- 10] in a vise that is equipped with soft jaws. Loosen the nut (Item 2) [Figure 20-51- 10].
P-33810
Remove the pump from the vise and remove the nut.
Remove the O-ring (Item 1) [Figure 20-51- 8] from the supply hose fitting.
20-51-4
Figure 20-51- 13
P-33991
1 Mark and remove the bolts (Item 1) [Figure 20-51- 13] and washers.
P-33988
Use a puller to remove the pump coupler (Item 1) [Figure 20-51- 11]. Figure 20-51- 12
NOTE: Different length bolts are used. Mark the bolts before removal for correct installation. Figure 20-51- 14 1
1
P-33992 P-33989
Remove the end cap (Item 1) [Figure 20-51- 14]. Remove the key (Item 1) [Figure 20-51- 12] from the pump shaft. Mark the pump sections for ease of assembly.
20-51-5
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) (CONTD) Disassembly (Contd)
Figure 20-51- 17
1 Figure 20-51- 15
P-33996
2 Remove the O-ring (Item 1) [Figure 20-51- 17].

P-33993
Figure 20-51- 18
Remove the O-ring (Item 1) [Figure 20-51- 15]. Remove the load seal and load seal backup ring (Item 2) [Figure 20-51- 15]. Figure 20-51- 16
1 1
P-33997
Remove the bearings (Item 1) [Figure 20-51- 18].
P-33995
Remove the housing (Item 1) [Figure 20-51- 16].
20-51-6
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) (CONTD) Disassembly (Contd)
Figure 20-51- 21
1 Figure 20-51- 19
P-33999
Remove the gear (Item 1) [Figure 20-51- 21].

P-35002
Figure 20-51- 22
Remove the plug (Item 1) [Figure 20-51- 19] from both bearings. Figure 20-51- 20
P-35000
1 Remove the bearings (Item 1) [Figure 20-51- 22].
P-33998
Remove the gear (Item 1) [Figure 20-51- 20].
20-51-7
Figure 20-51- 25
1 2
P-35003
Remove the drive shaft (Item 1) [Figure 20-51- 25].

P-35001
Remove the plate (Item 2) [Figure 20-51- 25]. Figure 20-51- 26
Remove the load seal and load seal back-up ring (Item 1) [Figure 20-51- 23]. Figure 20-51- 24
1 2
1
P-35004
Remove the O-ring (Item 1) [Figure 20-51- 26].

P-35002
Remove the plug (Item 1) [Figure 20-51- 24] from both bearings.
Remove the load seal and load seal back-up ring (Item 2) [Figure 20-51- 26].
20-51-8
Figure 20-51- 29
P-35001
P-35005
Figure 20-51- 30 Remove the housing (Item 1) [Figure 20-51- 27]. Figure 20-51- 28 1
P-35002
P-35006
20-51-9
Figure 20-51- 33
P-35001
P-35007
Figure 20-51- 34 Remove the gears (Item 1) [Figure 20-51- 31]. Figure 20-51- 32 1
P-35002
P-35008
20-51-10
Figure 20-51- 37
P-35011
Remove the snap ring (Item 1) [Figure 20-51- 37].

P-35009
Figure 20-51- 38
Remove the plate (Item 1) [Figure 20-51- 35] from the mount. Figure 20-51- 36 1
P-35012
Remove the seal (Item 1) [Figure 20-51- 38].
P-35010
Remove the gasket (Item 1) [Figure 20-51- 36].
20-51-11
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) (CONTD) Assembly Clean all parts in solvent and dry with compressed air. Apply clean hydraulic oil or assembly lube on the new Orings and seals. Figure 20-51- 39
Figure 20-51- 41
1
P-35010
Install the gasket (Item 1) [Figure 20-51- 41]. Figure 20-51- 42 1

P-35012
Install the seal (Item 1) [Figure 20-51- 39]. Figure 20-51- 40
1
P-35009
Install the plate (Item 1) [Figure 20-51- 42].
P-35011
Install the snap ring (Item 1) [Figure 20-51- 40].
20-51-12
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) (CONTD) Assembly (Contd) Figure 20-51- 43
Figure 20-51- 45
P-35001
Position the bearings as shown and install the load seal and load seal back-up ring (Item 1) [Figure 20-51- 45].
P-35002
Figure 20-51- 46 Install the plug (Item 1) [Figure 20-51- 43] in the bearings. Figure 20-51- 44
1
P-35008
Turn the bearing assembly over and install the bearings (Item 1) [Figure 20-51- 46] on the plate.
P-33994
Install the load seal back-up ring (Item 1) in the groove of the load seal (Item 2) [Figure 20-51- 44].
20-51-13
Figure 20-51- 49
1 2
P-35006
Figure 20-51- 50
P-35007
1 Install the gears (Item 1) [Figure 20-51- 47]. Figure 20-51- 48
P-35005
Install the bearings (Item 1) Press in on the plugs (Item 2) [Figure 20-51- 49] and install the housing (Item 1) [Figure 20-51- 50].
P-35002
Install the plug (Item 1) [Figure 20-51- 48] in the bearings.
20-51-14
Figure 20-51- 53
1
P-35003
Install the plate (Item 1) [Figure 20-51- 53].

P-33994
Install the driveshaft (Item 2) [Figure 20-51- 53]. Figure 20-51- 54
Install the load seal back-up ring (Item 1) in the groove of the load seal (Item 2) [Figure 20-51- 51]. Figure 20-51- 52
P-35002
P-35004
Install the plug (Item 1) [Figure 20-51- 54] in both bearings.
Install the load seal and load seal back-up ring (Item 1) [Figure 20-51- 52]. Install the O-ring (Item 2) [Figure 20-51- 52].
20-51-15
Figure 20-51- 57
1
P-35000
Turn the bearing assembly over and install the bearings (Item 1) [Figure 20-51- 57] on the plate.
P-33994
Figure 20-51- 58 Install the load seal back-up ring (Item 1) in the groove of the load seal (Item 2) [Figure 20-51- 55]. Figure 20-51- 56 1
P-33999
Install the gear (Item 1) [Figure 20-51- 58].

P-35001
Position the bearings as shown and install the load seal and load seal back-up ring (Item 1) [Figure 20-51- 56].
20-51-16
Figure 20-51- 61
1 2
P-33997
Install the bearings (Item 1) [Figure 20-51- 61].

P-33998
Figure 20-51- 62
Install the gear (Item 1) [Figure 20-51- 59]. Figure 20-51- 60 1
P-33995
Press in on the plugs (Item 2) [Figure 20-51- 61] and install the housing (Item 1) [Figure 20-51- 62].
P-35002
Install the plug (Item 1) [Figure 20-51- 60] in both bearings.
20-51-17
Figure 20-51- 65
1
P-33992
Install the end cap (Item 1) [Figure 20-51- 65].

P-33994
Figure 20-51- 66
Install the load seal back-up ring (Item 1) in the groove of the load seal (Item 2) [Figure 20-51- 63]. Figure 20-51- 64 1 1 1
2
P-33991
Install the bolts and washers (Item 1) [Figure 20-51- 66].
P-33993
Install the load seal and load seal back-up ring (Item 1) [Figure 20-51- 64]. Install the O-ring (Item 2) [Figure 20-51- 64].
20-51-18
Figure 20-51- 69
P-33811
1 Figure 20-51- 70
P-33989
Install the key (Item 1) [Figure 20-51- 67] on the shaft. Install the pump coupler on the shaft. Figure 20-51- 68
2
P-33812
Install the O-rings (Item 1) [Figure 20-51- 69] & [Figure 20-51- 70] on the high pressure fittings.
P-33987
Place the pump coupler (Item 1) [Figure 20-51- 68] in a vise that is equipped with padded jaws. Install the nut (Item 2) [Figure 20-51- 68]. Remove the pump from the vise.
20-51-19
HYDRAULIC GEAR PUMP (S/N 522311001 & ABOVE) (CONTD) Assembly (Contd)
Figure 20-51- 73
2 Figure 20-51- 71 3 1 2 2 2 2
P-33809
2 1 1
P-33808
Install the fitting (Item 1) [Figure 20-51- 73] on the pump. Install the bolts (Item 2) [Figure 20-51- 73].
Install the fittings (Item 1) [Figure 20-51- 71] on the pump. Install the bolts (Item 2) [Figure 20-51- 71]. Install the O-ring (Item 3) [Figure 20-51- 71]. Figure 20-51- 72
P-33810
Install the O-ring (Item 1) [Figure 20-51- 72] on the supply line fitting.
20-51-20
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Hydraulic Pump Work Sheet (Please review pump procedure as illustrated in Pump Testing on page 5) If any of the following adjustments are not obtainable, pump repair is required. The outline listed below, gives the four adjustments for setting the hydraulic pump. The adjustments are listed in the order in which they MUST be performed. Below each adjustment is a list of the steps. Behind each adjustment is the page location within the Service Manual for the complete adjustment procedure. I. Torque Limiter Supply Pressure Adjustment on page 5 41. Bottom Out Pump Margin Spool (Approximately 6 Turns In.) 42. Remove the plug and install fitting and hose from the Torque Limit Supply Spool to a drain pan. 43. Install a 725 psi (50 bar) pressure gauge on the test port on the six spool control valve. 44. Warm hydraulic fluid to 122 - 144 F (50 - 60 C). 45. Run Engine at High Idle 46. Adjust as Necessary to get 290 20 PSI (20 1,4 bar). 47. Record Pressure __________ TLS PRESSURE 48. Remove the Hose and Fitting from the Torque Limiter Supply Spool and Plug the Port 49. Reset Pump Margin Spool (Approximately 6 Turns Out.) II. Pump Margin Pressure Adjustment on page 6 50. Run Engine at High Idle 51. Adjust as Necessary to get 363 20 PSI (25 1,4 bar). 52. Record Pressure __________ PM PRESSURE 53. Remove 725 PSI (50 bar) pressure gauge. III. Back-up Relief Valve Adjustment on page 6 54. Install 5000 PSI (345 bar) gauge on the test port on the six spool valve. 55. Turn the load sense relief valve in 3/4 turn. 56. Run engine at high idle and curl the bucket until the bucket cylinder is fully extended and the relief valve opens. 57. Adjust backup relief valve as necessary to get 4350 50 PSI (300 3,4 bar).
20-52-1
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Hydraulic Pump Work Sheet (Contd) 58. Record Pressure __________ PM PRESSURE IV. Load Sense Relief Valve Adjustment on page 8 59. Install 5000 PSI (345 bar) Gauge on the test port on the six spool control valve. 60. Run Engine at High Idle and curl the bucket until the bucket cylinder is fully extended and the relief valve opens. 61. Adjust Load Sense Relief Valve as Necessary to get 4060 50 PSI (280 3,4 bar). 62. Record Pressure __________ PRESSURE 63. Remove the 5000 PSI (345 bar) Gauge, from the Pump Diagnostic Coupler at the Control Valve. V. Torque Limiter Adjustment on page 9 64. Remove the inlet hose from the six spool hydraulic control valve, install a cap on the valve and install the inlet hose on the inlet side of the hydraulic tester. 65. Route the outlet hose of the hydraulic tester to the hydraulic reservoir. 66. Bottom out the pump margin spool (approximately six turns in) 67. Run engine at high idle. 68. Free flow on the hydraulic tester is 40 GPM (152 L/min) 69. Adjust the hydraulic tester to 1450 PSI (100 bar) 70. Adjust torque limiter to 41 GPM (155 L/min). 71. Record Flow and Engine RPM. __________ FLOW 72. Adjust the Hydraulic Tester to 3480 PSI (240 bar). 73. Adjust the Torque Limiter to obtain 19 GPM (72 L/min) 74. Record Flow and Engine RPM. __________ FLOW
20-52-2
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Hydraulic Pump Work Sheet (Contd) 75. Remove the Hydraulic Tester. 76. Install the pump outlet hose on the six spool hydraulic control valve. 77. Reset pump margin spool to 363 20 PSI (25 1,4 bar). ALL PUMP ADJUSTMENTS ARE NOW COMPLETED
20-52-3
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Testing Information The testing of the piston pump must be done in the following order: Torque limiter supply pressure Pump margin pressure Load sense relief valve Torque Limiter All testing is done with the hydraulic oil at 122 to 140 F
Figure 20-52-1
(50 to 60 C).
Check and adjust as needed the engine high idle before any hydraulic testing. The hydraulic hoses, tubelines and fittings on the 442 Excavator are 24 DIN cone metric fittings. To test the torque limiter order the following parts to adapt the metric fittings to 37 JIC flare fittings: Order the following parts from your Bobcat dealer:
P-58652
Item 1 [Figure 20-52-1]: Female 24 DIN to male 37 JIC flare P/N 6698092. Item 2 [Figure 20-52-1]: Male 24 DIN to male 37 JIC flare P/N 6698093. Item 3 [Figure 20-52-1]: Male British pipe thread to male 37 JIC flare P/N 6698094. Item 4 [Figure 20-52-1]: British bonded seal P/N 6698095. Item 5 [Figure 20-52-1]: Female 37 JIC flare cap P/N 36K-8. MEL1610 Hose Kit (not shown).
20-52-4
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Testing Torque Limiter Supply Pressure Adjustment Figure 20-52-2
Figure 20-52-4
1 3 2 2
P-58096
1 Install a fitting and drain hose (Item 1) [Figure 20-52-4]. Place the other end of the hose in a drain pan. NOTE: To adjust the Torque Limiter Supply Pressure, the Pump Margin Spool must be temporarily bottomed out. Loosen the nut (Item 2) [Figure 20-52-4]. Turn the pump margin spool (bottom spool) (Item 3) [Figure 20-52-4] all the way in. (Approximately 6 turns) Start the engine and run at high idle. Loosen the nut (Item 4) and adjust the torque limiter supply pressure spool (Item 5) [Figure 20-52-4] until the pressure gauge reads 290 PSI (20 bar). Turn the adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure. 2 NOTE: 1/4 turn is approximately 35 PSI (2,4 bar). Repeat the procedure listed above until the pressure is set.
P-58094
P-58095
Install a 725 PSI (500 bar) pressure gauge on the test coupler (Item 1) [Figure 20-52-2]. Figure 20-52-3
Tighten the nut (Item 4) [Figure 20-52-4]. Stop the engine. Turn the pump margin spool (bottom spool) (Item 3) [Figure 20-52-4] back to its original position. (Approximately 6 turns) Tighten the nut (Item 2) [Figure 20-52-4]. Remove the hose (Item 1) [Figure 20-52-4] and install the plug. Install the cap on the torque limiter supply pressure adjustment spool (top spool).
Remove caps (Item 1) [Figure 20-52-3]. Remove the plug (Item 2) [Figure 20-52-3].
20-52-5
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Testing (Contd) Pump Margin Pressure Adjustment Figure 20-52-5
Figure 20-52-6
P-58094
1
P-40562
Install the cap (Item 1) [Figure 20-52-6] on the pump margin pressure adjustment spool (bottom spool). Remove the gauge from the test coupler. Back-up Relief Valve Adjustment
Start the engine and run at high idle. Loosen the nut (Item 1) and adjust the pump margin pressure adjustment spool (Item 2) [Figure 20-52-5] until the pressure gauge reads 363 PSI (25 bar). Turn the adjustment screw clockwise to increase pressure and counterclockwise to decrease pressure. NOTE: 1/4 turn is 50 PSI (3,4 bar).
Figure 20-52-7
1 Tighten the nut (Item 1) [Figure 20-52-5]. Repeat the procedure listed above until the pressure is set. Stop the engine.
P-33368
Turn the load sense adjustment screw (Item 1) [Figure 20-52-7] in 3/4 of a turn, increasing the relief pressure approximately 600 PSI (41,3 bar) to 4660 PSI (321 bar).The load sense relief is now set to a higher pressure than the backup relief.
20-52-6
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Testing (Contd) Pump Margin Pressure Adjustment (Contd) Figure 20-52-8
Figure 20-52-9
1 2
P-58098
Remove the plastic cap (Item 1) [Figure 20-52-9].
P-58095
Install a 5000 PSI (345 bar) pressure gauge on the test coupler (Item 1) [Figure 20-52-8]. Start the excavator and warm the hydraulic oil to operating temperature. Move the engine speed control to the high speed position. Curl the bucket until the bucket cylinder is fully extended and the relief valve opens. Record the pressure. The pressure at the gauge (Item 2) [Figure 20-52-8] should be 4350 PSI (300 bar). Stop the engine.
20-52-7
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Testing (Contd) Back-up Relief Valve Adjustment (Contd) Figure 20-52-10
Curl the bucket until the bucket cylinder is fully extended and the relief valve opens. Record the pressure. The pressure at the gauge (Item 2) [Figure 20-52-11] should be 4060 PSI (280 bar). Stop the engine.
Figure 20-52-12
P-58099
Loosen the lock nut (Item 1) [Figure 20-52-10].

P-33367
Turn the adjustment screw (Item 2) [Figure 20-52-10] in to increase pressure and out to decrease pressure. NOTE: One quarter turn is approximately 200 PSI (13,8 bar). Tighten the nut and retest the backup relief valve. Load Sense Relief Valve Adjustment Figure 20-52-11
1
P-33368
2 Loosen the lock nut (Item 1) [Figure 20-52-13]. Turn the adjustment screw (Item 2) [Figure 20-52-13] in to increase pressure and out to decrease pressure.
P-58095
Install a 5000 PSI (345 bar) pressure gauge on the test coupler (Item 1) [Figure 20-52-11]. Move the engine speed control to the high idle position.
NOTE: One quarter turn is approximately 200 PSI (13,8 bar). Tighten the lock nut and retest the load sense relief valve.
20-52-8
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Testing (Contd) Torque Limiter Adjustment Figure 20-52-14
Figure 20-52-16
P-40577
Install the adapter (Gates P/N 87945) (Item 1) [Figure 20-52-16] on the inlet hose. Figure 20-52-17
P-40567
Remove the inlet hose (Item 1) [Figure 20-52-14] from the hydraulic control valve. Figure 20-52-15
P-40578
Connect the inlet hose to the INLET side of the hydraulic tester (Item 1) [Figure 20-52-17].
P-40576
Install the adapter (Gates P/N 87957) (Item 1) and cap (Bobcat P/N 36K-8) (Item 2) [Figure 20-52-15].
20-52-9
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Testing (Contd) Figure 20-52-18
Figure 20-52-20
1
P-58655
Connect the OUTLET side of the hydraulic tester (Item 1) [Figure 20-52-20] to the fitting.
P-58653
Figure 20-52-21 Remove the hydraulic reservoir breather (Item 1) [Figure 20-52-18]. Figure 20-52-19
1
P-40580
Fully open the hydraulic tester flow control (Item 1) [Figure 20-52-21].
P-58654
Install a fitting (Item 1) [Figure 20-52-19] into the reservoir breather hole.
20-52-10
Figure 20-52-24
1 1
2
P-40580
The flow should be 43 GPM (163 L/mm) on the flow tester (Item 1) [Figure 20-52-24].
P-58094
Remove the cap (Item 1) [Figure 20-52-22] from the pump margin spool (bottom spool). Figure 20-52-23
Turn the hydraulic tester flow control (Item 2) clockwise until the gauge (Item 3) [Figure 20-52-24] shows 1450 PSI (100 bar). The gauge (Item 1) [Figure 20-52-24] should show 41 GPM (155 L/min) which is flow at low pressure. Figure 20-52-25
P-58097
Loosen the nut (Item 1) and turn the adjustment screw (Item 2) [Figure 20-52-23] all the way in (approximately 6 turns). Start the engine and run at high idle.
P-58650
Remove the dust cover (Item 1) [Figure 20-52-25].
20-52-11
Install the protective cap on the hydraulic pump torque limiter. Remove the hydraulic tester and fittings. Install the reservoir breather. Install the supply hose on the hydraulic control valve. Figure 20-52-27
1 2 1
P-58651
Check the 13 mm nut (Item 1) [Figure 20-52-26] to be sure it is locked in place.

P-58097
Adjust the flow at the hydraulic pump torque limiter by loosening the 27 mm nut (Item 2) [Figure 20-52-26] With an Allen wrench adjust the flow at low pressure. When the proper flow is obtained, 41 GPM (155 L/min) at 1450 PSI (100 bar), lock the 27 mm nut (Item 2) [Figure 20-52-26]. NOTE: Changing the flow at low pressure (27 mm nut) will affect flow at high pressure (13 mm nut). Turn the hydraulic tester flow control (Item 2) clockwise until the gauge (Item 3) [Figure 20-52-24 on Page 11] reads 3480 PSI (240 bar). NOTE: Do not exceed 4350 PSI (300 bar) with the hydraulic tester or the pump will be damaged. The gauge should show 19 GPM (72 L/min) which is flow at high pressure. Adjust the flow at the hydraulic pump torque limiter. Loosen the 13 mm nut (Item 1) [Figure 20-52-26] and with an Allen wrench adjust the flow at high pressure. When the proper flow is obtained, 19 GPM (72 L/min) at 3480 PSI (240 bar), lock the 13 mm nut (Item 1) [Figure 20-52-26]. NOTE: If adjustments were made to flow at high pressure verify the flow at low pressure.
Adjust the pump margin spool (Item 1) [Figure 20-52-27] back to the original position (approximately 6 turns out). Retest and adjust the pump margin spool as needed. (See Pump Margin Pressure Adjustment on Page 20-526.) ALL PUMP ADJUSTMENTS ARE NOW COMPLETED.
20-52-12
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Removal And Installation Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Remove the muffler. (See MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 60-211.) Remove the gear pump. (See Removal And Installation on Page 20-53-1.)
Figure 20-52-29
1 2
1
P-58531
IMPORTANT
I-2003-0888
Remove the bolts (Item 1) and hose (Item 2) [Figure 2052-29]. Figure 20-52-30
Figure 20-52-28
1 1 1 1
P-58530 P-58532
Loosen the hose clamp (Item 1) [Figure 20-52-30].
Remove the hoses (Item 1) [Figure 20-52-28].
20-52-13
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 20-52-31
Figure 20-52-33
1 1
P-58535
Remove the bolts (Item 1) [Figure 20-52-32] & [Figure 20-52-33] and washers.
P-58533
The hose (Item 1) [Figure 20-52-31] will be removed from the inlet fitting as the pump is removed. Figure 20-52-32
Installation: Tighten the bolts to 125-140 ft.-lb. (170-190 Nm) torque. Figure 20-52-34
P-58536 P-58534
Install a sling (Item 1) [Figure 20-52-34] on the pump. Separate the pump from the engine and remove the pump.
20-52-14
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Coupler Removal And Installation Figure 20-52-35
Figure 20-52-37
P-58539
Remove the plate (Item 1) [Figure 20-52-37]. 1

P-58537
Figure 20-52-38
Measure and record the distance (Item 1) [Figure 20-5235] between the coupler and pump pilot flange. Figure 20-52-36 1
P-58540
Slide the coupler (Item 1) [Figure 20-52-38] off the shaft. Installation: Slide the coupler on the shaft to the measurement recorded earlier.
P-58538
Remove the bolts (Item 1) [Figure 20-52-36].
20-52-15
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Torque Limiter Valve Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
O-Ring Plug Spring Spool Spring Seat Cap Nut Adjustment Screw Washer Adjustment Body
4 4
5 3 10 7 6 7 8
2 1 1 1 9
B-26227 442 Excavator Service Manual
20-52-16
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Torque Limiter Valve Removal and Installation Clean the outside of the pump with clean solvent and dry with compressed air before removing any components from the pump. Figure 20-52-39
P-58599
Remove the tubeline (Item 1) [Figure 20-52-39] from the pump control and torque limiter vale. NOTE: Mark the tubeline for correct installation. Remove the bolts (Item 2) [Figure 20-52-39] from the torque limiter valve. Installation: Tighten the mount bolts to 7.0-7.5 ft.-lb. (9,5-10,5 Nm) torque. Figure 20-52-40
P-58601
Remove the torque limiter (Item 1) [Figure 20-52-40] from the pump.
20-52-17
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Torque Limiter Valve Disassembly Figure 20-52-41
Figure 20-52-43
P-58604
Remove the control spool assembly (Item 1) [Figure 2052-43].

P-58602
Remove the O-ring (Item 1) [Figure 20-52-41] from the torque limiter valve. NOTE: Do not scratch or damage the mounting surface on the valve body. Remove the plug (Item 2) [Figure 20-52-41]. NOTE: The plug (Item 2) [Figure 20-52-41] is under spring pressure. Figure 20-52-42
NOTE: Use care not to scratch or damage the spool. Scratches in the spool can cause internal leakage. Figure 20-52-44
2 1
1
P11468
Remove the metering spool (Item 1) from the control spool (Item 2) [Figure 20-52-44].
P-58603
Remove the O-ring (Item 1) from the plug. Remove the two springs (Items 2 & 3) [Figure 20-52-42].
20-52-18
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Torque Limiter Valve Disassembly (Contd) Figure 20-52-45
Figure 20-52-47
1 1
P-58607
Remove the fittings (Item 1) [Figure 20-52-47].

P-58605
Figure 20-52-48 1 1
Remove the spring seat (Item 1). Remove the two springs (Item 2 & 3) [Figure 20-52-45]. Figure 20-52-46
1
P-58608
Remove the O-rings (Item 1) [Figure 20-52-48] from the fittings and plugs.
P-58606
The following procedures are only used if the adjustment assembly is removed. NOTE: If the adjustment assembly is removed and/or disassembled, the torque limiter must be tested and adjusted after the pump assembly is installed in the machine. See Initial Torque Limiter Valve Setting on page 26.)
Remove the plugs (Items) [Figure 20-52-46].
20-52-19
Figure 20-52-51
2 1
P-35326
With an Allen wrench hold the adjustment bolt (Item 1) and loosen the nut (Item 2) [Figure 20-52-51].
P11472
Figure 20-52-52 Remove the dust cap (Item 1) [Figure 20-52-49]. Figure 20-52-50 3 2 1 4
2
P-35327
P11473
Remove the adjustment screw (Item 1), O-ring washer (Item 2) and large nut (Item 3) from the adjustment body (Item 4) [Figure 20-52-52].
Loosen the large nut (Item 1) [Figure 20-52-50]. Turn the small nut (Item 2) [Figure 20-52-50] to remove the adjustment body.
20-52-20
P11475
Remove the O-ring (Item 1) [Figure 20-52-53] from the torque limiter valve body.
20-52-21
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Torque Limiter Valve Assembly Clean all the parts in solvent and dry with compressed air. Inspect seats and spools for wear. Apply clean oil to new O-rings and spools. The following procedures are only used if the adjustment assembly is removed. Figure 20-52-54
Figure 20-52-55 3 4 1 2
P-35327
Install the O-ring washer (Item 1) on the adjustment screw (Item 2) [Figure 20-52-55]. 1 Install the adjustment screw (Item 2) in the adjustment body (Item 3) [Figure 20-52-55]. Install the nut (Item 4) [Figure 20-52-55] on the adjustment body. Figure 20-52-56
P11475
Install the O-ring (Item 1) [Figure 20-52-54] in the torque limiter valve body. 1
P11473
Install the adjustment screw/adjustment body (Item 1) [Figure 20-52-56] assembly into the valve body.
20-52-22
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Torque Limiter Valve Assembly (Contd) Figure 20-52-57
Figure 20-52-59
1 1
P-58607
Install the fittings (Item 1) [Figure 20-52-59].

P11472
Figure 20-52-60
Install the dust cap (Item 1) [Figure 20-52-57]. NOTE: After the pump assembly is installed in the machine, the torque limiter must be tested and adjusted. See Initial Torque Limiter Valve Setting on page 26. Figure 20-52-58
1 1
P-58606
Install the plugs (Item 1) [Figure 20-52-60].
1
P-58608
Install the O-rings (Items 1) [Figure 20-52-58] on the plugs and fittings.
20-52-23
Figure 20-52-63
2 3
P-58604
Install the control spool (Item 1) [Figure 20-52-63].

P-58605
Install the two springs (Items 1 & 2) [Figure 20-52-61]. NOTE: Install the big spring first and the small spring second. Install the spring seat (Item 3) [Figure 20-52-61]. Figure 20-52-62
NOTE: Use care not to scratch or damage the spool. Scratches in the spool can cause internal leakage. Figure 20-52-64
2 1
P-58603
Install the springs (Items 1 & 2). Install the O-ring (Item 3) on the plug (Item 4) [Figure 20-52-64].
P11468
Install the plug in the valve body.
Install the metering spool (Item 1) in the control spool (Item 2) [Figure 20-52-62].
20-52-24
P-58602
Install the O-ring (Item 1) [Figure 20-52-65].
20-52-25
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Initial Torque Limiter Valve Setting The following procedures are only used if the adjustment assembly is removed. Figure 20-52-66
Figure 20-52-68
4.44 (113 mm)

P11473
Measure from the cap to the top of the small adjusting screw [Figure 20-52-68]. Set the small adjustment screw to 4.44 inches (113 mm). Figure 20-52-69
P11472
3 Remove the dust cap (Item 1) [Figure 20-52-66]. Figure 20-52-67
2 4
P-58601
3.98 (101 mm)

P11473
Align the linkage pin (Item 1) on the hydraulic piston pump into the hole (Item 2) [Figure 20-52-69] in the torque limiter valve. Turn the valve slightly to align the dowel pin (Item 3) on the hydraulic piston pump into the hole (Item 4) [Figure 20-52-69] in the torque limiter valve. NOTE: Care should be taken not to scratch or damage the valve spool. NOTE: Before tightening the bolts, make sure the dowel pin is aligned with the housing.
Measure from the cap to the top of the large adjustment screw. Set the large adjustment screw to 3.98 inches (101 mm) [Figure 20-52-67].
20-52-26
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Initial Torque Limiter Valve Setting (Contd) Figure 20-52-70
P-58600
Install the bolts (Item 1) [Figure 20-52-70]. Tighten the bolts to 7.0-7.5 ft.-lb. (9,5-10,5 Nm) torque. Figure 20-52-71
P-58599
Install the tubeline (Item 1) [Figure 20-52-71].
20-52-27
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Control Parts Identification 1. Cap 2. O-Ring 3. Jam Nut 4. Adjusting Screw 5. O-Ring 6. Adjustment Assembly 7. Adjustment Assembly 8. Disc 9. Spring 10. Spring 11. Spring 12. Spring 13. Spring Retainer 14. Spring Retainer 15. O-Ring 16. Plug 17. Bolt 18.O-Ring 19. O-Ring 20. Housing 21. Orifice 22. Spool
1 2 3 2 4 1 2 6 3 2 4 7 5 9 8 10
5 8
11 14 18 19 21
12 13
16 15 18 17 20 22 22 17 17 17
2 16
2 16
TS-01531
20-52-28
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Control Removal And Installation Figure 20-52-72
P-58599
Mark the tubeline (Item 1) [Figure 20-52-72] for correct assembly. Loosen and remove the tubeline (Item 1) [Figure 20-5272] from the pump control and torque limiter valve. Figure 20-52-73
P-58609
Remove the 4 bolts (Item 1) and remove the pump control (Item 2) [Figure 20-52-73] from the hydraulic piston pump. Installation: Tighten to 10 ft.-lb. and (13 Nm) torque.
20-52-29
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Control Disassembly And Assembly Figure 20-52-74
Figure 20-52-76
4 2
1
N-23359
P-58610
Remove the adjustment screw (Item 1) jam nut (Item 2), and O-ring washer (Item 3) from the adjustment assembly (Item 4) [Figure 20-52-76]. Remove the adjustment assembly (Item 4) [Figure 2052-76] from the pump control assembly. Figure 20-52-77
Remove the 3 O-rings (Item 1) [Figure 20-52-74] from the valve. Pump Margin Control Figure 20-52-75
4 1
1 3 3
N-23360
N-23358
Remove the adjustment seat (Item 1) [Figure 20-52-77] from the adjustment assembly. Remove the large spring (Item 2) and the small spring (Item 3) [Figure 20-52-77] from the adjustment assembly. Replace the O-ring (Item 4) [Figure 20-52-77] before installation.
Before disassembling the pump margin control, remove the cap (Item 1) and O-ring washer (Item 2) [Figure 2052-75] from the adjustment assembly. Measure the adjustment screw (Item 3) [Figure 20-5275], thread length for the correct initial adjustment.
20-52-30
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Control Disassembly And Assembly (Cont'd) Pump Margin Control (Cont'd) Figure 20-52-78
Figure 20-52-80
N-23380
Check the spool for scratches and be sure the orifice (Item 1) [Figure 20-52-80] is not plugged. Figure 20-52-81
N-23361
Remove the spring guide (Item 1) [Figure 20-52-78] from the pump control assembly. Figure 20-52-79
1 1
N-23362
Remove the plug (Item 1) [Figure 20-52-81] from the pump control.
N-23364
Remove the spool (Item 1) [Figure 20-52-79] from the pump control assembly.
20-52-31
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Control Disassembly And Assembly (Cont'd) Pump Margin Control (Cont'd) Figure 20-52-82
Figure 20-52-84
2 1
N-23366
Before disassembling the torque limiter supply control, remove the O-ring washer (Item 1) [Figure 20-52-84] from the adjustment assembly.
N-23363
Measure the adjustment screw (Item 2) [Figure 20-5284], thread length for the correct initial adjustment. Figure 20-52-85
Check the O-ring washer (Item 1) [Figure 20-52-82] and replace as needed. Torque Limiter Supply Control Figure 20-52-83
N-23367
1
N-23365
Loosen the jam nut (Item 1) [Figure 20-52-85].
Remove the cap (Item 1) [Figure 20-52-83].
20-52-32
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Control Disassembly And Assembly (Cont'd) Torque Limiter Supply Control (Cont'd) Figure 20-52-86
Figure 20-52-88
1 2
N-23377
4 3 1
N-23368
Remove the spring guide (Item 1) [Figure 20-52-88]. Figure 20-52-89
Remove the adjustment screw (Item 1), jam nut (Item 2), and O-ring washer (Item 3) from the adjustment assembly (Item 4) [Figure 20-52-86]. Figure 20-52-87
3 1 2
1
N-23378
N-23369
Remove the small spring (Item 1) and the large spring (Item 2) [Figure 20-52-87] from the adjustment assembly. Replace the O-ring (Item 3) [Figure 20-52-87] before installation.
20-52-33
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Pump Control Disassembly And Assembly (Cont'd) Torque Limiter Supply Control (Cont'd) Figure 20-52-90
Figure 20-52-92
2 1 1
N-23382
Check the O-ring washer (Item 1) [Figure 20-52-92] and replace as needed.
N-23379
Check the spool for scratches and be sure the orifice (Items 1 & 2) [Figure 20-52-90] are not plugged. Figure 20-52-91
1
N-23381
Remove the plug (Item 1) [Figure 20-52-91] from the pump control.
20-52-34
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Parts Identification
1. 2. 3. 4. 5. 6.
Seal Shaft Bolt Bearing Plug Piston
6 4
5 4
B-19529
20-52-35
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly
Figure 20-52-94
IMPORTANT
I-2003-0888
P-58598
Clean the outside of the hydraulic piston pump. Remove the O-ring (Item 1) [Figure 20-52-94]. Remove the torque limiter valve. See Torque Limiter Valve Removal and Installation on page 17. Remove the pump control assembly. See Pump Control Removal And Installation on page 29. Figure 20-52-93 1 1 Figure 20-52-95
P-58611
1
P-58597
Remove the screw (Item 1) [Figure 20-52-95] from the pin assembly.
Remove the bolts (Item 1) and inlet fitting (Item 2) [Figure 20-52-93].
20-52-36
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly (Cont'd) Figure 20-52-96
Figure 20-52-98
P-58614
1 Remove the 4 bolts (Item 1) [Figure 20-52-98]. 2

P-58612
Remove the block port assembly (Item 2) [Figure 20-5298] from the pump. Figure 20-52-99 1 2 3
Remove the pin assembly (Item 1) [Figure 20-52-96]. NOTE: The position of the dowel pin (Item 2) on the pin assembly, with the locating hole on the swash plate cradle (Item 3) [Figure 20-52-96]. Figure 20-52-97
1 Remove the O-ring (Item 1) [Figure 20-52-99].
N-23386
P-58613
Remove the destroking piston (Item 2) [Figure 20-5299]. Remove the stroking piston/spring assembly (Item 3) [Figure 20-52-99].
Remove the plug (Item 1) [Figure 20-52-97] from the pump housing and drain the oil. Mark the pump housing for proper installation.
20-52-37
Figure 20-52-102
1
N-23389

N-23387
Figure 20-52-103
Inspect the destroking piston (Item 1) [Figure 20-52-100] for scratches and replace as needed. Figure 20-52-101 1
2 1
N-23390
Remove the adjustment spacer(s) (Item 1) [Figure 2052-103] from the pump shaft.
N-23388
Remove the spring (Item 1) from the stroking piston (Item 2) [Figure 20-52-101], inspect all parts and replace as needed.
20-52-38
Figure 20-52-106
2 1
N-15287
Remove the retainer plate and pistons (Item 1) from the cylinder block (Item 2) [Figure 20-52-106].
N-23391
Lay the pump assembly on its side and remove the rotary group, cradle, and shaft (Item 1) [Figure 20-52-104] from the housing. Figure 20-52-105
NOTE: The following procedure shown is to disassemble the rotating group for inspection only. The rotating group parts can not be ordered separately and must be ordered as an assembly. Figure 20-52-107
N-23392
N-15299
Slide the rotary group (Item 1) from the shaft assembly (Item 2) [Figure 20-52-105]. NOTE: It is NOT important that the pistons are installed in their original positions. NOTE: Check that there are no scratches or metal deposits on the sliding surface. (Pistons must be replaced in sets).
To remove the spring from inside the cylinder block, use a threaded rod (or bolt) (Item 1) two trimmed washers (Item 2) and two nuts (Item 3) [Figure 20-52-107].
20-52-39
Figure 20-52-110
2 4 1 1
2 3
N-15290
N-15288
Tighten the nut (Item 1) until the spring is compressed enough to remove the snap ring (Item 2) [Figure 20-52110]. Loosen the nut to release the tension on the spring and remove the bolts and washers. Figure 20-52-111
Install the threaded rod and nut (Item 1) through the trimmed washer (Item 2) and through the block assembly (Item 3) [Figure 20-52-108]. NOTE: The modified washer (Item 2) must fit over the spring but must also fit inside the snap ring (Item 4) [Figure 20-52-108]. Figure 20-52-109
1 1 2 4 3 4
N-15291
Remove the spring (Item 1) the washer (Item 2) and the 3 pins (Item 3) [Figure 20-52-111] from the cylinder block.
N-15289
Install the second trimmed washer (Item 1) over the threaded rod (Item 2) install the nut (Item 3) [Figure 2052-109]. NOTE: The modified washer (Item 1) must fit between the three pins (Item 4) [Figure 20-52-109].
20-52-40
Figure 20-52-114
2 1 2
N-15284
Press the shaft (Item 1) from the bearing (Item 2) [Figure 20-52-114].
N-23393
Figure 20-52-115 Remove the cradle (Item 1) from the shaft (Item 2) [Figure 20-52-112]. Figure 20-52-113 1
3 1 2
N-23394
Remove the snap ring (Item 1) [Figure 20-52-115] from the housing.
N-23395
Loosen and remove the bolt (Item 1) and remove the torque limiter plate (Item 2) [Figure 20-52-113]. NOTE: The caps (Item 3) [Figure 20-52-113] cannot be replaced, a new cradle must be ordered.
20-52-41
Figure 20-52-118
N-15280
Remove the race (Item 1) [Figure 20-52-118] from the housing.

N-23396
Figure 20-52-119 Remove the seal (Item 1) [Figure 20-52-116] from the housing. NOTE: The shaft seal can be removed without removing the shaft. Figure 20-52-117 1 1 1
1 1
1
N-23397
Remove the 4 O-rings (Item 1) [Figure 20-52-119].
N-15277
Remove the 2 brass bearings (Item 1) [Figure 20-52117] from the housing.
20-52-42
Figure 20-52-122
N-23416
Remove the spacer (Item 1) [Figure 20-52-122] from the back port assembly.
N-23398
Figure 20-52-123 Remove the valve plate (Item 1) [Figure 20-52-120] from the housing. Figure 20-52-121
1 1
N-23418
Remove the stroking piston (Item 1) [Figure 20-52-123]. (Spring Side)

N-23415
With a bearing puller (Item 1) [Figure 20-52-121] remove the bearing race from the back port assembly.
20-52-43
N-23419
Remove the destroking piston (Item 1) [Figure 20-52124].
20-52-44
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Assembly Clean parts in solvent and dry with compressed air. Apply oil or assembly lube to new O-rings. Figure 20-52-125 1 2
Figure 20-52-127
N-23416
Install the spacer (Item 1) [Figure 20-52-127] in the back port assembly. Figure 20-52-128
N-23419
Apply Loctite 241 on the threads and install the destroking piston (Item 1) in the hole next to the alignment pin (Item 2) [Figure 20-52-125] and tighten. Figure 20-52-126 1
N-23417
Install the bearing race (Item 1) [Figure 20-52-128] in the back port assembly.
N-23418
Apply Loctite 241 on the threads and install the stroking piston (Item 1) [Figure 20-52-126] in the hole and tighten.
20-52-45
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Assembly (Cont'd) Figure 20-52-129
Figure 20-52-131
N-23394

N-15296
Figure 20-52-132
Press the race into the housing [Figure 20-52-129]. Figure 20-52-130 2
1 1
N-15285
Press the bearing (Item 1) onto the shaft (Item 2) [Figure 20-52-132].
N-23396
Install the shaft seal (Item 1) [Figure 20-52-130] in the housing.
20-52-46
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Assembly (Cont'd)
Figure 20-52-135
1 Figure 20-52-133 1
2 2
P-58614
Install the end plate (Item 1) and bolts (Item 2) [Figure 20-52-135] on the housing.
N-23423
Figure 20-52-136 To find the correct shim washer thickness for bearing end play, the shaft/bearing assembly (Item 1) [Figure 20-52133] must be installed in the housing. Figure 20-52-134
N-23429
Turn the housing over [Figure 20-52-136].
N-23425
20-52-47
Example: (In Inches): 0.150 Measure movement of shaft 0.001 Nominal Pre-load = 0.151 thickness of the spacer needed. When the proper thickness of shim washer is determined, remove the dial indicator from the pump housing. Remove the two end plate mounting bolts from the pump. Remove the shaft/bearing assembly from the pump housing. Figure 20-52-138
N-23430
Install a dial indicator on the housing as shown [Figure 20-52-137] and set it to zero. Pull the shaft up as far as it will go and record the reading on the dial indicator. Repeat the procedure several times. The reading must be the same each time. Add the nominal pre-load of 0.001 inch (0,025 mm), the actual pre-load is 0.000 inch (0,000 mm) to 0.002 inch (0,050 mm) to the reading found on the dial indicator [Figure 20-52-137].
1 1
N-15277
Install the 2 brass bearings (Item 1) [Figure 20-52-138] into the pump housing.
20-52-48
Figure 20-52-141
N-15291
1
N-15283
Apply clean grease to the three pins (Item 1) [Figure 2052-141] and install them in the appropriate groove. Install the washer (Item 2) and the spring (Item 3) [Figure 20-52-141]. NOTE: If the rotating group is damaged, the parts can not be ordered separately and must be order as an assembly. Figure 20-52-142
Apply Loctite 241 and install the torque limiter plate (Item 1) and bolt (Item 2) on the swash plate (Item 3) [Figure 20-52-139]. Figure 20-52-140
2 3 2 1 2 3
N-23393 N-15299
Install the cradle (Item 1) on the shaft (Item 2) [Figure 20-52-140].
To compress the spring inside the cylinder block, use a threaded rod (or bolt) (Item 1), 2 trimmed washers (Item 2) and 2 nuts (Item 3) [Figure 20-52-142].
20-52-49
HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Assembly (Cont'd) Figure 20-52-143 2 1 4 4
Figure 20-52-145
2 1
N-15290
3 NOTE: The modified washer (Item 1) [Figure 20-52144] must fit over the spring, but must also fit inside the snap ring (Item 2) [Figure 20-52145]. Tighten the nut (Item 1) until the spring is compressed enough to install the snap ring (Item 2) [Figure 20-52145]. Remove the threaded rod/washer assembly. Figure 20-52-146
N-15289
Install the threaded rod and nut (Item 1) through the modified washer (Item 2) and the block assembly (Item 3) [Figure 20-52-143]. NOTE: The modified washer (Item 2) must fit between the three pins (Item 4) [Figure 20-52-143]. Figure 20-52-144
2 1
3
P-58616 N-15288
Install the second modified washer (Item 1) over the threaded rod (Item 2) [Figure 20-52-144]. Install the nut (Item 3) [Figure 20-52-144] on the threaded rod.
Install the retainer (Item 1) [Figure 20-52-146].
20-52-50
Figure 20-52-149
N-15276
P-58615
Lay the pump housing on its side and install the rotary group assembly, swash plate, and shaft in the housing [Figure 20-52-149]. Figure 20-52-150
Install the piston assembly (Item 1) in the cylinder block (Item 2) [Figure 20-52-147]. NOTE: It is NOT important that the pistons are installed in their original positions. Figure 20-52-148
1 2
N-23390
Set the pump housing in the up-right position [Figure 2052-150]. Install the shim washer (Item 1) [Figure 20-52-150]. For procedure to determine shim washer thickness see [Figure 20-52-137 on Page 48].
N-15281
Slide the rotary group assembly (Item 1) on the shaft (Item 2) [Figure 20-52-148].
20-52-51
Figure 20-52-153 1 1 1
1
N-23397
Install the 4 O-rings (Item 1) [Figure 20-52-153] on the back port assembly.
P-58617
Figure 20-52-154 Install the bearing (Item 1) [Figure 20-52-151] on the shaft. Install the O-ring (Item 2) [Figure 20-52-151]. 2 Figure 20-52-152 1
N-23431
Grease the inside of the control piston (Item 1) [Figure 20-52-154]. 1 3

N-23399
Slide it over the control piston shaft (Item 2) [Figure 2052-154].
Install the valve plate (Item 1) on the back port assembly. The valve plate can only be installed one way by aligning the groove (Item 2) with the pin (Item 3) [Figure 20-52152].
20-52-52
Figure 20-52-157
1 1 2
P-58611
P-58618
Apply Loctite 241 on the bolt (Item 1) and install the load sensing assembly (Item 2) [Figure 20-52-157]. Tighten to 10 ft.-lbs. (13 Nm) torque. Install the torque limiter valve. (See Torque Limiter Valve Removal and Installation on Page 20-52-17.) Install the pump control assembly. (See Pump Control Removal And Installation on Page 20-52-29.) Place the hydraulic piston pump on its side and fill approximately half full.
Install the stroking piston and spring (Item 1) [Figure 2052-155]. Figure 20-52-156
1 Install a new O-ring on the plug. Figure 20-52-158
P-58614
1 Align the marks and install the back port assembly (Item 1) [Figure 20-52-156] on the pump housing. Install the 4 bolts (Item 2) [Figure 20-52-156]. Tighten the bolts to 88 ft.-lb. (119 Nm) torque.
P-58613
Install the plug (Item 1) [Figure 20-52-158] in the pump and tighten.
20-52-53
20-52-54
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Removal And Installation Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Remove the muffler and muffler mount. (See Removal And Installation on Page 60-21-1.)
Figure 20-53-2
IMPORTANT
I-2003-0888
P-58490
Remove the 4 bolts (Item 1) [Figure 20-53-2] and the hose. Figure 20-53-3
Figure 20-53-1
1 1
P-58491 P-58489
Remove the 2 bolts (Item 1) [Figure 20-53-3]. Installation: Apply thread adhesive (Loctite 242) to the bolt threads. Tighten the bolts to 48-55 ft.-lb. (65-75 Nm) torque. Remove the pump.
Remove the 4 bolts (Item 1) [Figure 20-53-1] and remove the hose.
20-53-1
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 20-53-4
P-58492
Remove the O-ring (Item 1) and pump coupler (Item 2) [Figure 20-53-4].
20-53-2
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Snap Ring Seal Pump Flange Set Screw Bushing Backup Ring Bearing Gear Housing Washer Bolt
3 1 2 2 4 5
7 8 7 6 2
8 9 2
5 10 5
11
20-53-3
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly Mark the pump body to pump flange for ease of assembly. Figure 20-53-5
Figure 20-53-7
P-58495
Figure 20-53-8 1 1
1
P-58493
Figure 20-53-6
P-58496
Separate and remove the flange (Item 1) [Figure 20-537] & [Figure 20-53-8] from the pump body.
P-58494
Remove the 2 bolts (Item 1) [Figure 20-53-5] & [Figure 20-53-6] and washers.
20-53-4
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly (Contd) Figure 20-53-9
Figure 20-53-11
P-58502
1
P-58499
Remove the bearings (Item 1) [Figure 20-53-11] from the gears. Figure 20-53-12
Remove the seal (Item 1) [Figure 20-53-9]. Figure 20-53-10
1 1
P-58501
P-58500
Remove the seal (Item 1) [Figure 20-53-12] and back-up ring from the bearings.
Remove the bearing/gear assembly (Item 1) [Figure 2053-10].
20-53-5
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly (Contd) Figure 20-53-13
P-58497
Remove the snap ring (Item 1) [Figure 20-53-13]. Figure 20-53-14
P-58498
20-53-6
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Assembly
Figure 20-53-17
2 Clean all parts in solvent and dry with compressed air. Apply clean hydraulic oil or assembly lube on the new Orings and seals. Figure 20-53-15 1
P-58501
Install the seal (Item 1) and back-up ring (Item 2) [Figure 20-53-17] on both bearings. Figure 20-53-18
P-58498
2 1
Install the seal (Item 1) [Figure 20-53-15]. Figure 20-53-16
1
P-58503
Install the bottom bearing (Item 1) [Figure 20-53-18] in the housing. NOTE: The position of the V portion (Item 2) on the bearing plate (Item 1) [Figure 20-53-18] must point towards the pressure port on the housing.
P-58497
20-53-7
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Assembly (Contd) Figure 20-53-19
Figure 20-53-21
P-58506
Install the pump flange (Item 1) [Figure 20-53-21] on the pump body.
P-58504
Install the gears (Item 1) [Figure 20-53-19]. Figure 20-53-20
Fully seat the flange on the alignment pins (Item 2) [Figure 20-53-20]
2
P-58505
Install the bearing (Item 1) [Figure 20-53-20]. NOTE: The position of the V portion (Item 3) on the bearing plate (Item 1) [Figure 20-53-20] must point towards the pressure port on the housing. Install the seal (Item 2) [Figure 20-53-20].
20-53-8
HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Assembly (Contd) Figure 20-53-22
P-58493
Figure 20-53-23
P-58494
Turn the pump over and install the washers and bolts (Item 1) [Figure 20-53-22] & [Figure 20-53-23]. Tighten the bolts to 133-155 ft.-lb. (180-210 Nm) torque.
20-53-9
20-53-10
ACCUMULATOR (S/N 522311001 & ABOVE) Description The accumulator provides short term reserve pressure for joystick function with the engine off and the key in the run position. Removal And Installation With the engine off and the key in the run position, move the control levers to relieve hydraulic pressure. Tilt the cab. (See Tilting The Cab on Page 10-160-2.)
Figure 20-60-2
P-33160
IMPORTANT
I-2003-0888
Remove the nut (Item 1) [Figure 20-60-2]. Figure 20-60-3
Figure 20-60-1
P-33161
1 Remove the accumulator (Item 1) [Figure 20-60-3].
P-33159
Remove the tee fitting (Item 1) [Figure 20-60-1].
20-60-1
20-60-2
ACCUMULATOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Description The accumulator provides short term reserve pressure for joystick function with the engine off and the key in the run position. Removal And Installation With the engine off and the key in the run position, move the control levers to relieve hydraulic pressure. Tilt the cab. (See Tilting The Cab on Page 10-160-2.)
IMPORTANT
I-2003-0888
Figure 20-61-4 1
P-58102
Remove the accumulator (Item 1) [Figure 20-61-4].
20-61-1
20-61-2
TRAVEL MOTOR Removal And Installation
Figure 20-70-3 2
Remove the track. (See Rubber Track Removal And Installation on Page 30-20-6.) Remove the drive sprocket. (See Drive Sprocket Removal And Installation on Page 30-30-5.) Figure 20-70-1 1 1
P-40958
1 Remove the bolts (Item 1) from the flange (Item 2) [Figure 20-70-3]. Installation: Clean and dry the threads. Apply thread lock adhesive (Loctite 242) to the bolt threads. Tighten the bolts to 118-133 ft.-lb. (160-180 Nm) torque.
P-40960
1 1
Remove the flange. Remove the travel motor.
Remove the 5 bolts (Item 1) and washers from the cover (Item 2) [Figure 20-70-1]. Remove the cover. Figure 20-70-2
1 1
P-40957
Remove the four hoses (Item 1) [Figure 20-70-2]. Install caps and plugs.
20-70-1
TRAVEL MOTOR (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Plug Snap Ring End Cover Gear Bearing Nut Housing Seal Piston Discs Spring Swash Plate O-Ring Piston Assy. Poppet Shaft
10 9 8
9 5 4 4
2 2 5 5
5 4 1
13 11 11 15
13 13 11 14 12
16
B-24939 442 Excavator Service Manual
20-70-2
TRAVEL MOTOR (CONTD) Disassembly Drain the travel motor oil. (See Draining The Travel Motor on Page 10-120-1.) Figure 20-70-4 1 1 2
Figure 20-70-6 1 2
P-61589
3 Remove the O-ring (Item 1) and planetary carrier (Item 2) [Figure 20-70-6]. Place the carrier in a vice equipped with padded jaws.
P-61585
Figure 20-70-7 Remove the drain plugs (Item 1), snap ring (Item 2) and cover (Item 3) [Figure 20-70-4]. 1 Figure 20-70-5 1 1
P-61591
Remove the snap rings (Item 1) [Figure 20-70-7].

P-61588
Drill a hole in the center of the bushing (Item 1) [Figure 20-70-5] using a number 3 drill bit. Thread the hole using a 1/4 x 28 inch N.F. tap. Install a 1/4 x 28 inch bolt in the bushing, and pull the bushing out.
20-70-3
TRAVEL MOTOR (CONTD) Disassembly (Contd) Figure 20-70-8
Figure 20-70-10
P-46412
P-61592
Remove the washer (Item 1) [Figure 20-70-10] from the drive shaft. Figure 20-70-11
Pry the planetary gears (Item 1) [Figure 20-70-8] off of the carrier. Record the orientation of the gear/bearing assembly. The gear/bearing assembly can only be installed in one direction. 2 Figure 20-70-9
1 1 2
P-61596
Remove the snap ring (Item 1). Remove the sun gear (Item 2) [Figure 20-70-11].
P-61593
Remove the washers (Item 1). Remove the drive shaft (Item 2) [Figure 20-70-9].
20-70-4
TRAVEL MOTOR (CONTD) Disassembly (Contd) Figure 20-70-12 1
Figure 20-70-14
P-61599
1
P-61597
Center punch and drill the nut where shown (Item 1) [Figure 20-70-14]. Split and remove the nut.
Remove the snap rings (Item 1) [Figure 20-70-12]. Figure 20-70-13 NOTE: The nut will be destroyed and a NEW nut must be installed. Figure 20-70-15
1 1
2
P-61598
Pry the planetary gears (Item 1) [Figure 20-70-13] off of the carrier. Record the orientation of the gear/bearing assembly. The gear/bearing assembly can only be installed in one direction.
P-61600
Install a puller (Item 1) on the ring gear (Item 2) [Figure 20-70-15]. Remove the ring gear.
20-70-5
Figure 20-70-18
1
P-61604
P-61602
Remove the snap ring (Item 1) and spacer (Item 2) [Figure 20-70-18]. Turn the ring gear over.
Remove the bearing (Item 1) [Figure 20-70-16]. Figure 20-70-19 Figure 20-70-17 2 1
P-61606 P-61603
Remove the bearing race (Item 1) [Figure 20-70-19]. Remove the bearing race (Item 1) and spacer (Item 2) [Figure 20-70-17]. Turn the ring gear over.
20-70-6
TRAVEL MOTOR (CONTD) Disassembly (Contd)
Figure 20-70-22
1 Figure 20-70-20
P-61609
P-61837
Remove the O-ring (Item 1) [Figure 20-70-22] from both seal rings. Turn the travel motor over.
Remove the bearing (Item 1) [Figure 20-70-20]. Figure 20-70-23 Figure 20-70-21
P-58848 P-61838
Remove the plug (Item 1) [Figure 20-70-23]. Remove the upper and lower seal ring assembly (Item 1) [Figure 20-70-21].
20-70-7
Figure 20-70-26 1
1 2 Loosen the retainer (Item 1) [Figure 20-70-26].

P-58849
P-58851
Figure 20-70-27 Remove the spring (Item 1) and O-ring (Item 2) [Figure 20-70-24]. Figure 20-70-25 1
P-58852
Remove the retainer and spring (Item 1) [Figure 20-7027].

P-58850
Remove the spring seat (Item 1) [Figure 20-70-25].
20-70-8
Figure 20-70-30
1
P-58855
P-58853
Remove the spring (Item 1) and O-ring (Item 2) [Figure 20-70-30]. Figure 20-70-31
Remove the poppet (Item 1) [Figure 20-70-28]. Figure 20-70-29
P-58856
P-58854
Remove the spring seat (Item 1) and spool (Item 2) [Figure 20-70-31].
20-70-9
Figure 20-70-34
P-61791

P-58857
Figure 20-70-35 Remove the plug (Item 1) [Figure 20-70-32]. Figure 20-70-33 1 3 2 1 2
P-61792
P-61790
Remove the poppet (Item 1), backup rings (Item 2) and O-ring (Item 3) [Figure 20-70-35].
Remove the spring (Item 1), shims (Item 2) and O-ring (Item 3) [Figure 20-70-33].
20-70-10
Figure 20-70-38
1 1
P-58862

P-61793
Figure 20-70-39 Remove the spool guide (Item 1) [Figure 20-70-36]. 3 Figure 20-70-37 2 1
1 2
P-61790
P-61794
Remove the spring (Item 1), shims (Item 2) and O-ring (Item 3) [Figure 20-70-39].
Remove the back-up rings (Item 1) and O-ring (Item 2) [Figure 20-70-37].
20-70-11
Figure 20-70-42
P-61793
Remove the spool guide (Item 1) [Figure 20-70-42].

P-61797
Figure 20-70-43 Remove the spool (Item 1) [Figure 20-70-40]. Figure 20-70-41 2 1 2 1
P-61794
P-61792
Remove the back-up rings (Item 1) and O-ring (Item 2) [Figure 20-70-43].
Remove the poppet (Item 1), back-up rings (Item 2), and O-ring (Item 3) [Figure 20-70-41].
20-70-12
Figure 20-70-46
1 1
P-61799

P-61798
Figure 20-70-47 Remove the plug (Item 1) [Figure 20-70-44]. 2 Figure 20-70-45 1 3 2 1
P-58849
P-61795
Remove the spring (Item 1) and O-ring (Item 2) [Figure 20-70-47].
Remove the spring seat (Item 1), spring (Item 2) and Oring (Item 3) [Figure 20-70-45].
20-70-13
Figure 20-70-50
P-58873
P-61800
Remove the retainer and spring (Item 1) [Figure 20-7050]. Figure 20-70-51
1 1
P-58874
P-61801
Remove the poppet (Item 1) [Figure 20-70-51].
Loosen the retainer (Item 1) [Figure 20-70-49].
20-70-14
Figure 20-70-54 5
Figure 20-70-52 2 5 4 2 1 1 3
P-61805
P-58875
Remove the spring seat (Item 1), spring (Item 2), spring seat (Item 3), spool (Item 4) and alignment pins (Item 5) [Figure 20-70-54]. Figure 20-70-55
Remove the 8 bolts (Item 1), and lock valve (Item 2) [Figure 20-70-52]. Figure 20-70-53
P-61806
P-61784
Remove the bearing race (Item 1) [Figure 20-70-55].
Turn the lock valve over. Remove the snap ring (Item 1) [Figure 20-70-53].
20-70-15
Figure 20-70-58
1 2 1 1
1
P-61782
P-61781
Remove the3 O-rings (Item 1) and snap ring (Item 2) [Figure 20-70-58]. Figure 20-70-59
Remove the 26 springs (Item 1) and spring retainer (Item 2) [Figure 20-70-56]. Figure 20-70-57
P-58887
Remove the brake piston (Item 1) [Figure 20-70-59].

P-61783
Remove the bearing and washer (Item 1) [Figure 20-7057].
20-70-16
Figure 20-70-62 1
Figure 20-70-60
P-58836
Remove the brake discs (Item 1) [Figure 20-70-62].

P-58888
Figure 20-70-63 Remove the quadrings (Item 1) [Figure 20-70-60]. Figure 20-70-61 1
P-58837
Remove the snap ring (Item 1) [Figure 20-70-63].

P-58889
Remove the cylinder block (Item 1) [Figure 20-70-61].
20-70-17
TRAVEL MOTOR (CONTD) Disassembly (Contd) Figure 20-70-64 1
Figure 20-70-66
P-58840
P-58838
Remove the shaft and piston assembly (Item 1) [Figure 20-70-66]. Figure 20-70-67
Remove the brake disc stop (Item 1) [Figure 20-70-64]. Figure 20-70-65 1 2 1 1
P-58841
P-58839
Remove the piston plate pivot (Item 1) and shaft (Item 2) [Figure 20-70-67].
Remove the sleeves (Item 1) and springs (Item 2) [Figure 20-70-65].
20-70-18
Figure 20-70-70
1 1
P-58847

P-58842
Figure 20-70-71 Remove the bearing (Item 1) [Figure 20-70-68]. Figure 20-70-69 1
P-61807A
P-61807
Remove the bearing race (Item 1) and seal (Item 2) [Figure 20-70-71].
Remove the piston assembly (Item 1) [Figure 20-70-69].
20-70-19
TRAVEL MOTOR (CONTD) Assembly The tools listed will be needed to assemble the travel motor: MEL XXXX Spanner Wrench. Clean all parts in solvent and dry with compressed air. Inspect all parts and replace any that are damaged. If any of the planetary gears are damaged, replace all the planetary gears and sun gear from the planetary assembly that is damaged. One damaged gear can cause a microscopic fatigue crack in mating teeth and cause premature failure after servicing. Apply oil to all Orings (as noted) and assembly lube to the bearings before installation. Figure 20-70-72
Figure 20-70-73
P-58847
Install the spring (Item 1) [Figure 20-70-73] in the piston. Figure 20-70-74
P-61807A P-61807
Install the seal (Item 1). Install the bearing race (Item 2) [Figure 20-70-72].
Install the piston assembly (Item 1) [Figure 20-70-74].
20-70-20
TRAVEL MOTOR (CONTD) Assembly (Contd)
Figure 20-70-77 1
Figure 20-70-75 1
P-61779
Install the swash plate (Item 1) [Figure 20-70-77].

P-61777
Figure 20-70-78 Install the piston pivot plate (Item 1) [Figure 20-70-75]. Figure 20-70-76 1 1
P-58842
Install the bearing (Item 1) [Figure 20-70-78].

P-61778
Install the piston assembly (Item 1) [Figure 20-70-76].
20-70-21
Figure 20-70-81 1
Figure 20-70-79 1
P-61673
P-61780
Install the swash plate/cylinder block assembly (Item 1) [Figure 20-70-81]. Figure 20-70-82
Install the shaft (Item 1) [Figure 20-70-79]. Figure 20-70-80 1 2 3 1
1 4
P-61674
5
P-61672
Apply assembly lube to the sleeves and springs (Item 1) [Figure 20-70-82] and install.
Install the swash plate (Item 1) with sockets (Item 2) on the plate engaging the studs (Item 3) of the hub, and the flat surface (Item 4) of the plate resting on the piston assembly (Item 5) [Figure 20-70-80].
20-70-22
TRAVEL MOTOR (CONTD) Assembly (Contd) Figure 20-70-83
Figure 20-70-85
P-61677
Install the brake discs (Item 1) [Figure 20-70-85].

P-61675
Figure 20-70-86 Install the brake disc stop (Item 1) [Figure 20-70-83]. Figure 20-70-84 1
1 1
P-58888
Install the quad rings (Item 1) [Figure 20-70-86].

P-61676
20-70-23
TRAVEL MOTOR (CONTD) Assembly (Contd) Figure 20-70-87 1
Figure 20-70-89
P-61783
P-58887
Install the washer and bearing (Item 1) [Figure 20-7089]. Figure 20-70-90
Install the brake piston (Item 1) [Figure 20-70-87]. 2 Figure 20-70-88 3 1 1 3
2 2
P-61781
2
P-61782
Install the spring retainer (Item 1) and springs (Item 2) [Figure 20-70-90] as shown. The lock valve alignment pins must engage the open spring slots (Item 3) [Figure 20-70-90] leaving one open spring slot on each side of the alignment pins.
Install the snap ring (Item 1) and three O-rings (Item 2) [Figure 20-70-88].
20-70-24
Figure 20-70-93
P-61784

P-61806
Figure 20-70-94 Install the bearing race (Item 1) [Figure 20-70-91]. Figure 20-70-92 5 1
5 1 3 1 4
P-58877
2
P-61805
Apply assembly lube to the valve plate (Item 1) [Figure 20-70-94] and install.
Install the spool (Item 1), spring seat (Item 2), spring (Item 3), spring seat (Item 4), and alignment pins (Item 5) [Figure 20-70-92].
20-70-25
Figure 20-70-97
1 2 2
P-58873
P-58875
Install the spring and retainer (Item 1) [Figure 20-70-97] and tighten. Figure 20-70-98
Install the lock valve (Item 1) on the hub. Install the eight bolts (Item 2) [Figure 20-70-95] and tighten to 55-60 ft.lb. (75-85 Nm) torque. Figure 20-70-96 1
1
P-61800
Install the spring seat (Item 1) [Figure 20-70-98].

P-58874
Install the poppet (Item 1) [Figure 20-70-96].
20-70-26
TRAVEL MOTOR (CONTD) Assembly (Contd) Figure 20-70-99 1 2
Figure 20-70-101 1 2
P-58855
P-58849
Install the O-ring (Item 1) and spring (Item 2) [Figure 2070-101]. Figure 20-70-102
Install the O-ring (Item 1) and spring (Item 2) [Figure 2070-99]. Figure 20-70-100 1
P-61798

P-61799
20-70-27
Figure 20-70-105
2 1 3 2 1
P-61792
P-61794
Install the O-ring (Item 1), back-up rings (Item 2) and poppet (Item 3) [Figure 20-70-105]. Figure 20-70-106
Install the O-ring (Item 1) and back-up rings (Item 2) [Figure 20-70-103]. Figure 20-70-104 1
P-61797
Install the spool (Item 1) [Figure 20-70-106].

P-61793
Install the spool guide (Item 1) [Figure 20-70-104].
20-70-28
Figure 20-70-109
2 1 1 2 3 2
P-61794
P-61790
Install the O-ring (Item 1) and back-up rings (Item 2) [Figure 20-70-109]. Figure 20-70-110
Install the O-ring (Item 1), shims (Item 2), and spring (Item 3) [Figure 20-70-107]. Figure 20-70-108 1
P-61793
Install the spool guide (Item 1) [Figure 20-70-110].

P-58862
20-70-29
Figure 20-70-113
1 Figure 20-70-111 2 3
P-61790
P-61792
Install the O-ring (Item 1), shims (Item 2) and spring (Item 3) [Figure 20-70-113]. Figure 20-70-114
Install the O-ring (Item 1), back-up rings (Item 2), and poppet (Item 3) [Figure 20-70-111]. Figure 20-70-112
P-58857

P-61791
Install the spool (Item 1) [Figure 20-70-112].
20-70-30
Figure 20-70-117
P-58853
Install the poppet (Item 1) [Figure 20-70-117].

P-58856
Figure 20-70-118 Install the spool (Item 1) and spring seat (Item 2) [Figure 20-70-115]. Figure 20-70-116 1 2 1
P-58852
Install the spring and retainer (Item 1) [Figure 20-70118].

P-58855
Install the O-ring (Item 1) and spring (Item 2) [Figure 2070-116].
20-70-31
Figure 20-70-121
P-58848

P-58850
Figure 20-70-122 Install the poppet (Item 1) [Figure 20-70-119]. Figure 20-70-120 1 2 1
P-61606
Install the bearing race (Item 1) [Figure 20-70-122].

P-58849
Turn the ring gear over. Install the O-ring (Item 1) and spring (Item 2) [Figure 2070-120].
20-70-32
Figure 20-70-125 1
P-61810
Install the bearing (Item 1) [Figure 20-70-125].

P-61604
Figure 20-70-126 Install the spacer (Item 1) and snap ring (Item 2) [Figure 20-70-123]. Figure 20-70-124
1
P-46426
Install the O-ring (Item 1) on both seal rings (Item 2) [Figure 20-70-126].
P-61787
Install the spacer (Item 1) and bearing race (Item 2) [Figure 20-70-124].
NOTE: Inspect the seal ring for burrs before installing the O-ring. Install the O-ring making sure it is not twisted. To remove any twists, gently pull a section of the O-ring and let it snap back. The O-ring, seal ring, hub assembly, and bearing carrier must be clean and free of any dust, oil film, or foreign matter. The O-ring and seal ring assembly has to be lubricated with rubbing alcohol, so the O-ring will slip past the housing retaining ring and seal uniformly in the housing radius. Dip the O-ring and seal ring assembly in a pan of alcohol.
20-70-33
Figure 20-70-129 1
P-61811
P-61785
Shake off the excess alcohol and install the seal ring assembly (Item 1) [Figure 20-70-129]. Use firm even pressure to pop the O-ring into the housing. Apply a light film of oil to the metal seal ring.
Shake off the excess alcohol and install the seal ring assembly (Item 1) [Figure 20-70-127] on the hub. Use firm even pressure to pop the O-ring into the housing. Apply a light film of oil to the metal seal ring. NOTE: Do not get any oil on the rubber O-ring. Figure 20-70-128
NOTE: Do not get any oil on the rubber O-ring. Figure 20-70-130
P-61812
P-61786
Check the seal stand off height. The stand off height must be uniform with no twists in the O-ring [Figure 2070-130].
Check the seal stand off height. The stand off height must be uniform with no twists in the O-ring [Figure 2070-128].
20-70-34
Figure 20-70-133
P-61598
P-61789
Install the gear/bearing assemblies (Item 1) [Figure 2070-133]. Figure 20-70-134
Install the ring gear (Item 1) [Figure 20-70-131]. Figure 20-70-132 1
1
P-61597
P-61599
Install the snap rings (Item 1) [Figure 20-70-134].
Apply Loctite 270 to the new nut (Item 1) [Figure 2070-132] and install. Use a spanner wrench (MEL XXXX) and tighten the nut to 1290 ft.-lb. (1750 Nm) torque.
20-70-35
Figure 20-70-137
2 2 1
P-61593
2 Install the driveshaft (Item 1) and washers (Item 2) [Figure 20-70-137]. Figure 20-70-138 Install the sungear (Item 1) and snap ring (Item 2) [Figure 20-70-135]. Figure 20-70-136 1 1
P-61596
P-61592
Install the planetary gears (Item 1) [Figure 20-70-138].

P-46412
Install the washer (Item 1) [Figure 20-70-136].
20-70-36
Figure 20-70-141
1 1 1
P-61588
Install a new bushing (Item 1) [Figure 20-70-141].

P-61591
Figure 20-70-142 Install the snap rings (Item 1) [Figure 20-70-139]. Figure 20-70-140 1 1 2 3 3 2
P-61585
P-61589
Install the cover (Item 1), snap ring (Item 2) and drain plugs (Item 3) [Figure 20-70-142].
Install the planetary carrier (Item 1) and O-ring (Item 2) [Figure 20-70-140].
20-70-37
20-70-38
SWIVEL JOINT Removal And Installation
Figure 20-80-3
IMPORTANT
I-2003-0888
P-38631
Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 20-80-1 Loosen the 3 right bolts (Item 1) [Figure 20-80-3]. Figure 20-80-4
1 1 1 2 1
P-38636 P-38630
Mark and remove the 4 hoses (Item 1) [Figure 20-80-1] from the top of the swivel joint. Figure 20-80-2 1 Remove the 3 left bolts (Item 1) [Figure 20-80-4] and washers. Remove the cover (Item 2) [Figure 20-80-4].
1
P-38638
Mark and remove the 4 hoses (Item 1) [Figure 20-80-2] from the side of the swivel joint.
SWIVEL JOINT (CONTD) Removal And Installation (Contd) Figure 20-80-5
Figure 20-80-7
1 1
P-38634

P-38632
Figure 20-80-8 Mark and remove the 2 tees (Item 1) and 2 hoses (Item 2) [Figure 20-80-5] Figure 20-80-6 1 1 1
P-38635
Remove the 4 bolts and nuts (Item 1) [Figure 20-80-8].

P-38633
Rotate and lower the swivel joint from the excavator.
Mark and remove the tee (Item 1) and 2 hoses (Item 2) [Figure 20-80-6].
20-80-2
SWIVEL JOINT (CONTD) Parts Identification
B-24943A
20-80-3
SWIVEL JOINT (CONTD) Disassembly And Assembly Mark the rotor and body for ease of assembly. Figure 20-80-9
Figure 20-80-11
1
P-40048
Remove the O-ring (Item 1) [Figure 20-80-11] from the end cap.
P-40046
Figure 20-80-12
Loosen the 4 bolts (Item 1) [Figure 20-80-9]. Figure 20-80-10
2 1 1
P-40049

P-40047
Remove the bolts (Item 1) and end cap (Item 2) [Figure 20-80-10].
20-80-4
SWIVEL JOINT (CONTD) Disassembly And Assembly (Contd) Figure 20-80-13
Figure 20-80-15 1
P-40052
P-40050
Remove the washer (Item 1) [Figure 20-80-15] from the rotor. NOTE: Use care not to scratch the rotor surface as damage to the finished surface could cause internal leakage. Figure 20-80-16 1 2 2
Remove the washer (Item 1) [Figure 20-80-13]. Figure 20-80-14
P-40051 P-40044
With a soft faced hammer drive the rotor (Item 1) [Figure 20-80-14] from the housing.
Remove the 2 seals (Item 1) and 6 O-rings (Item 2) [Figure 20-80-16].
20-80-5
20-80-6
SWING MOTOR Removal And Installation Remove the right side cover. (See RIGHT SIDE COVER on Page 40-160-1.) Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 20-90-1
Figure 20-90-3
1 1
P-38627
Remove the 2 bolts (Item 1) [Figure 20-90-3] and washers from the side of the center panel. Remove the panel (Item 2) [Figure 20-90-3].
P-38628
IMPORTANT
Figure 20-90-2
1 Figure 20-90-4 1
I-2003-0888
P-38629
Remove the 2 bolts (Item 1) [Figure 20-90-1] and [Figure 20-90-2] and washers from the top of the center panel. 2
P-38641
Mark and remove the 3 tee fittings (Item 1) [Figure 2090-4]. Mark and remove the hose (Item 2) [Figure 20-90-4].
20-90-1
SWING MOTOR (CONTD) Removal And Installation (Contd) Figure 20-90-5
Figure 20-90-7
2 1
1 2 1 1
P-38644
1
P-38642
Remove the 4mount bolts (Item 1) [Figure 20-90-7]. Installation: Tighten the bolts to 53 ft.-lb. (72 Nm) torque.
Mark and remove the 4 bolts (Item 1). Remove the split flange hoses (Item 2) [Figure 20-90-5]. Figure 20-90-6
Remove the motor. Figure 20-90-8
P-38645 P-38643
Remove the O-ring (Item 1) [Figure 20-90-8] from the swing motor drive carrier.
20-90-2
SWING MOTOR (CONTD) Parts Identification
1 2 3 4 5 6 7 8 9 10 11
Valve Plug End Cap Bolt O-ring Pin Bearing Snap Ring Locking Ring Seal Drive Shaft 7 8 7 6 2
11 1 5
10
2 3
8 9 5
B-19528
20-90-3
SWING MOTOR (CONTD) Disassembly Figure 20-90-9
Figure 20-90-11 1
1 Remove the fittings (Item 1) [Figure 20-90-11].

P-38674
P-38676
Figure 20-90-12 Remove the plug (Item 1) [Figure 20-90-9] and drain the oil from the swing motor. Figure 20-90-10 1
P-38677
Remove the crossport relief valves (Item 1) [Figure 2090-12].

P-38675
NOTE: Do not interchange the crossport relief valves. Remove the O-ring (Item 1) [Figure 20-90-10] from the plug. Mark the motor sections for proper installation.
20-90-4
SWING MOTOR (CONTD) Disassembly (Contd) Figure 20-90-13
Figure 20-90-15
1 1
1
P-38683
2
P-38681
Remove the end cap (Item 1) [Figure 20-90-15]. Figure 20-90-16
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-90-13]. Figure 20-90-14
1 2 1
P-38685

P-38682
Remove the 3 short bolts (Item 1) and 2 long bolts (Item 2) [Figure 20-90-14].
20-90-5
Figure 20-90-19
1 1
P-38687
Remove the retainer (Item 1) [Figure 20-90-19].

P-38679
Figure 20-90-20 Remove the valve plate (Item 1) [Figure 20-90-17]. Figure 20-90-18 1
P-38688
1
P-38686
Remove the seal (Item 1) [Figure 20-90-20] from the retainer.
20-90-6
Figure 20-90-23
2 1
1
P-38691
Figure 20-90-24
P-38689
Remove the O-ring (Item 1) [Figure 20-90-21]. Figure 20-90-22 1
P-38692
1
P-38690
Install a puller (Item 1) [Figure 20-90-23] and sleeve (Item 2) [Figure 20-90-23] by threading a bolt (Item 3) [Figure 20-90-23] into the end of the shaft (Item 1) [Figure 20-90-24]. Tighten the bolt to remove the rotary assembly.
Remove the shims (Item 1) [Figure 20-90-22]. NOTE: Add spacers between the head of the bolt and puller as needed to remove the rotary assembly.
20-90-7
Figure 20-90-27
1
P-38697
2 Remove the snap ring (Item 1) [Figure 20-90-27].

P-38694
Figure 20-90-28 Remove the pistons (Item 1) from the cylinder (Item 2) [Figure 20-90-25]. Figure 20-90-26 1
3 2 1
P-38698
Remove the washer (Item 1) [Figure 20-90-28].

P-38695
Put the shaft and bearing assembly in a press. Use care not to damage the control plate or shaft.
Remove the spring (Item 1) and shim (Item 2) from the center bore (Item 3) [Figure 20-90-26] of the cylinder.
20-90-8
Figure 20-90-31
P-38706
P-38701
Remove the bearing race (Item 1) [Figure 20-90-31] from the carrier. Put the shaft and bearing assembly in a press.
Remove the outer bearing (Item 1) [Figure 20-90-29]. Figure 20-90-32 Figure 20-90-30
2
P-38703 P-38700
Remove the inner bearing (Item 1) [Figure 20-90-32]. Remove the carrier (Item 1) and bearing race (Item 2) [Figure 20-90-30]
20-90-9
SWING MOTOR (CONTD) Assembly Clean all parts in solvent and dry with compressed air. Do not use cloth or paper because small pieces of material can get into the system and cause damage. Check all parts for rough surfaces and wear, replace any worn or damaged parts. Install new seals, O-rings and bearings. Lubricate the parts with clean hydraulic oil during assembly. Figure 20-90-33
Figure 20-90-34
P-38706
Install the outer bearing race (Item 1) in the carrier (Item 2) [Figure 20-90-34]. 1 Install the outer bearing race (Item 1) in the carrier (Item 2) [Figure 20-90-34]. Figure 20-90-35
P-38702
Put the shaft assembly in a vise and install the inner bearing (Item 1) [Figure 20-90-33]. 1 2
P-38707
Install the inner bearing race (Item 1) and bearing carrier (Item 2) [Figure 20-90-35] on the shaft assembly.
20-90-10
SWING MOTOR (CONTD) Assembly (Contd) Figure 20-90-36
Figure 20-90-38
P-38697

P-38708
Figure 20-90-39 Put the shaft assembly in a vise and install the outer bearing (Item 1) [Figure 20-90-36]. Figure 20-90-37 3
1 1 2
P-38695
Install the shim (Item 1) and spring (Item 2) in the center bore (Item 3) [Figure 20-90-39] cylinder.
P-38698
20-90-11
Figure 20-90-42
1
P-38689
Install the shims (Item 1) [Figure 20-90-42].

P-38693
Figure 20-90-43 Install the pistons (Item 1) [Figure 20-90-40] in the cylinder. Figure 20-90-41
1
P-38690
Install the O-ring (Item 1) [Figure 20-90-43]. 2

P-38678
Install the rotary assembly (Item 1) with a puller (Item 2) [Figure 20-90-41]. NOTE: Ensure the rotary assembly rotates freely and does not bind during installation.
20-90-12
Figure 20-90-46
1
P-38686

P-38688
Figure 20-90-47 Install the seal (Item 1) on the retainer (Item 2) [Figure 20-90-44]. Figure 20-90-45
P-38679
Install the valve plate (Item 1) [Figure 20-90-47]. 1

P-38687
Figure 20-90-48
1
P-38685

Figure 20-90-51
2 3
1
P-38681
1 Install the 3 O-rings (Item 1) and 2 back-up rings (Items 2 & 3) [Figure 20-90-51] on the two crossport relief valves. NOTE: The back-up ring (Item 2) is thicker than the back-up ring (Item 3) [Figure 20-90-51]. Figure 20-90-52
P-38684
Align the dowel pin (Item 1) in the end cap with the hole (Item 2) [Figure 20-90-49] in the valve plate. Install the end cap on the housing. Figure 20-90-50
1 1 1
P-38677 P-38682
Install the crossport relief valves (Item 1) [Figure 20-9052] and tighten to __ ft.-lb. (__ Nm) torque. Install the 2 long bolts (Item 1) and 3 short bolts (Item 2) [Figure 20-90-50]. Tighten the bolts to ___ ft.-lb. (__ Nm) torque.
20-90-14
SWING MOTOR (CONTD) Assembly (Contd) Figure 20-90-53 1
Figure 20-90-55
P-38674

P-38676
Fill the swing motor with clean hydraulic fluid before installation to provide startup lubrication. Install the fittings (Item 1) [Figure 20-90-53]. Figure 20-90-54
P-38675
Install the O-ring (Item 1) [Figure 20-90-54] on the plug.
20-90-15
20-90-16
SWING MOTOR DRIVE CARRIER Removal And Installation Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Remove swing motor. (See Removal And Installation on Page 20-90-1) Figure 20-91-1
Figure 20-91-3
1 1
P-38649
Install lifting brackets (Item 1) [Figure 20-91-3] and a chain hoist on the carrier. Figure 20-91-4
1
P-38646
Remove the 3 hoses (Item 1) [Figure 20-91-1]. Figure 20-91-2
1
P-38647
Remove the 12 bolts (Item 1) [Figure 20-91-4]. Installation: Tighten the bolts to 144 ft.-lb. (195 Nm) torque.
P-38648
Remove the hose clamps (Item 1) [Figure 20-91-2] to reposition the hoses.
20-91-1
SWING MOTOR DRIVE CARRIER (CONTD) Removal And Installation (Contd) Figure 20-91-5 1
P-38650
Install two mount bolts (Item 1) [Figure 20-91-5] in the threaded holes of the carrier. Tighten the bolts evenly to push the carrier off of the upper structure. Figure 20-91-6
1 2
P-38651
Remove the tee (Item 1) and hose (Item 2) [Figure 2091-6] from the hydraulic reservoir. Remove the wire harness (Item 3) [Figure 20-91-6] from the hydraulic reservoir. Remove the carrier.
20-91-2
SWING MOTOR DRIVE CARRIER (CONTD) Parts Identification
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Snap Ring Plunger Disc O-Ring Bolt Brake Housing Seal Seal Brake Disc Piston Belleville Spring Spring Support Driveshaft Shim Thrust Washer Shim Bearing Gear Pin Bearing Sun Gear Pinion Cage Planetary Gear Nut Locking Plate Bearing Seal Drive Housing Bearing Seal Washer Pinion
1 1 2 3 15 1 20 16 17
4 3
22 23 24
6 7
23 25 26
9 10 11 1 12 1 1 13 14 15 16 17 15 14 13 1 19 20 18 31 29 28
27
30 19
21
B
20-91-3
SWING MOTOR DRIVE CARRIER (CONTD) Disassembly Figure 20-91-7
Figure 20-91-9
1
P-38908
Remove the brake discs (Item 1) [Figure 20-91-9].

P-38906
Figure 20-91-10 Mark the brake housing (Item 1) [Figure 20-91-7] for ease of assembly. Remove the 4 bolts (Item 2) [Figure 20-91-7]. Remove the brake housing. Figure 20-91-8 1
P-38909
Turn the brake housing over and remove the O-ring (Item 1) [Figure 20-91-10].
P-38907
Remove the snap ring (Item 1) and plunger disc (Item 2) [Figure 20-91-8].
20-91-4
SWING MOTOR DRIVE CARRIER (CONTD) Disassembly (Contd) Figure 20-91-11
Figure 20-91-13
P-38912
1
P-38910
Note the orientation of the belleville spring (Item 1) [Figure 20-91-13]. Remove the spring.
Remove the snap ring (Item 1) [Figure 20-91-11]. Figure 20-91-14 Figure 20-91-12 1
P-38913 P-38911
Remove the support disc (Item 1) [Figure 20-91-12].
Turn the brake housing over and tap the piston out [Figure 20-91-14].
20-91-5
Figure 20-91-17
1 1
P-38916
Remove the pinion cage (Item 1) [Figure 20-91-17].

P-38914
Figure 20-91-18 Turn the brake housing over and remove the two seals (Item 1) [Figure 20-91-15]. Figure 20-91-16
1 1
P-38917
Remove the snap rings (Item 1) [Figure 20-91-18].

P-38915
Remove the driveshaft (Item 1) [Figure 20-91-16].
20-91-6
Figure 20-91-21
P-38920
P-38918
Remove the top and bottom thrust washers (Item 1) [Figure 20-91-21]. Repeat the procedure for the remaining two pins and gear/bearing assemblies. Figure 20-91-22
Drive the pin (Item 1) [Figure 20-91-19] out the bottom of the carrier. Figure 20-91-20
1 1
P-38922 P-38919
Remove the bearing (Item 1) [Figure 20-91-22]. Remove the gear and bearing assembly (Item 1) [Figure 20-91-20].
20-91-7
Figure 20-91-25
1 1
P-38925
P-38923
Remove the washer (Item 1) [Figure 20-91-25] from the carrier. Figure 20-91-26
Remove the snap ring (Item 1) [Figure 20-91-23] and washer. Figure 20-91-24 1
1
P-38926
Remove the 4 snap rings (Item 1) [Figure 20-91-26].

P-38924
Remove the sun gear (Item 1) [Figure 20-91-24].
20-91-8
Figure 20-91-29
P-38930

P-38928
Remove the planetary gear carrier (Item 2) [Figure 2091-29]. Use a pry bar to remove the planetary gear and bearing assembly [Figure 20-91-27]. NOTE: The bearings are not caged. There are 52 roller bearings per gear. Figure 20-91-28 Figure 20-91-30
P-38997
P-38929
Support the carrier in a press. Clamp the carrier shaft with approximately 800 lb. (1085 Nm) of force [Figure 20-91-30].
20-91-9
Figure 20-91-33
P-40000
1 Remove the nut (Item 1) [Figure 20-91-33].

P-38998
Figure 20-91-34 Remove the nut (Item 1) [Figure 20-91-31]. NOTE: The nut is torqued to 480-550 ft.-lb. (651-746 Nm) of torque. Remove the carrier from the press. Figure 20-91-32
P-40001
Press the pinion out the bottom of the carrier [Figure 2091-34].
P-38999
Remove the lock washer (Item 1) [Figure 20-91-32].
20-91-10
Figure 20-91-37
P-40004
1 Turn the carrier over and remove the scraper seal (Item 1) [Figure 20-91-37]. Figure 20-91-38 Remove the pinion (item 1) and top bearing (Item 2) [Figure 20-91-35]. Figure 20-91-36 1 2
P-40002
P-40005
P-40003
Remove the seal (Item 1) and bottom bearing race (Item 2) [Figure 20-91-38].
Remove the top bearing race (Item 1) [Figure 20-91-36].
20-91-11
P-40007
Press the lower bearing (Item 1) [Figure 20-91-39] off the shaft. Figure 20-91-40
P-40008
20-91-12
SWING MOTOR DRIVE CARRIER (CONTD) Assembly Clean all components compressed air. in solvent and dry with
Figure 20-91-43
Replace all seals and components that are worn or damaged. Figure 20-91-41
1
P-40014
1 Pack the lower bearing (Item 1) [Figure 20-91-43] with a good quality high temperature NLGI grease. Figure 20-91-44
P-40008
Install the washer (Item 1) [Figure 20-91-41]. Figure 20-91-42 1
P-40015
Press the bearing (Item 1) [Figure 20-91-44] on the shaft. 1
P-40009
NOTE: Make sure the tab (Item 1) [Figure 20-91-42] is installed in the slot of the shaft.
20-91-13
SWING MOTOR DRIVE CARRIER (CONTD) Assembly (Contd) Figure 20-91-45
Figure 20-91-47
P-40005
P-40006
Turn the carrier over and install the bearing race (Item 1) [Figure 20-91-47]. Figure 20-91-48
Apply a light coat of grease to the bearing side of the washer (Item 1) [Figure 20-91-45]. Figure 20-91-46 1
P-40004

P-40003
Install the seal (Item 1) and bearing race (Item 2) [Figure 20-91-46].
20-91-14
Figure 20-91-51
P-40017
Press the top bearing on the shaft [Figure 20-91-51].

P-40016
Figure 20-91-52 Install the shaft (Item 1) [Figure 20-91-49] in the carrier. Figure 20-91-50
P-40000
P-40014
Install the inner nut (Item 1) [Figure 20-91-52]. Tighten the nut to 147-221 ft.-lb. (200-300 Nm) torque to seat the bearings. Loosen the nut 15 to 30 degrees after the inner nut has been installed. The shaft should turn when 1.5-3.7 ft.-lb. (2-5 Nm) of force is applied to the shaft.
Apply clean hydraulic fluid or assembly lube to the top bearing (Item 1) [Figure 20-91-50].
20-91-15
Figure 20-91-55
1
P-38998
Install the outer nut (Item 1) [Figure 20-91-55].

P-38999
Tighten the nut to 480-550 ft.-lb. (650-750 Nm) torque. Install the washer (Item 1) [Figure 20-91-53]. Figure 20-91-54 2 1 Figure 20-91-56 3
P-40020 P-38997
Place the washer (Item 1) and snap ring (Item 2) [Figure 20-91-56] on the planetary carrier. Support the carrier in a press. Clamp the carrier shaft with approximately 800 lb. (1085 Nm) of force [Figure 20-91-54]. Apply assembly lube to the bottom of the planetary gear stud (Item 3) [Figure 20-91-56].
20-91-16
Figure 20-91-59
P-40023
Install the top roller bearings (Item 1) [Figure 20-91-59].

P-40021
Figure 20-91-60 Install the bottom roller bearings (Item 1) [Figure 20-9157] on the stud. Figure 20-91-58 1
P-40024
Install the washer (Item 1) [Figure 20-91-60] and snap ring.

P-40022
Repeat the procedure for two additional planetary gear studs. Install the gear (Item 1) [Figure 20-91-58].
20-91-17
Figure 20-91-63
2
P-40028
Install the gear (Item 1) [Figure 20-91-63].

P-40025
Figure 20-91-64 Install the planetary carrier (Item 1) [Figure 20-91-61] in the drive housing. Install the snap ring (Item 2) [Figure 20-91-61]. Apply assembly lube to the bottom of the planetary gear stud. Figure 20-91-62 1
P-40029
Install the top roller bearings (Item 1) [Figure 20-91-64]. 1
P-40027
Install the bottom roller bearings (Item 1) [Figure 20-9162].
20-91-18
Figure 20-91-67
1 1
P-38925
P-38926
Install the washers (Item 1) [Figure 20-91-67] on either side of the pinion cage. Figure 20-91-68
Install the washer (Item 1) [Figure 20-91-65]. Figure 20-91-66
P-38924
P-40036
Install the shaft (Item 1) [Figure 20-91-68].
Install the snap ring (Item 1) [Figure 20-91-66]. Apply assembly lube to the bearing (Item 2) [Figure 2091-66] and install the bearing.
20-91-19
Figure 20-91-71
P-40031
P-38923
Apply assembly lube to the roller bearings and install the bearings (Item 1) [Figure 20-91-71] in the gear. Figure 20-91-72
Install the snap ring (Item 1) [Figure 20-91-69]. Figure 20-91-70 1 1
P-40032
P-40030
Install the top washer (Item 1) [Figure 20-91-72]. Turn the pinion cage over.
Install the bottom washer (Item 1) [Figure 20-91-70].
20-91-20
SWING MOTOR DRIVE CARRIER (CONTD) Assembly (Contd)
Figure 20-91-75 1
Figure 20-91-73
P-40035
P-40033
Install the pin (Item 1) [Figure 20-91-75]. Repeat the procedure for two remaining pinion cage gears. Figure 20-91-76
Apply assembly lube to the thrust washers and install the top and bottom washers (Item 1) [Figure 20-91-73]. Figure 20-91-74 1
1 1
P-40037
P-40034
Turn the pinion cage over and install the snap rings (Item 1) [Figure 20-91-76]. Apply assembly lube to the bearing and install the bearing (Item 2) [Figure 20-91-76].
Install the gear/bearing assembly (Item 1) [Figure 20-9174].
20-91-21
Figure 20-91-79
2 1
P-38912
Install the piston (Item 1) [Figure 20-91-79].

P-38916
Install the belleville spring (Item 2) [Figure 20-91-79]. Install the pinion cage (Item 1) [Figure 20-91-77]. Figure 20-91-78 1 1 1 Figure 20-91-80
P-38911 P-38914
Install the spring support (Item 1) [Figure 20-91-80]. Install the 2 seals (Item 1) [Figure 20-91-78] in the brake housing.
20-91-22
Figure 20-91-83
1 1 2 2
P-38906
P-38910
Install the brake housing (Item 1) [Figure 20-91-83] on the carrier. Install the four bolts (Item 2) [Figure 20-91-83]. Tighten the bolts to 63 ft.-lb. (86 Nm) torque. Figure 20-91-84
Install the snap ring (Item 1) [Figure 20-91-81]. Figure 20-91-82
1
P-38909 P-40038
Install the driveshaft (Item 1) [Figure 20-91-84].
20-91-23
Figure 20-91-87
P-40041
P-40039
Lay the snap ring (Item 1) [Figure 20-91-87] in the brake housing. Figure 20-91-88
Install the internal and external brake discs (Item 1) [Figure 20-91-85]. Figure 20-91-86
P-40040
Install the plunger disc (Item 1) [Figure 20-91-86].

P-40042
Using a 2.0 inch ID x 2.25 inch OD x 2.750 inch long (50.8 mm ID x 57.2 mm OD x 69.9 mm long) steel tubing (Item 1) [Figure 20-91-88] Press down on the plunger disc to compress the brake discs and belleville spring. NOTE: The top external brake disc does not fully engage the brake carrier splines when first installed. Use care when compressing the discs to not damage the top disc.
20-91-24
1 2
P-40043
Install the snap ring (Item 1). Remove the tube (Item 2) [Figure 20-91-89] and press assembly from the carrier.
20-91-25
20-91-26
SWING BRAKE VALVE Removal And Installation Open the rear cover. Figure 20-92-1
Figure 20-92-3
P-33381
1 Remove the 2 bolts (Item 1) [Figure 20-92-3] and washers.

P-33379
Installation: Tighten the bolts to 6-7 ft.-lb. (8-10 Nm) torque. Remove the valve.
Remove the wire harness (Item 1) [Figure 20-92-1].
IMPORTANT
I-2003-0888
Figure 20-92-2
P-33380
Mark and remove the three hoses (Item 1) [Figure 2092-2].

20-92-1
SWING BRAKE VALVE (CONTD) Parts Identification
1. 2. 3. 4. 5. 6.
Housing Back-up Ring O-Ring Solenoid Valve Coil Nut
3 3 3 2 2 2 2
MS1536
20-92-2
SWING BRAKE VALVE (CONTD) Disassembly And Assembly Figure 20-92-4
Figure 20-92-6
P-35916
Remove the solenoid valve (Item 1) [Figure 20-92-6].

P-35914
Figure 20-92-7 Remove the nut (Item 1) [Figure 20-92-4]. Figure 20-92-5 1
P-35917
1 Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-92-7].
P-35915
Remove the coil (Item 1) [Figure 20-92-5].
20-92-3
20-92-4
SWING BRAKE RELEASE VALVE Removal And Installation Open the rear cover.
Figure 20-93-2
IMPORTANT
I-2003-0888
P-33386
Figure 20-93-1 1
Remove the two bolts (Item 1) [Figure 20-93-2]. Installation: Tighten the bolts to 6-7 ft.-lb. (8-10 Nm) torque. Remove the valve.
1 1 2 1
P-33385
Mark and remove the four tees (Item 1) [Figure 20-93-1]. Remove the hose (Item 2) [Figure 20-93-1].
20-93-1
SWING BRAKE RELEASE VALVE (CONTD) Parts Identification
1 2 3 4 5 6
Fitting O-ring Check Ball Valve Body Spool Spring
5 2 6 1
MS1535
20-93-2
SWING BRAKE RELEASE VALVE (CONTD) Disassembly And Assembly Place the valve in a vise that is equipped with soft jaws. Figure 20-93-3
Figure 20-93-5
P-36119
1 Remove the spring (Item 1) [Figure 20-93-5]. Figure 20-93-6

P-36117
Remove the fitting (Item 1) [Figure 20-93-3] from the R port. Figure 20-93-4
P-36120
Remove the spool (Item 1) [Figure 20-93-6]. 1
P-36118
Remove the O-ring (Item 1) [Figure 20-93-4] from the fitting.
20-93-3
SWING BRAKE RELEASE VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-93-7
Figure 20-93-9
P-36122
Remove the check ball (Item 1) [Figure 20-93-9].

P-36123
Remove the fitting (Item 1) [Figure 20-93-7] from the S2 port. Figure 20-93-8
NOTE: Do not remove the fittings from the A, P or S1 ports. The fittings are welded to the valve block. Removing the fittings will damage the block and fittings. Clean all parts in solvent and dry with compressed air before assembly.
P-36121
20-93-4
JOYSTICK CONTROL PATTERN SELECTOR VALVE Removal And Installation Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 20-100-1
Figure 20-100-3 2
3 1 4 1 1
P-33158
Remove the two bolts (Item 1) [Figure 20-100-3]. Installation: Install 2 washers (Item 2) between the frame and valve. Install 3 washers (Item 3) between the valves and install 1 washer (Item 4) [Figure 20-100-3] on the bolts. Tighten the bolts to 6-7 ft.-lb. (8-10 Nm) torque.
P-33156
Mark and remove the wire harness (Item 1) [Figure 20100-1].
IMPORTANT
I-2003-0888
Figure 20-100-2
1 1
P-33157
Mark and remove the 8 hoses (Item 1) [Figure 20-1002].

JOYSTICK CONTROL PATTERN SELECTOR VALVE (CONTD) Parts Identification
1 2 3 4 5 6 7
Valve Body Back up Ring O-ring Fitting Spool Coil Nut
2 2 2 3 3 3 4 3 6 5 2
MS1534
20-100-2
JOYSTICK CONTROL PATTERN SELECTOR VALVE (CONTD) Disassembly And Assembly Figure 20-100-4
Figure 20-100-6
1 1 1 2 2 1
P-36288
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-100-6] from the spool.
P-36284
Figure 20-100-7 Remove the nut (Item 1) and coil (Item 2) [Figure 20100-4] from the spool. Installation: Tighten the nut to 3-5 ft.-lb. (4-7 Nm) torque. NOTE: Overtightening the coil nut may cause spool or coil failure. Figure 20-100-5 1 2 2
P-36289
Remove the fitting (Item 1) [Figure 20-100-7]. NOTE: Do not remove the fittings (Item 2) [Figure 20100-7] The fittings are welded to the valve block. Removing the fittings will damage the fittings and valve block. Installation: Clean all components with solvent and dry with compressed air. Inspect all parts and replace any that are damaged. Use new O-rings and back-up rings. Apply clean hydraulic oil to the O-rings and back-up rings during assembly.
P-36286
20-100-3
20-100-4
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE) Removal And Installation Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 20-101-1
Figure 20-101-2
P-33163
1 2 Mark and remove the 4 hoses (Item 1) [Figure 20-1012]. Figure 20-101-3
P-33162
Mark and remove the wire harness (Item 1) [Figure 20101-1]. Mark and remove the two speed wire harness (Item 2) [Figure 20-101-1].
IMPORTANT
I-2003-0888
P-33164
Remove the 2 bolts (Item 1) [Figure 20-101-3] and washers. Installation: Tighten the bolts to 15-18 ft.-lb. (20-25 Nm) torque.
20-101-1
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE) (CONTD) Parts Identification
1 2 3 4 5 6
Nut Coil Spool O-Ring Back-up Ring Valve Body
1 2
3 4
5 4
5 4
MS1538
20-101-2
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE) (CONTD) Disassembly And Assembly Figure 20-101-4 1
Figure 20-101-6
P-36219

P-36217
Figure 20-101-7
Remove the nuts (Item 1) [Figure 20-101-4] from the spools. Installation: Tighten the nuts to 3-5 ft.-lbs (4-7 Nm) torque. NOTE: Overtightening the coil nuts may cause spool or coil failure. Figure 20-101-5 1 1
P-36220
Remove the 2 O-rings (Item 1) and back-up ring (Item 2) [Figure 20-101-7].
P-36218
Remove the coils (Item 1) [Figure 20-101-5].
20-101-3
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 522311001 & ABOVE) (CONTD) Disassembly And Assembly (Contd)
Figure 20-101-10
1 Figure 20-101-8 1
P-36223
P-36221
NOTE: Do not remove the 4 fittings (Item 1) [Figure 20-101-10]. The fittings are welded to the valve block. Removing the fittings will damage the fittings and valve block. Installation: Clean all components with solvent and dry with compressed air. Inspect all parts and replace any that are damaged. Use new O-rings and back-up rings.
Remove the spool (Item 1) [Figure 20-101-8] Figure 20-101-9
1 1
Apply clean hydraulic oil to the O-rings and back-up rings during assembly.
2 2
P-36222
Remove the 3 O-rings (Item 1) and 4 back-up rings (Item 2) [Figure 20-101-9].
20-101-4
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Removal And Installation Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 20-102-1
Figure 20-102-2
1 1
1
P-58103
1 Mark and remove the hoses (Item 1) [Figure 20-102-2]. Figure 20-102-3
P-58102
Cut and remove the tie straps (Item 1) [Figure 20-102-1].
IMPORTANT
I-2003-0888
P-58104
Mark and remove the hose (Item 1) [Figure 20-102-3].
20-102-1
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Mark the 3 wire harness connectors for ease of installation. Figure 20-102-4
Figure 20-102-6
P-58107
Installation: Install the washers (Item 1) [Figure 20-1026] between the floor plate and valve.
P-58105
Compress the wire retainer (Item 1) [Figure 20-102-4] to remove the wire harness connectors from the 3 solenoids. Figure 20-102-5
1
P-58106
Remove the bolts (Item 1) [Figure 20-102-5] and washers. Remove the valve.
20-102-2
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Nut O-Ring Coil Spool Plug Spring Ball Valve Body Back-up Ring Accumulator Valve Block Test Fitting W/Cap Pressure Reducing Valve
1 2
1 2
1 2 5 9 3 2
2 6 7
2 9 2 9
2 8 2 2 2 2 9 9 2 2 4
10 2 9 2 2 9 2 2 12 11 13
MS2024S
20-102-3
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly And Assembly Figure 20-102-7
Figure 20-102-9
1 1
P-58110
Remove the nuts (Item 1) [Figure 20-102-9]. Installation: Tighten the nuts to 3-5 ft.-lb. (4-7 Nm) torque. NOTE: Overtightening the coil nuts may cause spool or coil failure. Figure 20-102-10
P-58108
Remove the accumulator (Item 1) [Figure 20-102-7]. Figure 20-102-8
P-58109
P-58078
Remove the O-ring (Item 1) [Figure 20-102-10] from the nuts.
20-102-4
JOYSTICK LOCKOUT/TWO SPEED VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly And Assembly (Contd) Figure 20-102-11
Figure 20-102-13
P-58113
Remove the spools (Item 1) [Figure 20-102-13]. Figure 20-102-14

P-58111
Mark and remove the coils (Item 1) [Figure 20-102-11]. Figure 20-102-12 1 1 2
1 2 1
P-58114
Remove the back-up rings (Item 1) and O-rings (Item 2) [Figure 20-102-14].
P-58112
Remove the O-rings (Item 1) [Figure 20-102-12] from the spools.
20-102-5
Figure 20-102-17
P-58117
1 Remove the valve body (Item 1) [Figure 20-102-17]. Figure 20-102-18

P-58115
Remove the plug (Item 1) [Figure 20-102-15]. Figure 20-102-16 2
2 1 4 1
P-58118
3 Remove the back-up ring (Item 1) and O-rings (Item 2) [Figure 20-102-18].
P-58116
Remove the spring (Item 1) and ball (Item 2) [Figure 20102-16]. Remove the O-ring (Item 3) and back-up ring (Item 4) [Figure 20-102-16] from the plug.
20-102-6
1
P-58119
Remove the pressure reducing valve (Item 1) [Figure 20102-19]. Figure 20-102-20
P-58120
Remove the back-up rings (Item 1) and O-rings [Figure 20-102-20]. Installation: Clean all components with solvent and dry with compressed air. Inspect all parts and replace any that are damaged. Use new O-rings and back-up rings. Apply clean hydraulic oil to the O-rings and back-up rings during assembly.
20-102-7
20-102-8
RIGHT CONTROL LEVER (JOYSTICK) Testing Stop the engine. Open the right side cover. Figure 20-110-1 1
Figure 20-110-2
2
P-33804
Install a 1000 PSI (69 bar) gauge (Item 1) [Figure 20110-2] on the hose. Install a plug (Item 2) [Figure 20-110-2] on the valve section.
P-33803
Start the excavator and warm the hydraulic oil to operating temperature. At the 6 spool hydraulic control valve (Item 1) [Figure 20110-1], find the pilot line of the control lever (joystick) that is to be checked (boom, arm or bucket). Remove the hose from the control valve. Engage the circuit to be tested and record the operating pressure. The operating pressure should be approximately 507 PSI (35 bar). If the operating pressure is correct, check the valve section spool for proper operation. If the operating pressure is incorrect, adjust the pressure reducing valve. (See PRESSURE REDUCING VALVE (S/N 522311001 & ABOVE) on Page 20-33-1 or See PRESSURE REDUCING VALVE (S/N 528911001 & ABOVE AND 528611001 & ABOVE) on Page 20-32-1.) If the operating pressure is still incorrect, repair or replace the pressure reducing valve.
20-110-1
RIGHT CONTROL LEVER (JOYSTICK) (CONTD) Handle Removal And Installation Figure 20-110-3
Figure 20-110-5
P-35945
Disconnect the wire harness (Item 1) [Figure 20-110-5].

P-33029
Figure 20-110-6 Remove the 2 bolts (Item 1) [Figure 20-110-3] and washers. Remove the right arm rest. Figure 20-110-4 1
1 1
P-35946
1 2
P-35944
Mark the wires to the connector bodies (Item 1) [Figure 20-110-6]. Use a small flat blade screwdriver to depress the wire terminal tabs, and remove the individual wires from the connector body. Installation: Use a small flat blade screwdriver to rebend the wire terminal tabs on each wire before installing the individual wires in the connector bodies.
Remove the 4 bolts (Item 1) [Figure 20-110-4] and washers. Remove the cover (Item 2) [Figure 20-110-4].
20-110-2
RIGHT CONTROL LEVER (JOYSTICK) (CONTD) Handle Removal And Installation (Contd) Figure 20-110-7
Removal And Installation Figure 20-110-9
1
P-35947
P-33029
Remove the 2 bolts (Item 1) [Figure 20-110-9] and washers. Pull up on the joystick boot, and loosen the four mount bolts (Item 1) [Figure 20-110-7]. Remove the grommet and wire harness (Item 2) [Figure 20-110-7] from the joystick body. Pull up on the joystick boot. Figure 20-110-8 1 Remove the arm rest. Figure 20-110-10
2 1
2
P-35944
Remove the 4 bolts (Item 1) [Figure 20-110-10] and washers.

P-35948
Remove the cover (Item 2) [Figure 20-110-10]. Loosen the nut (Item 1) [Figure 20-110-8]. Remove the handle (Item 2) [Figure 20-110-8].
20-110-3
RIGHT CONTROL LEVER (JOYSTICK) (CONTD) Removal And Installation (Contd) Figure 20-110-11 When repairing hydrostatic and hydraulic systems, clean the work area before disassembly and keep all parts clean. Always use caps and plugs on hoses, tubelines and ports to keep dirt out. Dirt can quickly damage the system.
I-2003-0888
IMPORTANT
1 Figure 20-110-13 1
P-35945
Disconnect the wire harness (Item 1) [Figure 20-110-11]. Figure 20-110-12 1 1 1

P-35947
Pull up on the joystick boot and remove the 4 mount bolts (Item 1) [Figure 20-110-13] and washers. 1 Remove the joystick.
P-35949
20-110-4
RIGHT CONTROL LEVER (JOYSTICK) (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Handle Dust Boot Nut Swivel Joint/Bolt Washers Plate Plunger Assembly Seal Spool Assembly Spring Valve Body (Top) O-Ring Alignment Pin Valve Body (Bottom) Bolt
3 4 5 6
7 8 9
10
11
12 13
12 13 14
12 15
B-16943
20-110-5
RIGHT CONTROL LEVER (JOYSTICK) (CONTD) Disassembly And Assembly Figure 20-110-14
Figure 20-110-16 1
1
P-35926
P-35924
Remove the bolt (Item 1) [Figure 20-110-16] from inside the swivel joint. Figure 20-110-17
Remove the grommet and wire harness (Item 1) [Figure 20-110-14]. Figure 20-110-15
2 3 2 1
P-21715
P-35925
Remove the swivel joint (Item 1) and washers (Item 2) [Figure 20-110-17].
Mark the lever and swivel joint (Item 1) [Figure 20-11015] for correct orientation of the handle during assembly. Loosen the nut (Item 2) and remove the handle (Item 3) [Figure 20-110-15].
20-110-6
RIGHT CONTROL LEVER (JOYSTICK) (CONTD) Disassembly And Assembly (Contd) Figure 20-110-18
Figure 20-110-20
1 1
P-35929
P-35927
Remove the push rod (Item 1) [Figure 20-110-20] from the plunger body. Remove the O-ring (Item 2) [Figure 20-110-20].
Remove the plate (Item 1) [Figure 20-110-18]. Figure 20-110-21 Figure 20-110-19
1 1 1
P-35930 P-35928
Mark and remove the plunger assemblies (Item 1) [Figure 20-110-19]. NOTE: Install the plunger assemblies in the same bore the plungers were removed from.
Remove the spool assemblies (Item 1) [Figure 20-11021]. NOTE: Install the spool assemblies in the same bore the spools were removed from.
20-110-7
Figure 20-110-24
P-35934

P-35932
Figure 20-110-25 Mark the top of the spring seat (Item 1) [Figure 20-11022]. Compress the spring (Item 2) and remove the spring seat (Item 1) [Figure 20-110-22]. Figure 20-110-23 2
P-35935
Mark the joystick body (Item 1) [Figure 20-110-25] for ease of assembly. 1 2 3 Remove the bolt (Item 2) [Figure 20-110-25].
P-35933
Remove the spring (Item 1) and washers (Item 2) from the spool (Item 3) [Figure 20-110-23].
20-110-8
Figure 20-110-28
1 1 1
P-35938

P-35936
P-35937
Remove the bottom of the valve body (Item 1) [Figure 20-110-27].
20-110-9
20-110-10
LEFT CONTROL LEVER (JOYSTICK) Testing Stop the engine. Open the right side cover. Figure 20-111-1
Figure 20-111-2
1 2
P-33804
Install a 1000 PSI (69 bar) gauge (Item 1) [Figure 20111-2] on the hose. Install a plug (Item 2) [Figure 20-111-2] on the valve section.
P-33803
Start the excavator and warm the hydraulic oil to operating temperature. At the six spool hydraulic control valve (Item 1) [Figure 20-111-1], find the pilot line of the control lever (joystick) that is to be checked (boom, arm or bucket). Remove the hose from the control valve. Engage the circuit to be tested and record the operating pressure. The operating pressure should be approximately 507 PSI (35 bar). If the operating pressure is correct, check the valve section spool for proper operation. If the operating pressure is incorrect, adjust the pressure reducing valve. (See PRESSURE REDUCING VALVE (S/N 522311001 & ABOVE) on Page 20-33-1 or See PRESSURE REDUCING VALVE (S/N 528911001 & ABOVE AND 528611001 & ABOVE) on Page 20-32-1.) If the operating pressure is still incorrect, repair or replace the pressure reducing valve.
20-111-1
LEFT CONTROL LEVER (JOYSTICK) (CONTD) Handle Removal And Installation Figure 20-111-3
Figure 20-111-5
1 1 1 1
P-35939
1 Disconnect the wire harness (Item 1) [Figure 20-111-5].

P-35919
Figure 20-111-6 Remove the 4 screws (Item 1) [Figure 20-111-3]. Raise the console. Figure 20-111-4 2 1
1
P-35940
1 Mark the wires to the connector body (Item 1) [Figure 20-111-6].

P-35920
Use a small flat blade screwdriver to depress the wire terminal tabs, and remove the individual wires from the connector body. Installation: Use a small flat blade screwdriver to rebend the wire terminal tabs on each wire before installing the individual wires in the connector body.
Remove the 3 screws (Item 1) [Figure 20-111-4]. Remove the lower console cover (Item 2) [Figure 20111-4].
20-111-2
LEFT CONTROL LEVER (JOYSTICK) (CONTD) Handle Removal And Installation (Contd) Lower the console. Figure 20-111-7
Removal And Installation Lower the console. Figure 20-111-9
1 1 1 1 2
P-35919
P-35942
Remove the 4 screws (Item 1) [Figure 20-111-9]. Pull up on the joystick boot and loosen the 4 mount bolts (Item 1) [Figure 20-111-7]. Remove the grommet and wire harness (Item 2) [Figure 20-111-7] from the joystick body. Pull up on the joystick boot. Figure 20-111-8 1 Raise the console. Figure 20-111-10 2
2 1
P-35920
Remove the 3 screws (Item 1) [Figure 20-111-10]. Remove the lower console cover (Item 2) [Figure 20111-10].
P-35943
Loosen the nut (Item 1) [Figure 20-111-8]. Remove the handle (Item 2) [Figure 20-111-8].
20-111-3
LEFT CONTROL LEVER (JOYSTICK) (CONTD) Removal And Installation (Contd) Figure 20-111-11
Figure 20-111-13
1 1 1 1 1
P-35923
P-35921
Pull up on the joystick boot and remove the 4 bolts (Item 1) [Figure 20-111-13] and washers. Remove the joystick.
IMPORTANT
I-2003-0888
Figure 20-111-12
P-35922
Disconnect the wire harness (Item 1) [Figure 20-111-12] Lower the console.
20-111-4
LEFT CONTROL LEVER (JOYSTICK) (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.
Handle Dust Boot Nut Swivel Joint/Bolt Washers Plate Plunger Assembly Seal Spool Assembly Spring Valve Body (Top) O-Ring Alignment Pin Valve Body (Bottom) Bolt
3 4 5
6 7 8
9 10
11 12 13 12 13 14 12 15
B-16944
20-111-5
LEFT CONTROL LEVER (JOYSTICK) (CONTD) Disassembly and Assembly Figure 20-111-14
Figure 20-111-16 1
1
P-35926
P-35924
Remove the bolt (Item 1) [Figure 20-111-16] from inside the swivel joint. Figure 20-111-17
Remove the grommet and wire harness (Item 1) [Figure 20-111-14]. Figure 20-111-15 2 1 3 2
P-21715
P-35925
Remove the swivel joint (Item 1) and washers (Item 2) [Figure 20-111-17].
Mark the lever and swivel joint (Item 1) [Figure 20-11115] for correct orientation of the handle during assembly. Loosen the nut (Item 2) and remove the handle (Item 3) [Figure 20-111-15].
20-111-6
LEFT CONTROL LEVER (JOYSTICK) (CONTD) Disassembly And Assembly (Contd) Figure 20-111-18
Figure 20-111-20
1 1
P-35929
P-35927
Remove the push rod (Item 1) [Figure 20-111-20] from the plunger body. Remove the O-ring (Item 2) [Figure 20-111-20].
Remove the plate (Item 1) [Figure 20-111-18]. Figure 20-111-21 Figure 20-111-19
1 1 1
P-35930 P-35928
Mark and remove the plunger assemblies (Item 1) [Figure 20-111-19]. NOTE: Install the plunger assemblies in the same bore the plungers were removed from.
Remove the spool assemblies (Item 1) [Figure 20-11121]. NOTE: Install the spool assemblies in the same bore the spools were removed from.
20-111-7
Figure 20-111-24
P-35934

P-35932
Figure 20-111-25 Mark the top of the spring seat (Item 1) [Figure 20-11122]. Compress the spring (Item 2) and remove the spring seat (Item 1) [Figure 20-111-22]. Figure 20-111-23 1 2
P-35935
Mark the joystick body (Item 1) [Figure 20-111-25] for ease of assembly. 1 2 3 Remove the bolt (Item 2) [Figure 20-111-25].
P-35933
Remove the spring (Item 1) and washers (Item 2) from the spool (Item 3) [Figure 20-111-23].
20-111-8
Figure 20-111-28
P-35938

P-35936
P-35937
Remove the bottom of the valve body (Item 1) [Figure 20-111-27].
20-111-9
20-111-10
TRAVEL LEVER/FOOT PEDAL VALVE Left Travel Lever/Foot Pedal Valve Removal And Installation Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 20-112-1
Figure 20-112-2
1 1
P-33233
Remove the 4 bolts (Item 1) [Figure 20-112-2] and washers. 1 Installation: Tighten the bolts to 15-18 ft.-lb. (20-25 Nm) torque. Figure 20-112-3 Mark and remove the four tee fittings (Item 1) [Figure 20112-1].
P-33234
IMPORTANT
I-2003-0888
P-33232
20-112-1
TRAVEL LEVER/FOOT PEDAL VALVE (CONTD) Right Travel Lever/Foot Pedal Valve Removal And Installation Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 20-112-4
Figure 20-112-6
1
P-33236
Cut and remove the tie strap (Item 1) [Figure 20-112-6]. Figure 20-112-7
P-33234
1 Cut and remove the cable tie (Item 1) [Figure 20-112-4]. Reposition the hoses to gain access to the valve hoses. Figure 20-112-5 1 1
P-33237
Mark and remove the 3 tee fittings (Item 1) [Figure 20112-7] 1

P-33235
Mark and remove the tee fitting (Item 1) [Figure 20-1125].
20-112-2
TRAVEL LEVER/FOOT PEDAL VALVE (CONTD) Right Travel Lever/Foot Pedal Valve Removal And Installation (Contd) Figure 20-112-8
Figure 20-112-10
1 Remove the valve (Item 1) [Figure 20-112-10].

P-33239
P-33240
Figure 20-112-9
P-33238
Remove the 4 bolts (Item 1) [Figure 20-112-8] & [Figure 20-112-9] and washers. Installation: Tighten the bolts to 15-18 ft.-lb. (20-25 Nm) torque.
20-112-3
TRAVEL LEVER/FOOT PEDAL VALVE (CONTD) Parts Identification
1 2 3 4 5 6 7 8 9 10 11
Dust Boot Plunger Body O-Ring Push Rod Retainer Piston Spring Shim Spool Spring Valve Body 4 3 3 5 6 7 7 8 8 5 6 3 4 2 3 1 2 1
9 9
10 10
11
MS1546
20-112-4
TRAVEL LEVER/FOOT PEDAL VALVE (CONTD) Disassembly And Assembly Figure 20-112-11
Figure 20-112-13
1 1
P-33243
Loosen the set screw (Item 1) [Figure 20-112-13].

P-33241
Figure 20-112-14 Remove the bolt (Item 1) [Figure 20-112-11] from the pedal. Figure 20-112-12 1
P-33244

P-33242
Slide the plate (Item 1) [Figure 20-112-12] and remove the plate and handle assembly.
20-112-5
TRAVEL LEVER/FOOT PEDAL VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-112-15
Figure 20-112-17
2 2
P-33246
1 Remove the bolt (Item 1) [Figure 20-112-17].

P-33248
Installation: Align the hole (Item 1) in the pin with the set screw (Item 2) [Figure 20-112-15]. Figure 20-112-16
NOTE: Use care when removing the bolt, the plunger assemblies (Item 2) [Figure 20-112-17] are spring loaded. Figure 20-112-18
P-33247 P-33245
Remove the dust boots (Item 1) [Figure 20-112-16].
Remove the plunger assemblies (Item 1) [Figure 20-11218].
20-112-6
Figure 20-112-21
P-36227
P-36225
Remove the seal (Item 1) [Figure 20-112-21] from the push rod. Figure 20-112-22
Remove the push rod (Item 1) [Figure 20-112-19] from the plunger body. Figure 20-112-20
1
P-36229
P-36226
Remove the spool assemblies (Item 1) and springs (Item 2) [Figure 20-112-22].
Remove the O-ring (Item 1) [Figure 20-112-20] from the plunger body.
20-112-7
Figure 20-112-25
1
P-36232
P-36230
Do not remove the 4 fittings (Item 1) [Figure 20-112-25], the fittings are welded to the valve block. Removing the fittings will damage the block and fittings. Installation: Clean all components with solvent and dry with compressed air. Inspect all parts and replace any that are damaged. Use new O-rings and back-up rings.
Compress the spring (Item 1) until the retainer (Item 2) [Figure 20-112-23] can be removed. Figure 20-112-24
5 4 3 2 1
Apply clean hydraulic oil to the O-rings and back-up rings during assembly.
P-36231
Remove the retainer (Item 1), piston (Item 2), spring (Item 3) and shims (Item 4) from the spool (Item 5) [Figure 20-112-24].
20-112-8
HYDRAULIC FILTER MOUNT Removal And Installation Figure 20-120-1
Figure 20-120-3
1
P-40559
1
P-40557
Remove the 4 bolts (Item 1) [Figure 20-120-3] and washers. Figure 20-120-4
Remove the screw (Item 1) from the electrical connector (Item 2) [Figure 20-120-1]. Remove the electrical connector. Installation: Do not overtighten the screw. Figure 20-120-2
P-40533
Remove the filter mount [Figure 20-120-4].
P-40558
Remove the tube line (Item 1) [Figure 20-120-2].
20-120-1
20-120-2
HYDRAULIC RESERVOIR Removal And Installation Remove the rear cover. (See REAR COVER on Page 40150-1.) Remove the right side cover. (See RIGHT SIDE COVER on Page 40-160-1.) Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Remove the counterweight. (See COUNTERWEIGHT on Page 40-170-1.) Remove the filter mount. (See HYDRAULIC FILTER MOUNT on Page 20-120-1.) Figure 20-130-1
Figure 20-130-3
P-38627
Remove the 2 bolts (Item 1) [Figure 20-130-3] and washers from the side of the center panel. Remove the panel (Item 2) [Figure 20-130-3]. 1
IMPORTANT
P-38628
I-2003-0888
Figure 20-130-2
Figure 20-130-4
1 1
P-40535 P-38629
Remove the 2 bolts (Item 1) and [Figure 20-130-2] and washers from the top of the center panel.
Mark and remove the 5 hoses (Item 1) and disconnect the wire harness (Item 2) [Figure 20-130-4].
20-130-1
HYDRAULIC RESERVOIR (CONTD) Removal And Installation (Contd) Figure 20-130-5
Figure 20-130-7
1 1 1
P-40539
P-40537
Remove the bolt (Item 1) and hose clamp (Item 2) [Figure 20-130-7] from the rear of the hydraulic reservoir. Figure 20-130-8
Remove the 2 bolts (Item 1) [Figure 20-130-5] on the right side of the mount bracket. Figure 20-130-6
1 1 2
P-40540
P-40538
Remove the mount bolt (Item 1) [Figure 20-130-8] from the top of the hydraulic reservoir.
Remove the bolt (Item 1) and hose clamp (Item 2) [Figure 20-130-6] from the right hand side of the hydraulic reservoir.
20-130-2
Figure 20-130-11 1
2 1
P-40546
P-40541
Remove the 2 bolts (Item 1) and nuts from the fuel filter (Item 2) [Figure 20-130-11]. Remove the fuel filter. Figure 20-130-12
Remove the screw (Item 1) and disconnect the electrical connector (Item 2) [Figure 20-130-9]. Figure 20-130-10 1 1 1
2
P-40545
P-40543
Remove the bolt (Item 1) and hose clamp (Item 2) [Figure 20-130-12].
Mark and remove the 4 hoses (Item 1) [Figure 20-13010] from the fuel filter.
20-130-3
Figure 20-130-15
P-40548
P-40544
Mark and remove the 2 hoses (Item 1) [Figure 20-13015] from the right hand side of the hydraulic reservoir. Figure 20-130-16
Mark and remove the 2 wires (Item 1) [Figure 20-130-13] from the fuel sending unit. Figure 20-130-14
1 1
2
P-35231
P-40547
Remove the 2 bolts (Item 1) and nuts from the swing brake valve (Item 2) [Figure 20-130-14]. Remove the swing brake valve.
20-130-4
Figure 20-130-19
1 2 1
P-40550
1
P-35232
Remove the plug and fitting (Item 1) [Figure 20-130-19] from the bottom of the hydraulic reservoir. Remove the bolt (Item 2) [Figure 20-130-19] and washer. Figure 20-130-20
Remove the 4 bolts (Item 1) [Figure 20-130-17]. Figure 20-130-18
P-40549
P-40551
Mark and remove the hose (Item 1) [Figure 20-130-18].
Remove the 2 mount bolts (Item 1) [Figure 20-130-20] and washers from the right hand side of the hydraulic reservoir.
20-130-5
HYDRAULIC RESERVOIR (CONTD) Removal And Installation (Contd) Figure 20-130-21 1
Figure 20-130-23
P-40554
P-40552
Install a hoist (Item 1) [Figure 20-130-23] on the hydraulic reservoir. Figure 20-130-24
Remove the 2 mount bolts (Item 1) and bracket (Item 2) [Figure 20-130-21]. Figure 20-130-22
P-40555
P-40553
Raise the hoist and slide the hydraulic reservoir out the rear of the excavator [Figure 20-130-24].
Install a hoist (Item 1) [Figure 20-130-22] on the mount bracket. Raise the mount bracket up and to the right to provide clearance for the hydraulic reservoir to be removed.
20-130-6
OIL COOLER Description The oil cooler is a combined radiator/oil cooler. See Radiator/Oil Cooler Removal And Installation. (See RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) on Page 60-40-1 or See RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 60-41-1.)
20-140-1
20-140-2
SECONDARY FRONT AUXILIARY VALVE Removal And Installation Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 20-150-1
Figure 20-150-3
P-33155
Remove the 2 bolts (Item 1) [Figure 20-150-3] and nuts. Remove the valve.
P-33153
Mark and remove the wire harness (Item 1) [Figure 20150-1].
WARNING
I-2003-0888
Figure 20-150-2
P-33154

SECONDARY FRONT AUXILIARY VALVE (CONTD) Parts Identification
1 2 3 4 5 6 7 8 9 10
Nut O-Ring Coil Actuators Spring Spring Retainer Plate Valve Body Bolt Spool 2 6 5 2 4 7 2 3 2 1
10 6 5 2 4 2 3 2 1
MS1545
20-150-2
SECONDARY FRONT AUXILIARY VALVE (CONTD) Disassembly And Assembly Figure 20-150-4
Figure 20-150-6
1 1 1
P-36234
Remove the coils (Item 1) [Figure 20-150-6].

P-36233
Figure 20-150-7 Remove the nuts (Item 1) [Figure 20-150-4] from the spools. Installation: Tighten the nuts to 3-5 ft.-lbs (4-7 Nm) torque. NOTE: Overtightening the coil nuts may cause spool or coil failure. 1 Figure 20-150-5 1
1
P-36236
Remove the O-rings (Item 1) [Figure 20-150-7]. 1 Figure 20-150-8
P-36235
Remove the O-rings (Item 1) [Figure 20-150-5].
1
P-36237
Loosen the actuators (Item 1) [Figure 20-150-8].

SECONDARY FRONT AUXILIARY VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-150-9
Figure 20-150-11
1 2 3 3 2 1
P-36238 P-36239
Remove the spool (Item 1) [Figure 20-150-11]. Figure 20-150-12
Remove the actuators (Item 1), springs (Item 2) and spring retainers (Item 3) [Figure 20-150-9]. Figure 20-150-10 1
P-36240
Loosen the 4 bolts (Item 1) [Figure 20-150-12].

P-36244
Remove the O-ring (Item 1) [Figure 20-150-10] from the actuators.
20-150-4
SECONDARY FRONT AUXILIARY VALVE (CONTD) Disassembly And Assembly (Contd)
Figure 20-150-15
1 Figure 20-150-13
1 1 1
P-36241 P-36243
Do not remove the 4 fittings (Item 1) [Figure 20-150-15]. The fittings are welded to the valve block. Removing the fittings will damage the fittings and valve block. Installation: Clean all components with solvent and dry with compressed air. Inspect all parts and replace any that are damaged. Use new O-rings and back-up rings. Apply clean hydraulic oil to the O-rings and back-up rings during assembly.
Remove the 4 bolts (Item 1) and plate (Item 2) [Figure 20-150-13] from the valve body. Figure 20-150-14
P-36242
Remove the 4 O-rings (Item 1) [Figure 20-150-14] from the valve body.
20-150-5
20-150-6
HYDRAULIC BREAKER APPLICATION VALVE (S/N 522311001 & ABOVE) Removal And Installation Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 20-160-1
Figure 20-160-2
2 2 1
P-33166
Remove the tee fitting (Item 1) [Figure 20-160-2]. Remove the hose (Item 2) [Figure 20-160-2].
P-33165
Figure 20-160-3 2
Remove the wire harness (Item 1) [Figure 20-160-1] from the solenoid. NOTE: The solenoid nut (Item 2) [Figure 20-160-1] may have to be loosened and the solenoid turned to access the screw to remove the wire harness.
IMPORTANT
I-2003-0888
1
P-33167
Remove the bolts (Item 1) [Figure 20-160-3] and washers. Installation: Install 2 washers (Item 2) between the cab and valve. Install 1 washer (Item 3) [Figure 20-160-3] on the bolts. Tighten the bolts to 6-7 ft.-lb. (8-10 Nm) torque.
20-160-1
442 Evcavator Service Manual
HYDRAULIC BREAKER APPLICATION VALVE (S/N 522311001 & ABOVE) (CONTD) Parts Identification
1. 2. 3. 4. 5. 6.
Valve Body Back-up Ring O-Ring Spool Coil Nut
2 2 3 3 3 5 4
MS1536
20-160-2
HYDRAULIC BREAKER APPLICATION VALVE (CONTD) Disassembly And Assembly Figure 20-160-4
Figure 20-160-6
1 1
2 1 2 2 2
P-36282
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-160-6] from the spool.
P-36279
Figure 20-160-7 Remove the nut (Item 1) and coil (Item 2) [Figure 20160-4] from the spool. Installation: Tighten the nut to 3-5 ft.-lb. (4-7 Nm) torque. NOTE: Overtightening the coil nut may cause spool or coil failure. Figure 20-160-5 1 1
1 1
P-36283
NOTE: Do not remove the 4 fittings (Item 1) [Figure 20-160-7] The fittings are welded to the valve block. Removing the fittings will damage the block and fittings. Installation: Clean all components with solvent and dry with compressed air.
P-36280
Check all components for burrs, scratches or other damage and replace if necessary. Use new O-rings and back-up rings. Apply clean hydraulic oil to the O-rings and back-up rings during assembly.
20-160-3
442 Evcavator Service Manual
20-160-4
AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/ N 522311001 & ABOVE) Removal And Installation Tilt the cab. (See Tilting The Cab on Page 10-160-2.)
Figure 20-170-2
IMPORTANT
I-2003-0888
P-33250
Figure 20-170-1
Remove the 2 nuts (Item 1) [Figure 20-170-2] and washers. Remove the valve.
P-33249
20-170-1
AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/N 522311001 & ABOVE) (CONTD) Parts Identification
1 2 3 4 5 6 7 8
Plug Seal Valve Body Spool Spring Spring Seat O-Ring Adjustor 1 2 3 2
5 6 7
MS1537
20-170-2
AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/ N 522311001 & ABOVE) (CONTD) Disassembly And Assembly Figure 20-170-3
Figure 20-170-5
P-36247
1 Loosen the adjustor (Item 1) [Figure 20-170-5].

P-36245
Figure 20-170-6
Remove the 2 plugs (Item 1) [Figure 20-170-3]. Figure 20-170-4 4 3 2 1
1
P-36248
Remove the adjustor (Item 1), spring seat (Item 2), spring (Item 3) and spool (Item 4) [Figure 20-170-6].
P-36246
Remove the seals (Item 1) [Figure 20-170-4] from the plugs.
20-170-3
AUXILIARY HYDRAULIC FLOW CONTROL VALVE (S/ N 522311001 & ABOVE) (CONTD) Disassembly And Assembly (Contd)
Figure 20-170-9
1 Figure 20-170-7
1
P-36251
P-36249
NOTE: Do not remove the 3 fittings (Item 1) [Figure 20170-9]. The fittings are welded to the valve block. Removing the fittings will damage the block and fittings. Installation: Clean all components with solvent and dry with compressed air. Inspect all parts and replace any that are damaged. Use new O-rings and back-up rings. Apply clean hydraulic oil to the O-rings and back-up rings during assembly.
Remove the O-ring (Item 1) [Figure 20-170-7] from the adjustor. Figure 20-170-8
P-36250
Remove the seal (Item 1) [Figure 20-170-8] from the spool.
20-170-4
AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Removal And Installation Tilt the cab. (See Tilting The Cab on Page 10-160-2.)
Figure 20-171-2
IMPORTANT
I-2003-0888
P-58074
Compress the wire retainer (Item 1) [Figure 20-171-2] to remove the wire harness connector from the solenoid. Figure 20-171-3
Figure 20-171-1
1 1 2
1
P-58073
1
P-58076
Mark and remove the hoses (Item 1) [Figure 20-171-1]. Remove the bolts (Item 1) and washers. Remove the valve (Item 2) [Figure 20-171-3].
20-171-1
AUXILIARY HYDRAULIC FLOW CONTROL/HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9.
Valve Block O-Ring Back-up Ring Spool Plug Flow Regulator Spool Coil Nut 5 2 4 23 1
2 2 3 2
2 2 3 3
2 7 2
8 2 9
MS2023S
20-171-2
AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly And Assembly Figure 20-171-4
Figure 20-171-6
P-58079
Remove the coil (Item 1) [Figure 20-171-6]. 1 Figure 20-171-7

P-58077
Remove the nut (Item 1) [Figure 20-171-4]. Installation: Tighten the nut to 3-5 ft.-lbs (4-7 Nm) torque. NOTE: Overtightening the coil nut may cause spool or coil failure. Figure 20-171-5 1
P-58080
Remove the O-ring [Figure 20-171-7].
P-58078
20-171-3
AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly And Assembly (Contd) Figure 20-171-8
Figure 20-171-10
P-58083
Remove the flow regulator (Item 1) [Figure 20-171-10]. Figure 20-171-11

P-58081
P-58120
Remove the back-up rings (Item 1) and O-rings (Item 2) [Figure 20-171-11].
P-58082
Remove the O-rings (Item 1) and back-up rings (Item 2) [Figure 20-171-9].
20-171-4
AUXILIARY HYDRAULIC FLOW CONTROL/ HYDRAULIC BREAKER APPLICATION VALVE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly And Assembly (Contd) Figure 20-171-12
Figure 20-171-14
P-58086
Remove the spool (Item 1) [Figure 20-171-14]. 1 Figure 20-171-15

P-58084
Remove the plug (Item 1) [Figure 20-171-12]. Figure 20-171-13
1 1
P-58087
Remove the O-rings (Item 1) [Figure 20-171-15]. Installation: Clean all components with solvent and dry with compressed air.
P-58085
Inspect all parts and replace any that are damaged. Remove the O-ring (Item 1) [Figure 20-171-13]. Use new O-rings and back-up rings. Apply clean hydraulic oil to the O-rings and back-up rings during assembly.
20-171-5
20-171-6
BLADE VALVE Removal And Installation Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 20-180-1
Figure 20-180-2
1 2
2
P-33252
1
P-33251
Mark and remove the 2 hoses (Item 1) [Figure 20-1802]. Mark and remove the 2 tee fittings (Item 2) [Figure 20180-2]. Figure 20-180-3
Remove the linkage (Item 1) [Figure 20-180-1] from the valve.
IMPORTANT
I-2003-0888
1
P-33253
Remove the 2 bolts (Item 1) [Figure 20-180-3]. Remove the valve.
20-180-1
BLADE VALVE (CONTD) Parts Identification
1 2 3 4 5 6 7 8 9 10 11
Plunger Body O-Ring Push Rod Shim Retainer Piston Spring Spool Spring Valve Body Plug 4 5 6 7 33 2 2 1
1 2
3 2
4 5 6 7
4 4
8 8
9 9
2 11
10 2
MS1548
20-180-2
BLADE VALVE (CONTD) Disassembly And Assembly Figure 20-180-4 2
Figure 20-180-6
1 2 1 1
P-36267
P-36253
Installation: Install the roll pin (Item 1) through the tab (Item 2) [Figure 20-180-6] on the top of the block. Figure 20-180-7
Remove the 2 bolts (Item 1) from the plate (Item 2) [Figure 20-180-4]. Remove the plate. Figure 20-180-5 2
P-36256
2
P-36255
Remove the pin (Item 1) and block (Item 2) [Figure 20180-7].
Remove the roll pin (Item 1) through the hole (Item 2) [Figure 20-180-5] in the bottom plate.
20-180-3
BLADE VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-180-8 1 3
Figure 20-180-10
2
P-36259
1
P-36257
Remove the plunger assemblies (Item 1) [Figure 20-18010]. Figure 20-180-11
Remove the 4 outside bolts (Item 1) and center bolt (Item 2) [Figure 20-180-8]. NOTE: Use care when removing the bolts. The plunger assemblies (Item 3) [Figure 20-180-8] are spring loaded. Installation: Install the center bolt (Item 2) [Figure 20180-8] first to retain the plunger assemblies in proper alignment. Figure 20-180-9 2
P-36260
2 1 Remove the push rod (Item 1) [Figure 20-180-11] from the plunger body.
P-36258
Remove the plate (Item 1) [Figure 20-180-9]. Installation: Use care not to dislodge the plunger assemblies (Item 2) [Figure 20-180-9] until the plate (Item 1) [Figure 20-180-9] is secured by the center bolt (Item 2) [Figure 20-180-8].
20-180-4
BLADE VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-180-12
Figure 20-180-14
3 2 1 1
2 1
P-36264
P-36261
Remove the shims (Item 1), spool assemblies (Item 2) and springs (Item 3) [Figure 20-180-14]. Figure 20-180-15
Remove the O-ring (Item 1) [Figure 20-180-12] from the plunger body. Figure 20-180-13 1
P-36230
P-36262
Compress the spring (Item 1) until the retainer (Item 2) [Figure 20-180-15] can be removed from the spool.
Remove the O-ring (Item 1) [Figure 20-180-13] from the push rod.
20-180-5
BLADE VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-180-16
Figure 20-180-18
1 5 4 3 2 1
P-36115
P-36231
Remove the O-ring (Item 1) [Figure 20-180-18] from the plugs. Figure 20-180-19
Remove the retainer (Item 1), piston (Item 2), spring (Item 3), and shims (Item 4) from the spool (Item 5) [Figure 20-180-16]. Figure 20-180-17
1 1
P-36266
P-36265
NOTE: Do not remove the 4 fittings (Item 1) [Figure 20-180-19] The fittings are welded to the valve block. Removing the fittings will damage the block and fittings. Installation: Clean all components with solvent and dry with compressed air. Inspect all parts and replace any that are damaged. Use new O-rings and back-up rings. Apply clean hydraulic oil to the O-rings and back-up rings during assembly.
Remove the 2 plugs (Item 1) [Figure 20-180-17].
20-180-6
BLADE FLOAT VALVE Removal And Installation Open the rear cover. Figure 20-181-1
Figure 20-181-3
2 1
P-33389
Remove the tee (Item 1) [Figure 20-181-3]. Remove the hose (Item 2) [Figure 20-181-3].
P-33387
Figure 20-181-4 Remove the wire harness (Item 1) [Figure 20-181-1]. 1
IMPORTANT
I-2003-0888
P-33390
Figure 20-181-2 Remove the 2 bolts (Item 1) [Figure 20-181-4] and nuts. 1 2 Remove the valve.
P-33388
Remove the hose (Item 1) [Figure 20-181-2]. Remove the tubeline (Item 2) [Figure 20-181-2].
BLADE FLOAT VALVE (CONTD) Parts Identification
1 2 3 4 5 6 7 8 9 10 11 12
Plate O-Ring Valve Body Spring Retainer Spring O-Ring Solenoid Valve Coil Nut Bolt Spool Plug 8 2 3 6 5 4 7 6 9 1
10
11 4 5 6 12
MS1558
20-181-2
BLADE FLOAT VALVE (CONTD) Disassembly And Assembly Figure 20-181-5
Figure 20-181-7
1 1
P-36044
Remove the solenoid valve (Item 1) [Figure 20-181-7].

P-36042
Figure 20-181-8 Remove the nut (Item 1) [Figure 20-181-5] from the solenoid valve. Installation: Tighten the nut to 3-5 ft.-lb. (4-7 Nm) torque. NOTE: Overtightening the coil nuts (Item 1) [Figure 20-181-5] may cause spool or coil failure. Figure 20-181-6 1
P-36045
P-36043
Remove the O-ring (Item 1) and coil (Item 2) [Figure 20181-6].
20-181-3
BLADE FLOAT VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-181-9
Figure 20-181-11
2 1
P-36048

P-36046
Figure 20-181-12 Remove the spring (Item 1) and spring seat (Item 2) [Figure 20-181-9]. Figure 20-181-10 2 1
P-36049
Remove the spring (item 1) and spring seat (Item 2) [Figure 20-181-12].
P-36047
Remove the plug (Item 1) [Figure 20-181-10] from the opposite end of the valve.
20-181-4
BLADE FLOAT VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-181-13
Figure 20-181-15
P-36052

P-36050
3 2
1
P-36051
Mark the valve body (Item 1) [Figure 20-181-14] for ease of assembly. Remove the 4 bolts (Item 2) and remove the block (Item 3) [Figure 20-181-14].
20-181-5
20-181-6
BOOM OFFSET VALVE Removal And Installation Tilt the cab. (See Tilting The Cab on Page 10-160-2.)
Figure 20-190-17
IMPORTANT
I-2003-0888
P-33229
Figure 20-190-16
Remove the 4 bolts (Item 1) [Figure 20-190-17] and washers. 1 Installation: Tighten the bolts to 15-18 ft.-lb. (20-25 Nm) torque. Figure 20-190-18 1 2
P-33228
Mark and remove the hoses (Item 1) [Figure 20-190-16]. Remove the tee fitting (Item 2) [Figure 20-190-16].
P-33230
20-190-1
BOOM OFFSET VALVE (CONTD) Parts Identification
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Dust Boot Plunger Body O-Ring Push Rod Retainer Piston Spring Shim Spool Spring Valve body Seal Carrier Seal Fitting Bolt 5 6 7 8 8 13 9 14 9 3 10 10 15 15 3 14 12 6 7 12 13 3 4 3 5 3 4 2 3 1 2 1
11
MS1547
20-190-2
BOOM OFFSET VALVE (CONTD) Disassembly And Assembly Figure 20-190-19
Figure 20-190-21
P-36272
Remove the plate (Item 1) [Figure 20-190-21].

P-36269
Figure 20-190-22 Loosen the set screw (Item 1) [Figure 20-190-19]. Figure 20-190-20
P-36273
2 Remove the dust boots (Item 1) [Figure 20-190-22].

P-36270
Remove the pin (Item 1) [Figure 20-190-20]. Installation: Align the hole (Item 2) with the set screw (Item 3) [Figure 20-190-20]. Tighten the set screw.
20-190-3
BOOM OFFSET VALVE (CONTD) Disassembly And Assembly (Contd) Figure 20-190-23
Figure 20-190-25
1 2
P-36276
P-36274
Remove the plunger assemblies (Item 1) [Figure 20-19025]. Figure 20-190-26
Remove the bolt (Item 1) [Figure 20-190-23]. NOTE: Use caution when removing the bolt. The plunger assemblies (Item 2) [Figure 20-19023] are spring loaded. Figure 20-190-24
P-36260
1 Remove the push rod (Item 1) [Figure 20-190-26] from the plunger body.
P-36275
Remove the plate (Item 1) [Figure 20-190-24].
20-190-4
Figure 20-190-29
2 1
2 1
P-36277
P-36261
Remove the spool assembly (Item 1) and spring (Item 2) [Figure 20-190-29]. Figure 20-190-30
Remove the O-ring (Item 1) [Figure 20-190-27] from the plunger body. Figure 20-190-28 1 2 1
P-36230
P-36262
Compress the spring (Item 1) until the retainer (Item 2) [Figure 20-190-30] can be removed.
Remove the O-ring (Item 1) [Figure 20-190-28] from the push rod.
20-190-5
Figure 20-190-33
5 4 3 2 1
P-35994
1 2
P-36231
Remove the bolt (Item 1) and seal carrier (Item 2) [Figure 20-190-32] from the fittings. Figure 20-190-34
Remove the retainer (Item 1), piston (Item 2) spring (Item 3) and shims (Item 4) from the spool (Item 5) [Figure 20190-31]. Figure 20-190-32 2 2
1
P-35998
1 Installation: The lip (Item 1) on the seal carrier must fit in the groove (Item 2) [Figure 20-190-34] in the housing.
P-36278
Remove the two fittings (Item 1) [Figure 20-190-32] from the end of the valve body. NOTE: Do not remove the 2 fittings (Item 2) [Figure 20-190-32]. The fittings are welded to the valve block. Removing the fittings will damage the block and fittings.
20-190-6
Figure 20-190-37
P-35996
P-35995
Remove the O-ring (Item 1) [Figure 20-190-37] from the bolt. Installation: Clean all components with solvent and dry with compressed air. Inspect all parts and replace any that are damaged.
Remove the seal (Item 1) [Figure 20-190-35] from the seal carrier. Figure 20-190-36
Use new O-rings and back-up rings. 2 Apply clean hydraulic oil to the O-rings and back-up rings during assembly.
1 2
P-35997
Installation: Make sure the lips (Item 1) on the seal fit into the grooves (Item 2) [Figure 20-190-36] on the seal carrier.
20-190-7
20-190-8
BOOM LOAD HOLDING VALVE Removal And Installation Fully retract the bucket and arm cylinders. Lower the boom until the bucket is on the ground. With the engine off and the key in the run position, move the joysticks to relieve hydraulic pressure.
Figure 20-200-39
IMPORTANT
I-2003-0888
P-33392
Remove the 4 bolts (Item 1) [Figure 20-200-39]. Installation: Tighten the bolts to 15-18 ft.-lb. (20-25 Nm) torque. Remove the valve. Figure 20-200-40
Figure 20-200-38
3 2
1 1
P-33391 P-33393
Remove the load sense line (Item 1) Mark and remove the pilot pressure lines (Item 2) [Figure 20-200-38]. Remove the tubeline (Item 3) [Figure 20-200-38]. Remove the O-ring (Item 1) and back-up ring (Item 2) [Figure 20-200-40] from the valve.
20-200-1
BOOM LOAD HOLDING VALVE (CONTD) Parts Identification
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Relief Valve Seal Piston Spring Spring Seat O-Ring Plug Back-up Ring Relief Valve Cap Valve Body Seal Carrier Seal Fitting Bolt Poppet Seal Coupler Cap Fitting Plug
2 2 3 4 6 5 7 7 7 6 8 6 6 6 11 6 6 9 7 10
12 14 6 15 6 7 6 18 14 21 19 20 20 6 6 13 12 13 16 7
17
15
MS1539
20-200-2
BOOM LOAD HOLDING VALVE (CONTD) Disassembly Figure 20-200-41
Figure 20-200-43
1 2
P-36115

P-36092
Figure 20-200-44 Remove the O-ring (Item 1) and back-up ring (Item 2) [Figure 20-200-41]. Figure 20-200-42 1
P-36095
Loosen the bolt (Item 1) [Figure 20-200-44].

P-36094
20-200-3
BOOM LOAD HOLDING VALVE (CONTD) Disassembly (Contd) Figure 20-200-45
Figure 20-200-47
2 1 3
P-36114
P-36096
Remove the O-ring (Item 1) [Figure 20-200-47] from the 4 plugs. (Ported plug shown.) Figure 20-200-48
Remove the bolt (Item 1), washer (Item 2), spring (Item 3) and poppet (Item 4) [Figure 20-200-45]. Figure 20-200-46 1
P-36100
1 2 1
P-36097
Remove the cap (Item 1) [Figure 20-200-48] from the relief valve.
Remove the 3 plugs (Item 1). Mark and remove the ported plug (Item 2) [Figure 20-200-46]. NOTE: Make sure the ported plug is installed in the original location.
20-200-4
Figure 20-200-51
1 1 1
P-36103
Remove the fittings (Item 1) [Figure 20-200-51].

P-36101
Figure 20-200-52 Remove the relief valve (Item 1) [Figure 20-200-49]. Figure 20-200-50
2 1 1
P-36104
P-36102
Remove the coupler (Item 1) [Figure 20-200-52] from the fitting.
Remove the O-ring (Item 1) and back-up ring (Item 2) [Figure 20-200-50].
20-200-5
Figure 20-200-55
1 1 2
P-35995
P-35994
Remove the seal (Item 1) [Figure 20-200-55] from the seal carrier. Figure 20-200-56
Remove the bolt (Item 1) and seal carrier (Item 2) [Figure 20-200-53] from the two fittings. Figure 20-200-54
1
P-36105
Remove the 2 fittings (Item 1) [Figure 20-200-56].

P-35996
Remove the O-ring (Item 1) [Figure 20-200-54] from the bolt.
20-200-6
Figure 20-200-59
2 1 1
P-36108
P-36106
Remove the plug (Item 1) and poppet (Item 2) [Figure 20-200-59]. Figure 20-200-60
Remove the O-ring (Item 1) [Figure 20-200-57] from the fittings. Figure 20-200-58 1
P-36115
P-36107
Remove the O-ring (Item 1) [Figure 20-200-60] from the plug.
Loosen the plug (Item 1) [Figure 20-200-58].
20-200-7
Figure 20-200-63
P-36114
P-36109
Remove the O-ring (Item 1) [Figure 20-200-63] from the plug. Figure 20-200-64
Remove the seal (Item 1) [Figure 20-200-61] from the poppet. Figure 20-200-62
P-36111
1 Loosen the relief valve (Item 1) [Figure 20-200-64].

P-36110
Mark and remove the plug (Item 1) [Figure 20-200-62]. NOTE: The plug is ported and must be installed in the original location.
20-200-8
2 1
P-36112
Remove the relief valve (Item 1), spring (Item 2) and spring seat (Item 3) [Figure 20-200-65]. Figure 20-200-66
1 2 2
P-36113
Remove the O-ring (Item 1) and seals (Item 2) [Figure 20-200-66] from the relief valve.
20-200-9
BOOM LOAD HOLDING VALVE (CONTD) Assembly Clean all components with solvent and dry with compressed air. Check all components for wear or damage. Replace as needed. Always use new O-rings, back-up rings and seals. Apply clean hydraulic oil to the components during assembly.
Figure 20-200-68
P-36112
IMPORTANT
I-2056-0793
Install the spring retainer (Item 1) spring (Item 2) [Figure 20-200-68] in the housing. Figure 20-200-69
1 Figure 20-200-67
2 1 1
P-36111
Install the relief valve (Item 1) [Figure 20-200-69].
P-36113
Install the seals (Item 1) and O-ring (Item 2) [Figure 20200-67] on the relief valve.
20-200-10
BOOM LOAD HOLDING VALVE (CONTD) Assembly (Contd) Figure 20-200-70
Figure 20-200-72
P-36109
P-36114
Install the seal (Item 1) [Figure 20-200-72] on the poppet. Figure 20-200-73
Install the O-ring (Item 1) [Figure 20-200-70] in the ported plug. Figure 20-200-71 1
P-36115
1 Install the O-ring (Item 1) [Figure 20-200-73] on the plug.

P-36110
Install the ported plug (Item 1) [Figure 20-200-71] in the port marked E.
20-200-11
Figure 20-200-76
P-36105
1
P-36108
Install the 2 fittings (Item 1) [Figure 20-200-76]. Figure 20-200-77
Install the poppet (Item 1) and plug (Item 2) in the port (Item 3) [Figure 20-200-74]. Figure 20-200-75
4 1 3
P-35997
Install the seal (Item 1) in the seal carriers (Item 2) [Figure 20-200-77].
P-36106
NOTE: Make sure the lips (Item 3) fit into the grooves (Item 4) [Figure 20-200-77] on the seal carrier. Install the O-ring (Item 1) [Figure 20-200-75] on the fittings.
20-200-12
Figure 20-200-80
1
P-35998
P-35996
NOTE: Make sure the lip (Item 1) on the seal carrier fits in the groove (Item 2) [Figure 20-200-80] of the fitting. Figure 20-200-81
Install the O-ring (Item 1) [Figure 20-200-78] on the bolts. Figure 20-200-79
1 2
1
P-36104
P-35994
Install the coupler (Item 1) [Figure 20-200-81] on the fitting.
Install the bolt (Item 1) and seal carrier (Item 2) [Figure 20-200-79] in the fittings.
20-200-13
Figure 20-200-84
P-36101
1
P-36103
Install the relief valve (Item 1) [Figure 20-200-84] in the housing. Figure 20-200-85
Install the fittings (Item 1) [Figure 20-200-82]. Figure 20-200-83
2 1 1
P-36100
P-36102
Install the cap (Item 1) [Figure 20-200-85] on the relief valve.
Install the O-ring (Item 1) and back-up ring (Item 2) [Figure 20-200-83] on the relief valve.
20-200-14
Figure 20-200-88
1 2 1 3
P-36096
P-36114
Install the poppet (Item 1), spring (Item 2) and washer (Item 3) into the port (Item 4) [Figure 20-200-88] in the housing. Figure 20-200-89
Install the O-ring (Item 1) [Figure 20-200-86] on the plugs. (Ported plug shown.) Figure 20-200-87
1 2 1
P-36097
P-36095
Install the bolt (Item 1) [Figure 20-200-89].
Install the 3 plugs (Item 1) and ported plug (Item 2) [Figure 20-200-87]. NOTE: Make sure the ported plug is installed in the port marked E.
20-200-15
Figure 20-200-92
1 1
P-36093
Install the back-up ring (Item 1) [Figure 20-200-92].

P-36115
Figure 20-200-93 Install the O-ring (Item 1) [Figure 20-200-90] on the plug. Figure 20-200-91 1 1
P-36092

P-36094
Install the plug (Item 1) [Figure 20-200-91] in the housing.
20-200-16
OIL TEMPERATURE REGULATOR Description The oil temperature regulator, when closed, diverts hydraulic oil from the oil cooler to the hydraulic tank. The regulator opens at 131 F (55 C) allowing oil to flow through the cooler then to tank. Removal And Installation Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Remove the air cleaner. (See AIR CLEANER on Page 60-30-1.)
Figure 20-210-1
1 2
P-33728
Remove the 2 tee fittings (Item 1) [Figure 20-210-1].
IMPORTANT
I-2003-0888
Remove the hose (Item 2) [Figure 20-210-1]. Remove the 2 bolts (Item 3) [Figure 20-210-1]. Installation: Tighten the bolts to 6-7 ft.-lb. (8-10 Nm) torque. Remove the valve.
20-210-1
20-210-2
AUXILIARY HYDRAULICS SELECTOR VALVE Removal And Installation
Remove the tubelines (Item 1) and hoses (Item 2) [Figure 20-220-2]. Figure 20-220-3
The procedure is the same for both right and left auxiliary hydraulic selector valves. The left side is shown. Place the bucket on the ground.
WARNING
Hydraulic fluid escaping under pressure can have sufficient force to enter a persons 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-36383
Remove the 2 bolts (Item 1) [Figure 20-220-3]. Stop the engine. With the engine off, and the key in the run position, move the control levers to relieve hydraulic pressure. Installation: Tighten the bolts to 29-37 ft.-lb. (40-50 Nm) torque. Remove the auxiliary hydraulics selector valve (Item 2) [Figure 20-220-3].
IMPORTANT
I-2056-0793
Mark the hoses and tubelines for correct installation. Figure 20-220-2 2 1
P-36381
20-220-1
20-220-2
HYDRAULIC PISTON PUMP DRIVE COUPLER Removal And Installation Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Remove the muffler. (See MUFFLER (S/N 522311001 & ABOVE) on Page 60-20-1 or See MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 60-21-1.) Figure 20-230-4
Figure 20-230-6
P-38128
Figure 20-230-7
P-35231
Loosen the clamp (Item 1) [Figure 20-230-4]. Rotate the clamp to provide clearance to the suction fitting bolts. Figure 20-230-5
P-38129
Remove the 2 pump mount bolts (Item 1) [Figure 20230-6] & [Figure 20-230-7] and washers. 1 Installation: Tighten the bolts to 125-140 ft.-lb. (170-190 Nm) torque. Slide the pump away from the engine.
1
P-35232
20-230-1
HYDRAULIC PISTON PUMP DRIVE COUPLER (CONTD) Removal And Installation (Contd) Figure 20-230-8
Figure 20-230-10
1 1 1 1 1
P-38133
Remove the eight bolts (Item 1) [Figure 20-230-10].

P-38132
Mark the flywheel cover to engine block (Item 1) [Figure 20-230-8] for ease of assembly. Figure 20-230-9
Installation: Apply a medium strength thread adhesive (Loctite 242) to the bolt threads. Tighten the bolts to 29-37 ft.-lb. (40-50 Nm) torque.
1 1
P-38130
Remove the 9 remaining bolts (Item 1) [Figure 20-2309]. Installation: Apply a medium strength thread adhesive (Loctite 242) to the bolt threads. Tighten the bolts to 29-37 ft.-lb. (40-50 Nm) torque. Remove the cover (Item 2) [Figure 20-230-9].
20-230-2
UNDERCARRIAGE BLADE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1 GREASE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOWER TRACK ROLLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1 30-70-3 30-70-2 30-70-1 30-60-1 30-60-5 30-60-2 30-60-1
UNDERCARRIAGE
TRACK DAMAGE IDENTIFICATION . . . . . . . . . . . . . . . . . . . 30-80-1 Abrasion Of Embedded Metals . . . . . . . . . . . . . . . . . . . . . 30-80-2 Abrasion Of The Track Roller Side . . . . . . . . . . . . . . . . . . 30-80-9 Cracks And Cuts On The Lug Side Rubber . . . . . . . . . . . . 30-80-8 Cracks On The Lug Side Rubber Due To Fatigue . . . . . . . 30-80-6 Cuts On The Edges Of Track Roller Side . . . . . . . . . . . . 30-80-10 Cuts On The Lug Side Rubber. . . . . . . . . . . . . . . . . . . . . . 30-80-5 Cutting Of Steel Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1 Lug Abrasion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-7 Separation Of Embedded Metals. . . . . . . . . . . . . . . . . . . . 30-80-3 Separation Of Embedded Metals Due To Corrosion . . . . . 30-80-4 TRACK FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 30-30-1 Drive Sprocket Removal And Installation. . . . . . . . . . . . . . 30-30-5 SPECIFICATIONS TRACK IDLER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber Track Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . Rubber Track Removal And Installation. . . . . . . . . . . . . . . Steel Track Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . Track Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Track Lug Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UPPER TRACK ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 30-40-5 30-40-2 30-40-1 30-20-1 30-20-2 30-20-6 30-20-3 30-20-4 30-20-1 30-50-1 30-50-4 30-50-2 30-50-1
30-01
30-02
BLADE Removal And Installation Lower the blade to the ground. Remove the blade cylinders. (See BLADE CYLINDER on Page 20-24-1.) Figure 30-10-1
Figure 30-10-3
1
P-33439
Remove the right pivot pin (Item 1) [Figure 30-10-3]. Figure 30-10-4
P-33437
Figure 30-10-2
1 1
P-33440
Place a hydraulic jack (Item 1) [Figure 30-10-4] under the left arm of the blade. Remove the pivot pin (Item 2) [Figure 30-10-4].
P-33438
Remove the right and left pivot pin retaining nut and bolt (Item 1) [Figure 30-10-1] & [Figure 30-10-2]. Installation: Tighten the bolts to 48-55 ft.-lb. (65-75 Nm) torque.
WARNING
W-2019-1285
30-10-1
BLADE (CONTD) Removal And Installation (Contd) Figure 30-10-5
P-33441
Lower the jack and remove the shims (Item 1) [Figure 30-10-5] from both sides on both of the blade arms. Figure 30-10-6
P-33442
Install a chain hoist (Item 1) [Figure 30-10-6] in the center of the blade crossmember. Lift and remove the blade.
30-10-2
TRACKS Track Lug Height Rubber Track The lug height of a new rubber track is 1.1406 inch (29,0 mm). Figure 30-20-1 Straight Edge
B-14489
To find the percentage of wear on an excavator track, measure the height of the lug by placing a straight edge across the top of three lugs and measure the distance from the base of the track to the bottom of the straight edge [Figure 30-20-1]. Divide this measurement by the new track height and multiply by 100. This will give the percentage of track lug left. Example: Lug height 0.9125 inch (23,18 mm) 0.9125 x 100 = 80 1.1406 80% of the track lug is remaining with 20% wear on the track lugs.
30-20-1
TRACKS (CONTD) Rubber Track Clearance NOTE: The wear of the pins and bushings on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension and maintain the correct tension. (See SERVICE SCHEDULE on Page 10-50-1 for the correct service interval) NOTE: On new excavators or on excavators with new rubber tracks installed, check and adjust as needed the rubber track clearance two to three times on the first day of operation. Raise one side of the machine (approximately four inches) using the boom and arm.
Figure 30-20-2
P-32889
Figure 30-20-3
P-32888
Raise the blade fully and install jack stands (Item 1) [Figure 30-20-2] & [Figure 30-20-3] under the blade and track frame. Lower the boom until all machine weight is on the jack stands. Stop the engine
WARNING
AVOID INJURY OR DEATH Keep fingers and hands out of pinch points when checking the track tension.
W-2142-0189
30-20-2
TRACKS (CONTD) Rubber Track Clearance (Contd) Figure 30-20-4
Steel Track Clearance NOTE: The wear of the pins and bushings on the undercarriage vary with the working conditions and the different types of soil conditions. It is necessary to inspect track tension and maintain the correct tension. (See SERVICE SCHEDULE on Page 10-50-1 for the correct service interval.). NOTE: On new excavators or on excavators with new steel tracks installed, check and adjust as needed the steel track clearance two to three times on the first day of operation. Park the excavator on a flat and level surface. Figure 30-20-6 1
P-32891
Figure 30-20-5
0.79 (20 mm)
Track Frame
Track Sag 0.787 (20 mm) 1 Track Roller
Track
B-14067
Measure the track sag at the third roller (Item 1) [Figure 30-20-4] from the front of the track frame. Do not get fingers in pinch points between the track and track roller. Use a bolt or dowel of the appropriate size to check the gap between the amount contact edge of the roller and the top edge of the track guide lug [Figure 30-20-5]. Rubber track clearance 0.787 inches (20 mm).
MS-1989
Put a straight edge (Item 1) on the top of the track surface between the rear sprocket and the top idler wheel. Measure between the top of the track and the bottom of the straight edge [Figure 30-20-6]. Steel track clearance 0.79 inches (20 mm).
WARNING
AVOID INJURY Keep fingers and hands out of pinch points when checking the track tension.
W-2142-0189
30-20-3
TRACKS (CONTD) Track Adjustment Figure 30-20-7
Figure 30-20-9
1 1 2
P-32893
P-32891
Install the track tensioning adapter (Item 1) [Figure 3020-9] on the end of a grease gun. Figure 30-20-10
Loosen the top bolt (Item 1) [Figure 30-20-7]. Remove the bottom bolt and washer (Item 2) [Figure 3020-7]. Pivot the cover out of the way. Figure 30-20-8 1
P-32894
Install the adapter (Item 1) [Figure 30-20-10] on the track tensioner. 1
P-32892
WARNING
W-2019-1285
Remove the grease fitting adapter (Item 1) [Figure 3020-8] from the end of a grease gun.
30-20-4
TRACKS (CONTD) Track Adjustment (Contd) Figure 30-20-11
Figure 30-20-13
1 2
P-32974
P-32896
To release track tension, loosen the tensioner (Item 1) [Figure 30-20-13]. Do not remove the tensioner. After track tension has been released, remove all grease from the tensioner area. Repeat the procedure for the other track.
Figure 30-20-12
1 2
P-32895
Add grease to the track tensioner until the track tension indicator (Item 1) [Figure 30-20-11] & [Figure 30-20-12] is flush with the cylinder edge (Item 2) [Figure 30-20-11] & [Figure 30-20-12].
30-20-5
TRACKS (CONTD) Rubber Track Removal And Installation Fully raise the blade. Figure 30-20-14 Put jack stands 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
Stop the engine and exit the excavator. Figure 30-20-16 1 1
1 2
P-40663
Use the boom and arm to lift the blade end of the machine and install jack stands (Item 1) [Figure 30-2014] under the blade. Figure 30-20-15
P-32891
Loosen the top bolt (Item 1) [Figure 30-20-16]. Remove the bottom bolt and washer (Item 2) [Figure 3020-16]. Pivot the cover out of the way.
1
P-40662
Swing the upperstructure 180 and use the boom and arm to lift the opposite end of the track frame and install jack stands (Item 1) [Figure 30-20-15] under the frame.
30-20-6
TRACKS (CONTD) Rubber Track Removal And Installation (Contd) Figure 30-20-17
Figure 30-20-19
P-40670
P-32974
Insert a second steel rod or pipe (Item 1) [Figure 30-2019], at a distance of two lugs, between the track and the idler wheel. Continue to turn the track until the first pipe contacts the track frame. Stop the engine. Figure 30-20-20
To release track tension, loosen the tensioner (Item 1) [Figure 30-20-17]. Do not remove the tensioner. After track tension has been released, remove all grease from the tensioner area. Start the engine. Slowly turn the track in the forward direction. Figure 30-20-18
P-40671
1 Insert a pry bar (Item 1) [Figure 30-20-20] between the track and the idler wheel and pry out on the track until the track slides off the idler wheel.
P-40669
Remove both steel rods.
Insert a steel rod or pipe (Item 1) [Figure 30-20-18] (approximately 1.750 inch [44.5 mm] diameter) between the track and track frame.
30-20-7
TRACKS (CONTD) Rubber Track Removal And Installation (Contd) Figure 30-20-21
P-40888
Pry the track off of the track frame [Figure 30-20-21]. To install the rubber track: Put the track over the rear drive sprocket lugs. Put the front of the track onto the front idler wheel. See Track Adjustment for adding grease to the grease spring and for checking track tension. (See Track Adjustment on Page 30-20-4)
30-20-8
TRACK FRAME Disassembly And Assembly Remove the track. (See Rubber Track Removal And Installation on Page 30-20-6.) Figure 30-30-1 1
WARNING
P-62574
AVOID INJURY OR DEATH Spring loaded components under pressure can cause serious injury or death. Do not disassemble the coil spring assembly.
W-2617-1004
Figure 30-30-3
P-40855
Slide the idler (Item 1) [Figure 30-30-1] towards the front of the track frame. Figure 30-30-2
1 2 1
P-40857
Raise the hoist and remove the idler assembly (Item 1) [Figure 30-30-3]. Assembly: Install the idler assembly with the track tension guide (Item 2) [Figure 30-30-3] towards the outside of the track frame. (See TRACK IDLER on Page 30-40-1.)
P-40856
Install a lifting chain (Item 1) [Figure 30-30-2] and hoist on the idler assembly. DO NOT DISASSEMBLE OR REPAIR THE COIL SPRING ASSEMBLY (Item 3) [Figure 30-30-3].
30-30-1
TRACK FRAME (CONTD) Disassembly And Assembly (Contd) Figure 30-30-4
Figure 30-30-6
1 2
P-40708
P-40858
Use wood blocks (Item 1) [Figure 30-30-6] to support the track. Figure 30-30-7
Remove the track tension fitting (Item 1) [Figure 30-304]. Remove the two bolts (Item 2) [Figure 30-30-4]. Installation: Tighten the bolts to 48-55 ft.-lb. (65-75 Nm) torque. Figure 30-30-5
2 1
1
P-40709
Remove the nut (Item 1) [Figure 30-30-7] and washer from both sides of the roller. Installation: Tighten the nut to 125-140 ft.-lb. (170-190 Nm) torque.
P-40859
Remove the roller (Item 2) [Figure 30-30-7]. See Upper Roller Disassembly And Assembly. (See UPPER TRACK ROLLER on Page 30-50-1.)
Remove the grease cylinder (Item 1) and plate (Item 2) [Figure 30-30-5]. See Grease Cylinder Disassembly And Assembly. (See GREASE CYLINDER on Page 30-70-1) NOTE: The track does not need to be removed to remove and install the top or bottom rollers. If the track is installed, lift and block the excavator and relieve track tension. (See Track Adjustment on Page 3020-4.)
30-30-2
TRACK FRAME (CONTD) Disassembly And Assembly (Contd) Figure 30-30-8
1
P-40692
Remove the four bolts (Item 1) [Figure 30-30-8]. Installation: Apply thread adhesive (Loctite 242) to the bolt threads. Tighten the bolts to 48-55 ft.-lbs (65-75 Nm) torque. Figure 30-30-9
P-40693
Remove the roller (Item 1) [Figure 30-30-9]. See Lower Roller Disassembly And Assembly. (See LOWER TRACK ROLLER on Page 30-60-1.)
30-30-3
TRACK FRAME (CONTD) Disassembly And Assembly (Contd) DO NOT DISASSEMBLE OR REPAIR THE COIL SPRING ASSEMBLY (Item 2) [Figure 30-30-10].
Figure 30-30-11
WARNING
3 2
P-15318
P-62574
Remove the seal (Item 1), back-up ring (Item 2) and Oring (Item 3) [Figure 30-30-11] from the cylinder.
W-2617-1004
Figure 30-30-10
P-15317
Remove the cylinder (Item 1) from the coil spring assembly (Item 2) [Figure 30-30-10].
30-30-4
TRACK FRAME (CONTD) Drive Sprocket Removal And Installation Remove the track. (See Rubber Track Removal And Installation on Page 30-20-6.) Figure 30-30-12
P-40959
Remove the sixteen bolts (Item 1) [Figure 30-30-12]. Installation: Apply thread adhesive (Loctite 242) to the bolt threads. Tighten the bolts to 177-203 ft.-lb. (240-275 Nm) torque. Figure 30-30-13
1
P-40956
Remove the drive sprocket (Item 1) [Figure 30-30-13].
30-30-5
30-30-6
TRACK IDLER Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Bolt Washer Track Tension Guide Recoil Spring Assembly Block Mount Roll Pin O-Ring Shaft O-Ring Seal Bushing Idler Wheel
3 1
5 1 2 7 6
2 10 11 10 5 6 7 12 10 11 10 8 9 8 11 13 12 11
MS1755
30-40-1
TRACK IDLER (CONTD) Disassembly Mark the recoil spring to idler for correct assembly. Figure 30-40-1
Figure 30-40-2
1 1
P-40861
Remove the recoil spring assembly (Item 1) [Figure 3040-2].

P-40860
Loosen the two bolts (Item 1) [Figure 30-40-1]. DO NOT DISASSEMBLE OR REPAIR THE COIL SPRING ASSEMBLY (ITEM 1) [Figure 30-40-2].
WARNING
W-2617-1004
WARNING
Figure 30-40-3 2 1 3
P-62574
W-2617-1004
1 3
P-40862
Remove the bolts and washers (Item 1) track tension guide (Item 2) and blocks (Item 3) [Figure 30-40-3].
30-40-2
TRACK IDLER (CONTD) Disassembly (Contd)
Figure 30-40-6
1 Figure 30-40-4
P-40865
P-40863
Remove the seal/O-ring assembly (Item 1) [Figure 3040-6] from both mounts. NOTE: The steel seals are a matched set. Always install the outer seal so it will run against the original inner seal. If replacing seals, always install a matched set. Figure 30-40-7
Apply moderate heat to the plug (Item 1) [Figure 30-404] to melt the thread adhesive and remove the plug. Drain the oil from the idler. Figure 30-40-5
2 1
P-40868 P-40864
Remove the roll pin (Item 1) and mount (Item 2) [Figure 30-40-5] from both sides of the idler.
Remove the seal/O-ring assembly (Item 1) [Figure 3040-7] from both sides of the idler. Remove the O-ring (Item 2) [Figure 30-40-7] from both ends of the shaft.
30-40-3
TRACK IDLER (CONTD) Disassembly (Contd) Figure 30-40-8
Figure 30-40-10
P-40867
P-40866
Remove the bushings (Item 1) [Figure 30-40-10] from both sides of the idler.
Remove the shaft (Item 1) [Figure 30-40-8]. Figure 30-40-9
1
P-40705
Remove the O-ring (Item 1) [Figure 30-40-9] from the seal.
30-40-4
TRACK IDLER (CONTD) Assembly
Figure 30-40-13 1
Clean all parts in solvent and dry with compressed air. The seal assemblies are a matched set and must be replaced in pairs. Figure 30-40-11
P-40754
Place the seal assembly in the installation tool (Item 1) [Figure 30-40-13]. The O-ring and seal ring assembly has to be lubricated with alcohol, so the O-ring will slip past the housing retaining ring and seal uniformly in the motor housing radius. Dip the seal assembly in a pan of alcohol. Install the bushings (Item 1) [Figure 30-40-11] in the idler. Figure 30-40-12 1 1 Figure 30-40-14
P-40867
P-40870 P-40705
Shake off the excess alcohol and install the seal assembly (Item 1) [Figure 30-40-14] in the mount. Install the O-ring (Item 1) [Figure 30-40-12] on the seal ring. Repeat this procedure all four seal assemblies. The O-ring and seal ring must be clean and free of any dust, oil film or foreign matter. NOTE: Inspect the seal ring for burrs before installing the O-ring. Install the O-ring making sure it is not twisted. To remove any twists, gently pull a section of the O-ring and let it snap back.
Use firm even pressure on the installation tool to pop the O-ring into the housing. Remove the installation tool.
TRACK IDLER (CONTD) Assembly (Contd) Figure 30-40-15
Figure 30-40-17
1
P-40872
Install the shaft (Item 1) [Figure 30-40-17] in the mount.

P-40871
Figure 30-40-18 The seal assembly stand off height must be equal and the O-ring must not be twisted [Figure 30-40-15]. Repeat the seal assembly installation for the second mount. Figure 30-40-16 1
1
P-40873
Install the roll pin (Item 1) [Figure 30-40-18].
P-40869
Install the O-ring (Item 1) [Figure 30-40-16] on the shaft.
30-40-6
Apply a light film of oil to both metal seal rings. NOTE: Do not get any oil on the rubber O-rings. Figure 30-40-21 1 1
P-40754
P-40875
Place the seal assembly (Item 1) [Figure 30-40-19] in the installation tool. The O-ring and seal ring assembly has to be lubricated with alcohol, so the O-ring will slip past the housing retaining ring and seal uniformly in the housing radius. Dip the O-ring and seal ring assembly in a pan of alcohol. Figure 30-40-20 1
Install the shaft/mount assembly (Item 1) [Figure 30-4021] in the idler. Figure 30-40-22
P-40754
Place the seal assembly (Item 1) [Figure 30-40-22] in the installation tool.
P-40874
The O-ring and seal ring assembly has to be lubricated with alcohol, so the O-ring will slip past the housing retaining ring and seal uniformly in the housing radius. Dip the O-ring and seal ring assembly in a pan of alcohol.
Shake off the excess alcohol and install the seal assembly (Item 1) [Figure 30-40-20] in the idler. Use firm even pressure on the installation tool to pop the O-ring into the housing. Remove the installation tool. The seal assembly stand off height must be equal and the O-ring must not be twisted.
30-40-7
Figure 30-40-25
P-40878

P-40876
Apply a light film of oil to both metal seal rings. Shake off the excess alcohol and install the seal ring assembly (Item 1) [Figure 30-40-23] in the idler. Use firm even pressure on the installation tool to pop the O-ring into the housing. 1 Remove the installation tool. Figure 30-40-24 NOTE: Do not get any oil on the rubber O-rings. Figure 30-40-26
P-40879
Install the mount (Item 1) [Figure 30-40-26] on the shaft.
P-40877
The seal assembly stand off height must be equal and the O-ring (Item 1) [Figure 30-40-24] must not be twisted.
30-40-8
TRACK IDLER (CONTD) Assembly (Contd) Figure 30-40-27 1
Figure 30-40-29
1 2
P-40863

P-40880
Figure 30-40-30 Press down on the mount (Item 1) and install the roll pin (Item 2) [Figure 30-40-27]. Figure 30-40-28 1 2 3
2 1 3
P-40862
Install the track tension guide (Item 1) [Figure 30-40-30] on the bolt and washer.
P-40881
Install the bolts and washers (Item 2) [Figure 30-40-30] through the recoil spring frame. Add 12 oz. (0.35 L) of 80 w/90 gear oil through the fill hole (Item 1) [Figure 30-40-28]. Apply thread adhesive (Loctite 242) to the threads of the plug. Install the spacer blocks (Item 3) [Figure 30-40-30] on the bolts. Install the recoil spring assembly on the idler mounts.
30-40-9
1
P-40860
Tighten the bolts (Item 1) [Figure 30-40-31] to 125-140 ft.-lb. (170-190 Nm) torque.
30-40-10
UPPER TRACK ROLLER Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9.
NUT WASHER SNAP RING SEAL COVER SEAL (TWO PIECE) SNAP RING BEARING ROLLER SHAFT
1 2 3 4 5 6 7 8
7 6 5 4 3 2 1
MS1757
30-50-1
UPPER TRACK ROLLER (CONTD) Disassembly Figure 30-50-1
Figure 30-50-3
P-40713
Remove the seal cover (Item 1) [Figure 30-50-3].

P-40711
Figure 30-50-4 Clamp the roller in a vise [Figure 30-50-1]. Figure 30-50-2 1 2
P-40714
P-40712
Clean any rust and corrosion from the end of the shaft (Item 1) [Figure 30-50-4] to ease removal of the inner seal.
30-50-2
UPPER TRACK ROLLER (CONTD) Disassembly (Contd) Figure 30-50-5
Figure 30-50-7
P-40739
Press the shaft (Item 1) [Figure 30-50-7] out of the roller.

P-40737
Figure 30-50-8 The roller is equipped with a two piece seal. Pry up on the outer seal (Item 1) until the inner seal (Item 2) [Figure 30-50-5] is separated from the outer seal. Remove both seals. Figure 30-50-6 1
P-40740
1 Press the shaft (Item 1) [Figure 30-50-8] off the shaft.
P-40738
Remove the snap ring (Item 1) [Figure 30-50-6]. Remove the roller from the vise and drain the oil. Turn the roller over and remove the external snap ring seal cover, inner and outer seal and internal snap ring.
30-50-3
UPPER TRACK ROLLER (CONTD) Disassembly (Contd) Figure 30-50-9
Assembly Clean all parts in solvent and dry with compressed air. Figure 30-50-10
P-40741
P-29463
Remove the bearing (Item 1) [Figure 30-50-9] from inside the roller.
Inspect the bearings (Item 1) and shaft (Item 2) [Figure 30-50-10] for wear or damage. Replace any worn parts. Figure 30-50-11
P-40743
Remove all paint and corrosion from the seal surface (Item 1) [Figure 30-50-11] on both sides of the roller.
30-50-4
UPPER TRACK ROLLER (CONTD) Assembly (Contd) Figure 30-50-12
Figure 30-50-14
P-40744
P-40745
Press the shaft/bearing assembly into the roller [Figure 30-50-14]. Figure 30-50-15
Apply assembly lube to both bearings (Item 1) [Figure 30-50-12]. Figure 30-50-13
P-40746
P-40742
Turn the roller over and press the bearing over the shaft and in to the roller [Figure 30-50-15].
Press the bearing (Item 1) [Figure 30-50-13] on the shaft.
30-50-5
Figure 30-50-18
P-40749
P-40747
Apply a small bead of high temperature silicone sealant around the OD (Item 1) [Figure 30-50-18] of the outer seal. Figure 30-50-19
Install the snap ring (Item 1) [Figure 30-50-16] on both sides of the roller. Figure 30-50-17
1 Install the outer seal (Item 1) [Figure 30-50-19].
P-40750
P-40748
Apply grease to the ID (Item 1) [Figure 30-50-17] of the outer seal.
30-50-6
Figure 30-50-22
P-40713
1 Install the seal cover (Item 1) [Figure 30-50-22].

P-40751
Figure 30-50-23 Apply a light coat of grease to the outside of the inner seal (Item 1) [Figure 30-50-20]. Figure 30-50-21 1 1
P-40712

P-40752
Turn the roller over and add 4 oz. (0.12 L) of 10W-30 oil to the assembly. Install the outer seal, inner seal, seal cover and external snap ring.
Install the inner seal (Item 1) [Figure 30-50-21]. NOTE: The inner seal must be fully seated in the outer seal to prevent any leaks.
30-50-7
30-50-8
LOWER TRACK ROLLER Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9.
ROLL PIN MOUNT O- RING SEAL BUSHING ROLLER PLUG O-RING SHAFT 1 2 7 5 4 4
3 6
3 4 1 4 5
3 8 9 8 2
MS1756
30-60-1
LOWER TRACK ROLLER (CONTD) Disassembly Figure 30-60-1
Figure 30-60-3
P-40696
1
P-40695
Remove the roll pin (Item 1) [Figure 30-60-3] from both sides of the roller. Figure 30-60-4
Figure 30-60-2
2 1
1
P-40697 P-40694
The track frame is equipped with four external guide rollers (Item 1) [Figure 30-60-1] and two internal guide rollers (Item 1) [Figure 30-60-2] per side. The disassembly procedure is shown on the internal guide roller. The procedure is the same for both rollers. Apply moderate heat to the plug (Item 2) [Figure 30-602] to melt the thread adhesive and remove the plug. Drain the oil from the roller.
Remove the mount (Item 1) [Figure 30-60-4] from both sides of the roller.
30-60-2
LOWER TRACK ROLLER (CONTD) Disassembly (Contd) Figure 30-60-5
Figure 30-60-7
1
P-40705
1
P-40706
Remove the O-ring (Item 1) [Figure 30-60-7] from all four seal assemblies. Figure 30-60-8
Remove the seal/O-ring assembly (Item 1) [Figure 3060-5] from both mounts. Figure 30-60-6 1
P-40701
P-40699
Remove the O-ring (Item 1) [Figure 30-60-8] from both ends of the shaft.
Remove the seal/O-ring assembly (Item 1) [Figure 3060-6] from both sides of the roller. NOTE: The steel seals are a matched set. Always install the outer seal so it will run against the original inner seal. If replacing seals, always install a matched set.
30-60-3
LOWER TRACK ROLLER (CONTD) Disassembly (Contd) Figure 30-60-9
P-40700
Remove the shaft (Item 1) [Figure 30-60-9]. Figure 30-60-10
P-40703
Remove the bushings (Item 1) [Figure 30-60-10] from both sides of the roller.
30-60-4
LOWER TRACK ROLLER (CONTD) Assembly Clean all parts in solvent and dry with compressed air. The seal assemblies are a matched set and must be replaced in pairs. Install the bushings (Item 1) [Figure 30-60-10 on Page 4] Figure 30-60-11 1
Figure 30-60-12 1
P-40754
Place the seal assembly in the installation tool (Item 1) [Figure 30-60-12]. The O-ring and seal ring assembly has to be lubricated with alcohol, so the O-ring will slip past the housing retaining ring and seal uniformly in the housing radius. Dip the seal assembly in a pan of alcohol.
P-40705
Figure 30-60-13
Install the O-ring (Item 1) [Figure 30-60-11] on the seal ring. Repeat this procedure all four seal assemblies. The O-ring and seal ring must be clean and free of any dust, oil film or foreign matter. NOTE: Inspect the seal ring for burrs before installing the O-ring. Install the O-ring making sure it is not twisted. To remove any twists, gently pull a section of the O-ring and let it snap back.
P-40755
Shake off the excess alcohol and install the seal assembly (Item 1) [Figure 30-60-13] in the mount. Use firm even pressure on the installation tool to pop the O-ring in to the mount. Remove the installation tool.
30-60-5
LOWER TRACK ROLLER (CONTD) Assembly (Contd) Figure 30-60-14
Figure 30-60-16
1
P-40759

P-40707
Figure 30-60-17 The seal assembly stand off height must be equal and the O-ring must not be twisted [Figure 30-60-14]. Repeat the seal assembly installation for the second mount. Figure 30-60-15
P-40760
Install the roll pin (Item 1) [Figure 30-60-17]. 1
P-40758
30-60-6
LOWER TRACK ROLLER (CONTD) Assembly (Contd) Figure 30-60-18 1
Figure 30-60-20
P-40757
P-40754
The seal assembly (Item 1) [Figure 30-60-20] stand off height must be equal and the O-ring must not be twisted.
Place the seal assembly (Item 1) [Figure 30-60-18] in the installation tool. The O-ring and seal ring assembly has to be lubricated with alcohol, so the O-ring will slip past the housing retaining ring and seal uniformly in the housing radius. Dip the O-ring and seal ring assembly in a pan of alcohol. Figure 30-60-19
P-40756
Shake off the excess alcohol and install the seal assembly (Item 1) [Figure 30-60-19] in the roller. Use firm even pressure on the installation tool to pop the O-ring into the motor housing. Remove the installation tool.
30-60-7
Figure 30-60-23
1 1
P-40763
Install the roller (Item 1) [Figure 30-60-23] over the shaft.

P-40761
Figure 30-60-24 Figure 30-60-22 1
P-40754 P-40762
Place the seal assembly in the installation tool (Item 1) [Figure 30-60-24]. Apply a light film of oil to both metal seal rings (Item 1) [Figure 30-60-21] & [Figure 30-60-22]. NOTE: Do not get any oil on the rubber O-rings. The O-ring and seal ring assembly has to be lubricated with alcohol, so the O-ring will slip past the housing retaining ring and seal uniformly in the housing radius. Dip the O-ring and seal ring assembly in a pan of alcohol.
30-60-8
Figure 30-60-27
1 1
P-40766

P-40764
Apply a light film of oil to both metal seals (Item 2) [Figure 30-60-27]. Shake off the excess alcohol and install the seal assembly (Item 1) [Figure 30-60-25] in the idler. Use firm even pressure on the installation tool to pop the O-ring into the roller. Remove the installation tool. Figure 30-60-26 1 NOTE: Do not get any oil on the rubber O-rings. Figure 30-60-28
P-40767

P-40765
The seal assembly stand off height must be equal and the O-ring (Item 1) [Figure 30-60-26] must not be twisted.
30-60-9
Figure 30-60-31
1 1 2
P-40694

P-40768
Press down on the mount (Item 1) and install the roll pin (Item 2) [Figure 30-60-29]. Add 13 oz. (.38L) 80W/90 gear oil to the internal guide rollers. Add 6 oz. (.18 L) 80/W90 gear oil to the external guide rollers. Figure 30-60-30
P-40769
Add the oil through the fill hole (Item 1) [Figure 30-6030]. Apply thread adhesive (Loctite 242) to the plug.
30-60-10
GREASE CYLINDER Parts Identification
1. 2. 3. 4. 5. 6. 7. 8.
ADJUSTER WASHER PLATE HOUSING SEAL SEAL BACK-UP RING CYLINDER
1 2 3 4 5 6 7 8
MS1759
30-70-1
GREASE CYLINDER (CONTD) Disassembly Figure 30-70-1
Figure 30-70-3
1 1 3
P-40885
P-40882
Remove the seal (Item 1) and backup ring (Item 2) [Figure 30-70-3]. Remove any corrosion or paint (Item 3) [Figure 30-70-3] from the end of the cylinder.
Install a brass drift through the track tensioner mount (Item 1) [Figure 30-70-1]. Tap the cylinder out of the housing. Figure 30-70-2
P-40883
30-70-2
GREASE CYLINDER (CONTD) Assembly Clean all parts in solvent and dry with compressed air. Figure 30-70-4
Figure 30-70-6
P-40887
1 Fully seat the cylinder (Item 1) [Figure 30-70-6]. Install the seal (Item 2) [Figure 30-70-6] into the seal bore of the housing.
P-40884
Install the back-up ring (Item 1) [Figure 30-70-4]. Install the seal (Item 2) [Figure 30-70-4]. Apply clean hydraulic fluid to the OD of the seal. Figure 30-70-5
P-40886
Install the cylinder (Item 1) [Figure 30-70-5] in the housing. Install the housing seal (Item 2) [Figure 30-70-5] over the cylinder.
30-70-3
30-70-4
TRACK DAMAGE IDENTIFICATION Cutting Of Steel Cords The following pages show photos and illustrations of track damage and the probable cause of the damage. It is intended to be used for identifying the reason for track damage and how to avoid future track damage. Damage: Figure 30-80-1
Causes Of The Damage: When applied to rubber tracks under the following circumstances, tension in excess of the breaking strength of the embedded steel cords causes steel cords to be cut: Figure 30-80-3
PI-13035
P-3864
When the rubber track is detracting, the idler or sprocket rides on the projections of the embedded metal [Figure 30-80-3]. 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. Prevention: The following preventions should be taken to minimize the risk of this damage:
Figure 30-80-2
Steel Cords
PI-13034
Periodical checking on site of the recommended track tension. (See TRACKS on Page 30-20-1.) Avoiding quick turns on bumpy and rocky fields. Drive carefully to avoid having stones and other articles clog the rubber tracks. Driving over sharp objects should be avoided. If this is impossible, do not make turns while driving over sharp objects.
Embedded steel cords are cut off [Figure 30-80-1] & [Figure 30-80-2]. Replacement: Replacement is required [Figure 30-80-1] & [Figure 3080-2].
30-80-1
TRACK DAMAGE IDENTIFICATION (CONTD) Abrasion Of Embedded Metals Damage: Figure 30-80-4
Causes Of The Damage: When the track rollers, sprockets and idler gears roll over the embedded metals, abrasion of embedded metals is 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 under a sandy field condition for a long time.
P-3865
In proportion to the service time, embedded metals will gradually wear away by friction [Figure 30-80-4]. Replacement: Figure 30-80-5
Abrasion
D1=0.67D
PI-13037
Replacement is required when the width of the embedded metals (D1) becomes 67% of their original width (D) [Figure 30-80-5].
30-80-2
TRACK DAMAGE IDENTIFICATION (CONTD) Separation Of Embedded Metals Damage: Figure 30-80-6
Figure 30-80-8
Guide
PI-13040
When a rubber track is detracted, it becomes stuck between the guide or the undercarriage frame, causing the separation of embedded metals [Figure 30-80-8].
P-4379
Figure 30-80-9 Extraordinary outer forces applied to embedded metals cause their separation from the rubber track's body [Figure 30-80-6]. Replacement: Even a partial separation of embedded metals requires 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: Figure 30-80-7
PI-13041
Abrasion
Abnormally worn sprockets as shown will pull embedded metals out [Figure 30-80-9]. Prevention: Idler Similar to the prevention against the cutting of the steel cords: Rubber Track Recommended track tension should be periodically checked. (See TRACKS 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 30-80-7].
30-80-3
TRACK DAMAGE IDENTIFICATION (CONTD) Separation Of Embedded Metals Due To Corrosion Damage: Figure 30-80-10
Causes Of The Damage: Figure 30-80-11 Embedded Metal
Good
Separation of Bonded Rubber Cover

PI-13043
P-4378
Due to corrosion of embedded metals, the adhesion to the rubber body deteriorates, resulting in complete separation [Figure 30-80-10]. Replacement: Even a partial separation of embedded metals requires a rubber track replacement.
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 30-80-11]. Excessively salty fields, like the sea shore. Strong acidic or alkali soil conditions 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. When the bonded rubber cover is separated from the embedded metal projections and the metals in the rubber body become loose, it is time to consider replacement of the rubber track.
30-80-4
TRACK DAMAGE IDENTIFICATION (CONTD) Cuts On The Lug Side Rubber Damage:
Causes Of The Damage: Figure 30-80-13
Cuts Figure 30-80-12
PI-13045
P-4377
Cuts on the lug side rubber often occurs as one of the most typical failure modes [Figure 30-80-12] Replacement: When a cut on the lug side rubber reaches the embedded steel cords, it should be immediately repaired with cold vulcanization rubber.
When rubber tracks drive over projections or sharp stones in the fields, the concentrated forces applied cause cuts on the lug side rubber surface. In case of making turns on projections, the lug side rubber surface will have an even higher chance to be cut. If the cuts run through the embedded steel cords, it might result in the steel cords' breakage due to their corrosion. It is highly recommended to repair the cuts with cold vulcanization rubber as soon as they are observed [Figure 30-80-13]. Prevention: 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.
30-80-5
TRACK DAMAGE IDENTIFICATION (CONTD) Cracks On The Lug Side Rubber Due To Fatigue Damage:
Replacement: When the cracks reach so deep that they expose the steel cords, track replacement is required. Causes Of The Damage:
Figure 30-80-14 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, external injuries on the lug side rubber sometimes cause more chance of cracking. Machine operators should observe soil conditions when driving, so as not to cause external injuries to the lug side rubber. In order to minimize the occurrence of ozone cracks, attention should be paid to the following instructions for maintenance: 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-4382
Figure 30-80-15
P-4380
Small cracks around the root of the lug as a result from operation fatigue [Figure 30-80-14] & [Figure 30-80-15].
30-80-6
TRACK DAMAGE IDENTIFICATION (CONTD) Lug Abrasion Prevention: Figure 30-80-16
Replacement: No replacement is required. 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: Making quick and repeated turns on concrete and asphalt roads
P-4381
Driving up and down hilly paths with slippage Figure 30-80-17 Making frequent turns on paths covered with rocks and wood Lug Abrasion
PI-13049
As its service time proceeds, the lug side inevitably undergoes abrasion [Figure 30-80-16] & [Figure 30-8017].
30-80-7
TRACK DAMAGE IDENTIFICATION (CONTD) Cracks And Cuts On The Lug Side Rubber Damage: Figure 30-80-18
Crack at the edge of embedded metal
Cut on lug side rubber
PI-13051
CD-13050
Sometimes cracks and cuts on the lug side rubber at the edges of the embedded metals can be observed [Figure 30-80-18]. Replacement: Basically, no replacement is required unless the cuts on the lug side rubber are discovered all around the edges of the embedded metals, as this will result in a complete cut off.
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 30-80-19]. 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.
30-80-8
TRACK DAMAGE IDENTIFICATION (CONTD) Abrasion Of The Track Roller Side Damage: Figure 30-80-20
Track Roller Abrasion
PI-13053
P-4383
The rubber surface on which track rollers run is gradually abraded. It will end in the exposure of the embedded metals [Figure 30-80-20]. Replacement: It is recommended to replace the rubber track when more than half of the embedded metals are completely exposed.
The abrasion of the track roller side rubber surface occurs because of sand and gravel being clogged between the rubber and the outside surface of the track rollers. The stress pushes the sand and gravel against the side of the rubber track to cause the abrasion [Figure 30-80-21]. The level of abrasion is highly dependent on terrain conditions. A higher level of abrasion will occur when the rubber tracks are operated in fields covered with many stones and gravel. Small stones hardened with mud, stuck to the track rollers increase the abrasion level. After 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.
30-80-9
TRACK DAMAGE IDENTIFICATION (CONTD) Cuts On The Edges Of Track Roller Side Damage:
Causes Of The Damage: This damage is caused by objects on the field or by interference with the machine frame. In case of damage by objects on the operating ground:
Figure 30-80-22 Figure 30-80-24
P-4384 PI-13056
Figure 30-80-23 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 the damage. Especially, when a machine drives over concrete ridges, this type of damage easily occurs [Figure 30-80-24].
Edge
Edge
PI-13055
Both edges of a rubber track have no special reinforcements. It sometimes occurs during operation that they are cut or torn off [Figure 30-80-22] & [Figure 30-80-23]. Replacement: In such case, the rubber track does not have to be replaced.
30-80-10
TRACK DAMAGE IDENTIFICATION (CONTD) Cuts On The Edges Of Track Roller Side (Contd) In case of damage by interference with the machine frame: Figure 30-80-25
Cut
Tear
PI-13057
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 30-80-25]. 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 retracking.
30-80-11
30-80-12
UPPERSTRUCTURE & SWING SECTION ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1 Bushing Removal And Installation . . . . . . . . . . . . . . . . . . 40-130-4 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-130-1 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1 Bushing Removal And Installation . . . . . . . . . . . . . . . . . . 40-120-8 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-120-1 BUCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-140-1 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 Cab Visor Removal And Installation . . . . . . . . . . . . . . . . 40-20-23 Door, Left Side, Right Side And Rear Window Installation 40-20-21 Door, Left Side, Right Side And Rear Window Removal . 40-20-20 Door Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-20-8 Front Window Disassembly And Assembly (S/N 522311001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-14 Front Window Gas Strut Removal And Installation . . . . . 40-20-17 Front Window Pivot Frame Removal And Installation . . . 40-20-18 Front Window Removal And Installation . . . . . . . . . . . . . . 40-20-9 Lower Front Widow Removal And Installation . . . . . . . . . 40-20-19 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 Top Window Removal And Installation. . . . . . . . . . . . . . . 40-20-24 CONTROL LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1 COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-170-1 ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 40-60-3 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1 FLOOR MAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-110-1 FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1 Continued On Next Page SPECIFICATIONS UPPERSTRUCTURE & SWING SECTION
40-01
UPPERSTRUCTURE & SWING SECTION (CONTD) LEFT CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Console Lockout Switch Removal And Installation . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1 40-50-8 40-50-6 40-50-1
REAR COVER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-150-1 RIGHT CONSOLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1 RIGHT SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-160-1 SEAT AND SEAT MOUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1 SWING FRAME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1 Bushing Removal And Installation . . . . . . . . . . . . . . . . . . 40-100-5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 40-100-1 UPPERSTRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 Swing Bearing Removal And Installation . . . . . . . . . . . . . . 40-10-6
40-02
UPPERSTRUCTURE Removal And Installation Build the service lifting brackets used to remove and install the upperstructure [Figure 40-10-1] & [Figure 40-10-2]. Figure 40-10-1 Lifting Bracket (two needed)
MS1570
Figure 40-10-2 Spreader Bar
MS1569
40-10-1
UPPERSTRUCTURE (CONTD) Removal And Installation (Contd) Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Drain the fuel tank. (See Draining The Fuel Tank on Page 10-80-8.) Remove the swing motor. (See SWING MOTOR on Page 20-90-1.) Remove the swivel joint. (See SWIVEL JOINT on Page 20-80-1.)
Mark the track frame to swing bearing (Item 1) [Figure 40-10-3]. Figure 40-10-4
1 Remove the arm. (See ARM on Page 40-130-1.) Remove the boom. (See BOOM on Page 40-120-1) Remove the cab. (See CAB on Page 40-20-1.) Remove the right side cover. (See RIGHT SIDE COVER on Page 40-160-1.) Remove the rear cover. (See REAR COVER on Page 40150-1.) Remove the seat. (See SEAT AND SEAT MOUNT on Page 40-30-1.) Remove the engine. (See ENGINE (S/N 522311001 & ABOVE) on Page 60-60-1 or See ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 60-61-1.) Remove the counterweight. (See COUNTERWEIGHT on Page 40-170-1.) Remove the air cleaner. (See AIR CLEANER on Page 60-30-1.) Figure 40-10-3
P-40236 P-40231
Remove the two bolts (Item 1) [Figure 40-10-4]. Remove the air cleaner mount (Item 2) [Figure 40-10-4]. Figure 40-10-5 2
Install the boom pivot pin (Item 1). Install a chain (Item 2) [Figure 40-10-5] on the pivot pin.
P-40242
40-10-2
UPPERSTRUCTURE (CONTD) Removal And Installation (Contd) Figure 40-10-6
Figure 40-10-8
2 1
P-40234
Install a lifting bracket (Item 1) on the left front cab mount. Install a chain (Item 2) [Figure 40-10-6] on the lifting bracket. Figure 40-10-7
P-40253
Position the spreader bar (Item 1) [Figure 40-10-8] as shown and attach the lifting chains to the bar. 1 2 NOTE: The chain hoist the spreader bar and lifting chains are attached to must have a swivel hook to allow the upperstructure to be turned.
P-40233
Apply a small amount of lifting pressure to the upperstructure with the chain hoist.
Install the rear lifting brackets (Item 1) using the counterweight bolt holes. Use two 20 mm x 64 mm MC grade 8.8 bolts (Item 2) [Figure 40-10-7] to install the brackets. Install the chains (Item 3) [Figure 40-10-7] to the lifting brackets.
40-10-3
Figure 40-10-11
P-40235
P-40240
Raise the upperstructure. Make sure the upperstructure is level as it is being raised [Figure 40-10-11]. Lower the upperstructure and adjust the lifting chains as needed to pull the upperstructure squarely off of the track frame. Figure 40-10-12
Remove the two bolts (Item 1) and washers. Remove the cover (Item 2) [Figure 40-10-9]. NOTE: The cover is located below the air cleaner mount. Figure 40-10-10
P-40237
P-40241
Remove the upperstructure [Figure 40-10-12]. Position the upperstructure on suitable support stands or blocks.
Remove the bolts (Item 1) [Figure 40-10-10]. Rotate the upperstructure by hand and continue removing the bolts. NOTE: The upperstructure is mounted to the track frame with 30 bolts.
40-10-4
Figure 40-10-15
1 2.0 (51 mm) 3.750 (95 mm)
P-40248
B-13678
Install the bolts (Item 1) [Figure 40-10-15] until the bolt is 2.0 inches (51 mm) above the track frame. Lower the upperstructure on to the track frame.
Make four alignment pins by using 16 mm x 100 mm long MC bolts. Cut the head off of the bolts at 3.750 inches (95 mm), then taper the end [Figure 40-10-13]. Cut a slot (Item 1) [Figure 40-10-13] in the end of the bolts so the bolts can be removed with a flat blade screwdriver. Figure 40-10-14
Figure 40-10-16
1 1 1
P-40241
Install the bolts (Item 1) [Figure 40-10-16]. Do not tighten the bolts at this time. Turn the upperstructure by hand and continue installing the bolts. Remove the alignment pins as the bolts are installed. After all thirty bolts have been installed, tighten the bolts to 206 ft.-lb. (279 Nm) torque.
P-40247
Install the bolts (Item 1) [Figure 40-10-14] approximately 90 apart in the track frame.
40-10-5
UPPERSTRUCTURE (CONTD) Swing Bearing Removal And Installation Figure 40-10-17
Figure 40-10-19 1 1 1
P-40249
P-40251
Mark and remove three bolts (Item 1) [Figure 40-10-18] & [Figure 40-10-19] from the front and rear of the swing bearing. NOTE: The swing bearing is installed with twenty seven bolts that are 70 mm in length and three bolts that are 80 mm in length.
Mark the swing bearing to upperstructure (Item 1) [Figure 40-10-17]. Figure 40-10-18
P-40250
40-10-6
UPPERSTRUCTURE (CONTD) Swing Bearing Removal And Installation (Contd) Figure 40-10-20
P-40252
Support the swing bearing with a jack and remove the bolts (Item 1) [Figure 40-10-20]. Installation: Tighten the bolts to 240 ft.-lb. (325 Nm) torque. Lower the swing bearing away from the upperstructure. Figure 40-10-21 FRONT OF MACHINE
OUTER RACE SOFT ZONE IS AT THE FILLER PLUG INNER RACE SOFT ZONE IS IDENTIFIED BY A LETTER S STAMPED ON RING
PI-13677A
If a new swing bearing is being installed, locate the soft zone area [Figure 40-10-21]. Install the swing bearing so that the soft zone is positioned to the left hand side of the excavator. NOTE: DO NOT locate the soft zone to the front or rear of excavator.
40-10-7
40-10-8
CAB Removal And Installation Build the service lifting brackets used to remove and install the cab [Figure 40-20-1] & [Figure 40-20-2]. Figure 40-20-1
Cab Bracket (two needed)
1.0 (25 mm) 1.250 (32 mm)

O 0.750 (19 mm) O 1.0 (25 mm)
O 0.750 (19 mm)
Material: 2 X 2-0.187 inch wall hot rolled angle iron
1.250 (32 mm)

MS1371
Figure 40-20-2
Spreader Bar (one needed)
Material: 1.50 X 1.50-0.187 inch wall hot rolled angle iron

MS1372
40-20-1
CAB (CONTD) Removal And Installation (Contd) Figure 40-20-3
Figure 40-20-5
1
P-32701
Remove the floor mat (Item 1) [Figure 40-20-5].

P-33538
Excavators S/N 522311001 & Above use [Figure 40-206], [Figure 40-20-7] and [Figure 40-20-8] Install the brackets (Item 1) [Figure 40-20-3] on the cab. Figure 40-20-6 Use four grade 10.9 bolts (Item 2) [Figure 40-20-3] to fasten the brackets to the cab. Figure 40-20-4 1 1 2 2 1 1
P-33790
P-33537
Remove the five screws (Item 1) and right console front cover (Item 2) [Figure 40-20-6].
Install the lifting chain (Item 1) and spreader bar (Item 2) [Figure 40-20-4].
40-20-2
Figure 40-20-9
1 1 1
P-33029
2
P-33791
Remove the two bolts (Item 1) [Figure 40-20-9] and washers from the right arm rest. Remove the arm rest. Figure 40-20-10
Remove the three screws (Item 1) and remove the cover (Item 2) [Figure 40-20-7]. Figure 40-20-8 1
1 2 1 1
P-61833
P-33792
Remove the six screws (Item 1) and cover (Item 2) [Figure 40-20-10].
Disconnect the cab wire harness (Item 1) [Figure 40-208] from the fuse panel. Pull the harness out of the right console.
40-20-3
Figure 40-20-13
1 1
P-33030
Figure 40-20-14
P-61832
Remove the foam (Item 1) [Figure 40-20-11]. Figure 40-20-12 1
P-33031
Remove the two storage compartment bolts (Item 1) [Figure 40-20-13] & [Figure 40-20-14] and washers. Remove the storage compartment. (If equipped)
P-61831
Remove the tubes (Item 1) from the back of the heater unit (Item 2) [Figure 40-20-12].
40-20-4
Figure 40-20-17
1 1
P-33037
Figure 40-20-18
P-61454
Excavators S/N 528911001 & Above & S/N 528611001 & Above only: Disconnect the wire harness (Item 1) [Figure 40-20-15]. Figure 40-20-16
1
P-35013
Remove the rear cab mount nuts (Item 1) [Figure 40-2017] & [Figure 40-20-18] and washers. Installation: Tighten the nuts to 81-92 ft.-lb. (110-125 Nm) torque.
P-61488
Remove the ground cable (Item 1) [Figure 40-20-16].
40-20-5
CAB (CONTD) Removal And Installation (Contd) Figure 40-20-19 2
Figure 40-20-20
1 1 1
P-35015
Figure 40-20-21
P-33042
Excavators S/N 522311001 & Above Only: Remove the eleven bolts (Item 1) and washers. Remove the bottom cover (Item 2) [Figure 40-20-19]. 1 Installation: Tighten the bolts to 18-19 ft.-lb. (110-125 Nm) torque.
P-35014
Remove the front cab mount bolts (Item 1) [Figure 4020-20] & [Figure 40-20-21] washers and nuts. Installation: Tighten the bolts to 81-92 ft.-lb. (110-125 Nm) torque.
40-20-6
Figure 40-20-24
P-33793
Figure 40-20-23
P-33795
Install a chain hoist and remove the cab [Figure 40-2024]. 1 NOTE: Use a chain hoist of sufficient capacity.
P-33794
Remove the side cab mount bolts (Item 1) [Figure 40-2022] & [Figure 40-20-23]. Installation: Tighten the bolts to 48-55 ft.-lb. (65-75 Nm) torque.
40-20-7
CAB (CONTD) Door Removal And Installation Figure 40-20-25
Figure 40-20-27
2 1
P-36819
P-36829
Installation: The tab (Item 1) must fit in the slot (Item 2) [Figure 40-20-27] of the hinge.
Remove the roll pin (Item 1) [Figure 40-20-25] from the top and bottom door hinge pin. Figure 40-20-26
P-36824
Have an assistant support the door and remove top and bottom door hinge pin (Item 1) [Figure 40-20-26]. Remove the door.
40-20-8
CAB (CONTD) Front Window Removal And Installation Figure 40-20-28
Figure 40-20-30
2 1
P-40734
P-40674
Use a small blade screw driver to depress the wire terminal tabs (Item 1) [Figure 40-20-30]. Remove the individual wires from the back of the electrical connector. Figure 40-20-31
Remove the two screws (Item 1) and wiper motor cover (Item 2) [Figure 40-20-28]. Figure 40-20-29
P-40735 P-40736
Disconnect the electrical connector (Item 1) [Figure 4020-29]. Mark the wires for correct installation.
Remove the wire terminals (Item 1) [Figure 40-20-31] from the wires. Installation: Install new wire terminals on the wires.
40-20-9
CAB (CONTD) Front Window Removal And Installation (Contd) Figure 40-20-32
Figure 40-20-34
2 2 1 1 3
P-40679
Figure 40-20-35
P-40676
Wrap a wire (Item 1) securely around the electrical harness wires (Item 2) [Figure 40-20-32]. 2 Figure 40-20-33 3 1 1
P-40681
Position the wires (Item 1) in the bottom hole (Item 2) [Figure 40-20-34] and pull the wire harness up and through the upper hole (Item 1) [Figure 40-20-35].
P-40678
Wrap the wires with electrical tape (Item 1) [Figure 4020-33].
NOTE: Do not remove the wire (Item 3) [Figure 40-2034] and [Figure 40-20-35] from the upper or lower holes. The wire will be used to reinstall the wire harness. Remove the electrical tape (Item 2) [Figure 40-20-35].
40-20-10
Figure 40-20-38
2 1 1
P-40685
P-40682
Remove the caps (Item 1) from the pivot bolts (Item 2) [Figure 40-20-38]. (Both Sides) Figure 40-20-39
Remove the wire (Item 1) from the wire harness (Item 2) [Figure 40-20-36]. Figure 40-20-37
1 4
2 3 1
P-40687
P-40683
With the help of a second person, support the lift arms (Item 1) and remove the lock nut (Item 2) washers (Item 3) and bolt (Item 4) [Figure 40-20-39]. (Both Sides)
Make sure the front window latches (Item 1) [Figure 4020-37] are in the latched position. (Both Sides)
40-20-11
Figure 40-20-42
P-40684
P-40690
Support the front window and turn the latches (Item 1) [Figure 40-20-42] to the unlatched position. (Both Sides)
Remove the bushing (Item 1) [Figure 40-20-40]. (Both Sides) Figure 40-20-41
P-40688
Carefully raise the lift arms to the fully raised position [Figure 40-20-41].
40-20-12
P-40691
Figure 40-20-44
3 1
P-40733
With the help of a second person, raise and tilt the window [Figure 40-20-43] until the groove (Item 1) in the guide (Item 2) is disengaged from the track (Item 3) [Figure 40-20-44] on the cab frame. (Both sides) Installation: Align the groove in the guide with the track. Remove the front window.
40-20-13
CAB (CONTD) Front Window Disassembly And Assembly (S/N 522311001 & Above) Remove the front window. (See Front Window Removal And Installation on Page 40-20-9)
Figure 40-20-47
1 Figure 40-20-45
P-40724
Remove the cap (Item 1) [Figure 40-20-47] from the window latch pivot bolt. (Both Sides) 1 Figure 40-20-48
P-40722
Remove the guide (Item 1) [Figure 40-20-45]. (Both Sides) Figure 40-20-46
1
P-40725
Loosen the lock nut (Item 1) [Figure 40-20-48]. (Both Sides)
2
P-40723
Remove the two screws (Item 1) from the visor (Item 2) [Figure 40-20-46]. Remove the visor.
40-20-14
CAB (CONTD) Front Window Disassembly And Assembly (S/N 522311001 & Above) (Contd) Figure 40-20-49
Figure 40-20-51
3 4
P-40728
2
P-40726
Remove the rubber cord (Item 1) [Figure 40-20-51]. Installation: Install the rubber cord with the rounded side facing out. Do not stretch or cut the rubber cord during installation. The cord will shrink to its original length leaving a gap. Figure 40-20-52
Remove the lock nut (Item 1), wave washers (Item 2) latch (Item 3), and washer (Item 4) [Figure 40-20-49] (Both Sides) Figure 40-20-50
1 1
P-40730 P-40727
Remove the window (Item 1) [Figure 40-20-52]. Locate the end of the rubber cord (Item 1) [Figure 40-2050].
40-20-15
CAB (CONTD) Front Window Disassembly And Assembly (S/N 522311001 & Above) (Contd) Figure 40-20-53
P-40731
Remove the rubber seal (Item 1) [Figure 40-20-53]. Installation: Install the rubber seal with the groove for the rubber cord to the outside of the frame. Apply window cleaner as a lubricant to the rubber seal for ease of installation. Figure 40-20-54
P-40732
Remove the grommet (Item 1) [Figure 40-20-54] from the window.
40-20-16
CAB (CONTD) Front Window Gas Strut Removal And Installation Remove the front window. (See Front Window Removal And Installation on Page 40-20-9.) Figure 40-20-55
Figure 40-20-57
P-40718
1 2 Pivot the retainer (Item 1) away from the gas strut (Item 2) [Figure 40-20-57]. (Both Sides) Figure 40-20-58
P-40716
Pivot the retainer (Item 1) away from the gas strut (Item 2) [Figure 40-20-55]. (Both Sides) Figure 40-20-56
1 2
2 1
P-40719
Remove the retainer (Item 1) [Figure 40-20-58]. (Both Sides) Remove the gas struts (Item 2) [Figure 40-20-58]. (Both Sides)
P-40717
Support the pivot frame (Item 1) and remove the retainer (Item 2) [Figure 40-20-56]. (Both Sides)
40-20-17
CAB (CONTD) Front Window Pivot Frame Removal And Installation Remove the front window. (See Front Window Removal And Installation on Page 40-20-9.) Remove the front window gas struts. (See Front Window Gas Strut Removal And Installation on Page 40-20-17.) Figure 40-20-59
P-40720
Figure 40-20-60
P-40721
Remove the tie straps (Item 1) [Figure 40-20-59] and [Figure 40-20-60]. Remove the bolts (Item 2) [Figure 40-20-60]. (Both Sides) Remove the frame.
40-20-18
CAB (CONTD) Lower Front Widow Removal And Installation Raise the front window. Figure 40-20-61
Figure 40-20-63
1
P-40805
Remove the pad (Item 1) and washer (Item 2) [Figure 40-20-63].

P-40802
Remove the rubber seal (Item 1) [Figure 40-20-61]. Figure 40-20-62
P-40803
Lift the window from the channel (Item 1) [Figure 40-2062]. Remove the window.
40-20-19
CAB (CONTD) Door, Left Side, Right Side And Rear Window Removal The procedure is the same for all the windows. The lower door window is shown. Figure 40-20-64
Figure 40-20-66 1
P-40808
Remove the rubber seal (Item 1) [Figure 40-20-66] from the window.
P-40807
Loosen the adhesive on the corners of the rubber seal (Item 1) [Figure 40-20-64]. Figure 40-20-65
P-40812
With the aid of a second person, support the window and bend the inner lip of the rubber seal (Item 1) [Figure 4020-65] away from the frame and press the window and seal out.
40-20-20
CAB (CONTD) Door, Left Side, Right Side And Rear Window Installation The procedure is the same for all the windows. The lower door window is shown. Figure 40-20-67 2
Figure 40-20-69
P-40812
1 With the aid of a second person, place the window in the frame [Figure 40-20-69]. Figure 40-20-70
P-40808
Install the window (Item 1) in the rubber seal (Item 2) [Figure 40-20-67]. Figure 40-20-68
P-40814
2 1
P-40811
Pull the cord (Item 1) bending the rubber seal (Item 2) [Figure 40-20-70] in past the window frame until all sides of the rubber seal are installed.
Install a cord (Item 1) in the groove (Item 2) [Figure 4020-68] around the rubber seal.
40-20-21
CAB (CONTD) Door, Left Side, Right Side And Rear Window Installation (Contd) Figure 40-20-71
1 1
P-40807
Clean and dry the corners of the window (Item 1) [Figure 40-20-71]. Apply urethane adhesive (P/N 6808882) to the corners. NOTE: The urethane adhesive has a four hour initial cure time and will achieve full strength after twenty four hours at 72 F (22 C) and fifty percent humidity. The cure time will be longer with lower temperatures and/or lower humidity.
40-20-22
CAB (CONTD) Cab Visor Removal And Installation Figure 40-20-72
1 1
P-40955
Remove the caps (Item 1) [Figure 40-20-72] from the bolts. Figure 40-20-73
2 1
P-40953
Remove the five bolts (Item 1) nuts and washers. Remove the urethane adhesive (Item 2) [Figure 40-2073] and remove the cab visor. Installation: Clean and dry the surface. Apply urethane adhesive (P/N 6808882). NOTE: The urethane adhesive has a four hour initial cure time and will achieve full strength after twenty four hours at 72 F (22 C) and fifty percent humidity. The cure time will be longer with lower temperatures and/or lower humidity.
40-20-23
CAB (CONTD) Top Window Removal And Installation Figure 40-20-74
P-40954
Remove the urethane adhesive (Item 1) [Figure 40-2074] around the outside diameter of the window. Remove the window. Installation: Clean and dry the surface around the window opening. Apply urethane adhesive (P/N 6808882). NOTE: The urethane adhesive has a four hour initial cure time and will achieve full strength after twenty four hours at 72 F (22 C) and fifty percent humidity. The cure time will be longer with lower temperatures and/or lower humidity.
40-20-24
SEAT AND SEAT MOUNT Removal And Installation Figure 40-30-1
Figure 40-30-3
P-36822
1
P-36820
Remove the four bolts (Item 1) [Figure 40-30-2] & [Figure 40-30-3] and washers from the seat mount.
Pull the slide handle (Item 1) [Figure 40-30-1] up and slide the seat forward, off of the seat rails. Figure 40-30-2
P-36821
40-30-1
SEAT AND SEAT MOUNT (CONTD) Removal And Installation (Contd) Figure 40-30-4
P-36823
Remove the four bolts (Item 1) and washers. Remove the bottom of the seat (Item 2) [Figure 40-30-4] from the seat mount.
40-30-2
RIGHT CONSOLE Description The right console is a welded on component of the floor pan and is not removable. See instrument panel removal and installation. (See INSTRUMENT PANEL on Page 50-100-1.)
40-40-1
40-40-2
LEFT CONSOLE Removal And Installation The cab must be removed or raised approximately 24 (610 mm) to remove the left console. (See CAB on Page 40-20-1.) Figure 40-50-5
Figure 40-50-7
2
P-61458
Lower the console and remove the two screws (Item 1). Remove the cover (Item 2) [Figure 40-50-7]. 1 1
P-61456
Figure 40-50-8
Install blocks (Item 1) [Figure 40-50-5] to support the cab if the cab is not removed. Figure 40-50-6 1
1 1
P-61459
1 1
P-61457
Remove the six hoses (Item 1) [Figure 40-50-8] from the joystick. NOTE: Mark the hoses for correct installation.
Remove the five screws (Item 1) [Figure 40-50-6].
40-50-1
LEFT CONSOLE (CONTD) Removal And Installation (Contd) Figure 40-50-9
Figure 40-50-11
1 1
P-61462

P-61460
Figure 40-50-12 Disconnect the three wire harnesses (Item 1) [Figure 4050-9]. Figure 40-50-10
1 1
P-61463
Remove the dust boots (Item 1) [Figure 40-50-12] from the battery disconnect switch.
P-61461
40-50-2
Figure 40-50-15
1 1 1
P-61466
P-61464
Remove the screw (Item 1) and lift the bracket (Item 2) [Figure 40-50-15] from the console. Figure 40-50-16
Mark and remove the battery cables (Item 1) [Figure 4050-13] from the battery disconnect switch. Figure 40-50-14
P-61467
P-61465
Remove the cable housing (Item 1) [Figure 40-50-16] from the bracket.
Remove the cables, wire harnesses and hoses (Item 1) [Figure 40-50-14] from the console.
40-50-3
Figure 40-50-19
1 2
1
P-61471
P-61468
Remove the bolt (Item 1) [Figure 40-50-19] and washer from the gas strut. Lower the console.
Remove the control cable wire (Item 1) [Figure 40-5017] from the bracket. Remove the control cable (Item 2) [Figure 40-50-17] from the console. Figure 40-50-18
Figure 40-50-20
P-61472
Remove the bolt (Item 1) [Figure 40-50-20] and washers.

P-61470
Disconnect the wire harness (Item 1) [Figure 40-50-18] from the console switch. Raise and support the console.
40-50-4
P-61473
Remove the console [Figure 40-50-21].
40-50-5
LEFT CONSOLE (CONTD) Disassembly And Assembly Figure 40-50-22
Figure 40-50-24
2
P-61476
1 Raise the dust boot (Item 1) [Figure 40-50-24].

P-61474
Figure 40-50-25 Remove the two bolts (Item 1) and remove the arm rest (Item 2) [Figure 40-50-22]. Figure 40-50-23 1 2 1 2 3 2
P-61477
1 Remove the four bolts (Item 1), four washers (Item 2) and four nylon washers (Item 3) [Figure 40-50-25].
P-61475
Remove the two bolts (Item 1) and washers from the handle (Item 2) [Figure 40-50-23]. Remove the handle.
40-50-6
LEFT CONSOLE (CONTD) Disassembly And Assembly (Contd) Figure 40-50-26
Figure 40-50-28
1 2 1
P-61480
Remove the switch (Item 1) [Figure 40-50-28].

P-61478
Figure 40-50-29 Remove the key (Item 1) and dust cover (Item 2) [Figure 40-50-26] from the battery disconnect. Figure 40-50-27
2 1 1 2 1
P-61481
Remove the bolt (Item 1), washer, and nut from the gas strut (Item 2) [Figure 40-50-29].
P-61479
Remove the gas strut. Remove the two screws (Item 1) from the battery disconnect (Item 2) [Figure 40-50-27]. Remove the battery disconnect.
40-50-7
LEFT CONSOLE (CONTD) Disassembly And Assembly (Contd) Figure 40-50-30
Console Lockout Switch Removal And Installation The cab is shown removed for photo clarity. Figure 40-50-32
1 1
P-61482
P-61485
Remove the nut (Item 1) from the bumper (Item 2) [Figure 40-50-30]. Remove the bumper. Figure 40-50-31
Disconnect the wire harness (Item 1) [Figure 40-50-32]. Figure 40-50-33
1 2 1
P-61486
P-61483
Remove the nut (Item 1) from the console switch (Item 2) [Figure 40-50-33]. Remove the console lockout switch.
Remove the bushing (Item 1) [Figure 40-50-31] from both sides of the console.
40-50-8
ENGINE SPEED CONTROL Removal And Installation Open the right side cover. Figure 40-60-1
Figure 40-60-3
1 2
P-63445
1 Remove the 4 screws (Item 1) and cover (Item 2) [Figure 40-60-3].

P-63474
2 3
Figure 40-60-4
Remove the nut (Item 1). Loosen the nut (Item 2) [Figure 40-60-1]. Remove all tie straps from the speed control cable (Item 3) [Figure 40-60-1]. Figure 40-60-2
1 1 1
P-63447
Remove the 3 bolts and nuts (Item 1), knob (Item 2) and plate (Item 3) [Figure 40-60-4].
P-63444
Remove the 4 screws (Item 1) [Figure 40-60-2].
40-60-1
ENGINE SPEED CONTROL (CONTD) Removal And Installation (Contd) Figure 40-60-5
P-63473
Remove the engine speed control (Item 1) [Figure 4060-5].
40-60-2
ENGINE SPEED CONTROL (CONTD) Disassembly And Assembly Figure 40-60-6
Figure 40-60-8
P-63478

P-63476
Figure 40-60-9 Remove the cap (Item 1) [Figure 40-60-6]. Figure 40-60-7
P-63479
Remove the handle assembly (Item 1) [Figure 40-60-9].

P-63477
Remove the nut and bolt (Item 1) [Figure 40-60-7].
40-60-3
ENGINE SPEED CONTROL (CONTD) Disassembly And Assembly (Contd) Figure 40-60-10
2
P-63480
Remove the retainer (Item 1) [Figure 40-60-10]. Assembly: Install the retainer (Item 1) over the cable (Item 2). Seat the retainer in the notch (Item 3) [Figure 40-60-10].
40-60-4
CONTROL LEVERS Description The travel (See TRAVEL LEVER/FOOT PEDAL VALVE on Page 20-112-1), boom offset (See BOOM OFFSET VALVE on Page 20-190-1) and blade control levers (See BLADE VALVE on Page 20-180-1) are removed with the respective valve.
40-70-1
40-70-2
FUEL TANK Removal And Installation Drain the fuel tank. (See Draining The Fuel Tank on Page 10-80-8.) Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Remove the right side cover. (See RIGHT SIDE COVER on Page 40-160-1.) Remove the rear cover. (See REAR COVER on Page 40150-1.) Figure 40-80-1
Figure 40-80-3
1 1
2
P-38627
Remove the two bolts (Item 1) [Figure 40-80-3] and washers from the side of the center panel. 1 Remove the panel (Item 2) [Figure 40-80-3]. Figure 40-80-4 1
P-38628
Figure 40-80-2
P-40145
1 Remove the bolt (Item 1) [Figure 40-80-4] and washer from the electrical connector mount bracket. Remove the mount bracket.
P-38629
Remove the two bolts (Item1) [Figure 40-80-1] and [Figure 40-80-2] and washers from the top of the center panel.
40-80-1
FUEL TANK (CONTD) Removal And Installation (Contd) Figure 40-80-5
Figure 40-80-7
1
P-40148
P-40146
Remove the two bolts (Item 1) [Figure 40-80-7] and washers from both rear legs of the support bracket. Remove the support bracket.
Remove the two bolts (Item 1) [Figure 40-80-5] and washers from the front leg of the support bracket. Figure 40-80-6
Figure 40-80-8
1 1 1 2
P-40150 P-40147
Mark and disconnect the wires (Item 1) [Figure 40-80-8] from the sending unit. Remove the bolt (Item 1) [Figure 40-80-6] and washer from the front of the support bracket. Remove the tie strap (Item 2) [Figure 40-80-8].
40-80-2
FUEL TANK (CONTD) Removal And Installation (Contd) Figure 40-80-9
Figure 40-80-11
2 1
P-40153
P-40151
Install a hoist (Item 1) using the threaded holes (Item 2) [Figure 40-80-11]. Figure 40-80-12
Mark and remove the hoses (Item 1) [Figure 40-80-9]. Install caps and plugs. Figure 40-80-10 1 1
P-40154
1
P-40152
Remove the two bolts (Item 1) [Figure 40-80-12] and washers from the bottom of the fuel tank. Raise the hoist and remove the fuel tank.
Remove the bolt (Item 1) [Figure 40-80-10] and washer from the mount bracket.
40-80-3
40-80-4
HORN Removal And Installation Figure 40-90-1
P-40465
Access to the horn is through the front of the upperstructure, behind the boom offset cylinder [Figure 40-90-1]. Figure 40-90-2 1 3
P-40466
Cut and remove the tie straps (Item 1) [Figure 40-90-2]. Remove the wires (Item 2) [Figure 40-90-2]. Remove the bolt (Item 3) [Figure 40-90-2], washer and nut. Remove the horn.
40-90-1
40-90-2
SWING FRAME Removal And Installation Remove the bucket. (See BUCKET on Page 40-140-1.) Remove the arm. (See ARM on Page 40-130-1.) Remove the boom. (See BOOM on Page 40-120-1.) Figure 40-100-1
Figure 40-100-3
P-33701
Remove the pin (Item 1) [Figure 40-100-3]. Figure 40-100-4
P-33699
Remove the bolt (Item 1) [Figure 40-100-1] and washer. Figure 40-100-2 2
P-38468
Remove the two return to tank hose bracket bolts (Item 1) [Figure 40-100-4]. Reposition the return to tank hose (Item 2) [Figure 40100-4].
P-33700
40-100-1
SWING FRAME (CONTD) Removal And Installation (Contd) Figure 40-100-5 1 2 3
Figure 40-100-7
P-38471
1
P-38469
Remove the bolts (Item 1) [Figure 40-100-7] and washers from the top and bottom pivot pins. Figure 40-100-8
Mark the hoses (Item 1) [Figure 40-100-5] for correct length and orientation. Remove the two bolts (Item 2), washers and clamp (Item 3) [Figure 40-100-5]. Figure 40-100-6
2 1 1
P-38472
Remove the spacers (Item 1) [Figure 40-100-8].
P-38470
Remove the two spacers (Item 1) [Figure 40-100-6]. Remove the clamp (Item 2) [Figure 40-100-6].
40-100-2
SWING FRAME (CONTD) Removal And Installation (Contd) Figure 40-100-9
Figure 40-100-11 2
P-38475
1
P-38473
Use a porta power (Item 1) to remove the top pin (Item 2) [Figure 40-100-11]. Figure 40-100-12
Install the boom cylinder pin (Item 1) [Figure 40-100-9]. Install the spacer, washer and bolt (Item 2) [Figure 40100-9]. Figure 40-100-10 2
1 1
P-38476
Use a porta power (Item 1) to remove the bottom pin (Item 2) [Figure 40-100-12].
P-38474
Install a chain hoist (Item 1) [Figure 40-100-10] on the pin.
40-100-3
SWING FRAME (CONTD) Removal And Installation (Contd) Figure 40-100-13 1
Figure 40-100-15
1
P-38479
2
P-38477
Mark and remove the shims (Item 1) [Figure 40-100-15] from the bottom of the swing frame. NOTE: The top and bottom of the swing bracket uses three different shim thickness. 0.079 inch (2 mm) 0.098 inch (2.5 mm) 0.118 inch (3 mm) Figure 40-100-16
As the lower pin (Item 1) is being removed, reposition the hoses (Item 2) [Figure 40-100-13] to gain pin clearance. Remove the lower pin. Separate the swing frame from the excavator. Figure 40-100-14
1 1
P-38480 P-38478
Mark and remove the shims (Item 1) [Figure 40-100-14] from the top of the swing frame.
Pull the swing frame (Item 1) away from the excavator and remove the hoses (Item 2) [Figure 40-100-16] from the swing frame.
40-100-4
SWING FRAME (CONTD) Bushing Removal And Installation Figure 40-100-17
P-38482
Figure 40-100-18
P-38481
Remove the top bushing (Item 1) [Figure 40-100-17] and bottom bushing (Item 1) [Figure 40-100-18]. Installation: Install the bushings until the bushings are flush with the bushing mounts.
40-100-5
40-100-6
FLOOR MAT Removal And Installation Figure 40-110-1
P-32701
Pull up on and remove the floormat (Item 1) [Figure 40110-1].
40-110-1
40-110-2
BOOM Removal And Installation Remove the bucket. (See BUCKET on Page 40-140-1.) Remove the arm. (See ARM on Page 40-130-1.) Figure 40-120-1
Figure 40-120-3
P-33401
P-33396
P-33403
Raise the cylinder and remove the shims (Item 1) [Figure 40-120-4] from both sides of the rod end. 1
P-33399
40-120-1
BOOM (CONTD) Removal And Installation (Contd) Figure 40-120-5
Figure 40-120-7
1
P-38247
P-38246
Remove the hoses (Item 1) [Figure 40-120-7] from the boom cylinder base and rod end. Figure 40-120-8
Lower the chain hoist until the boom is on the ground [Figure 40-120-5].
IMPORTANT
I-2003-0888
1 1
P-38248
Figure 40-120-6 Install a sling (Item 1) [Figure 40-120-8] on the boom cylinder.
2 2
P-33391
Remove the load sense line (Item 1) and two pilot hoses (Item 2) [Figure 40-120-6].
40-120-2
Figure 40-120-11
1 1
P-38251

P-38249
Figure 40-120-12 Remove the bolt (Item 1) [Figure 40-120-9] and washer. Figure 40-120-10 1
P-38252
P-38250
Raise the hoist and remove the shims (Item 1) [Figure 40-120-12] from both sides of the base end of the cylinder. Remove the cylinder.
40-120-3
Figure 40-120-15
1 1
1
P-38255
P-38253
Remove the bolt (Item 1) [Figure 40-120-15] and washer. Figure 40-120-16
Remove the hoses (Item 1) [Figure 40-120-13] from the base and rod end of the arm cylinder. Figure 40-120-14 1
P-38256

P-38254
Install a sling (Item 1) [Figure 40-120-14] on the cylinder.
40-120-4
Figure 40-120-19
1 1
1 1
P-38259
P-38257
Mark and remove the bucket cylinder and auxiliary hoses (Item 1) [Figure 40-120-19] from the end of the boom. Figure 40-120-20
Raise the cylinder and remove the pin (Item 1) [Figure 40-120-17]. Figure 40-120-18 2 1 1 3 1 1
P-38260
2 3
P-38258
Mark the hoses (Item 1) and remove the bolts (Item 2), washers and hose guides (Item 3) [Figure 40-120-20].
Raise the cylinder and remove the shims (Item 1) [Figure 40-120-18] from both sides of the cylinder. Remove the cylinder.
40-120-5
BOOM (CONTD) Removal And Installation (Contd)
Figure 40-120-23
1 Figure 40-120-21 3 3
1 2
P-38263
1
P-38261
Mark the hoses for correct length and orientation. Remove the bolt (Item 1) [Figure 40-120-23] and clamp. Remove the bolt (Item 2) washer and hose clamp (Item 3) [Figure 40-120-23]. Remove the return to tank hose (Item 4) [Figure 40-12023]. Figure 40-120-24
Mark the hoses (Item 1) [Figure 40-120-21] for correct length and orientation. Remove the bolts (Item 2) and hose clamps (Item 3) [Figure 40-120-21] from both sides of the boom. Figure 40-120-22
1 1 1
P-38264 P-38262
Mark the hoses and remove the two bolts (Item 1) washers and hose guide (Item 2) [Figure 40-120-22].
Remove the hoses (Item 1) [Figure 40-120-24] from the boom. Remove the chain hoist from the boom.
40-120-6
Figure 40-120-27
P-38265
P-38269
Remove the boom pivot pin nut (Item 1) [Figure 40-12027] and washer. Figure 40-120-28
Figure 40-120-26
P-38266 P-38268
Remove the boom pivot pin (Item 1) [Figure 40-120-28]. Install the boom cylinder base end retaining pin (Item 1) [Figure 40-120-25] & [Figure 40-120-26] and bolt. Install the hoist as shown [Figure 40-120-25] & [Figure 40-120-26]. The boom will be balanced when the chain hoist is raised. Raise the boom until the arm end of the boom is approximately 37 inches (940 mm) above the ground. Move the boom away from the swing frame.
40-120-7
P-38267
Remove the shims (Item 1) [Figure 40-120-29] from both sides of the boom swing frame. NOTE: The shims may stay on the boom when the boom is removed. Bushing Removal And Installation Figure 40-120-30
1
P-38270
Remove the bushing (Item 1) [Figure 40-120-30] from both sides of the boom. Installation: Install the bushings until they are flush with the side of the boom.
40-120-8
ARM Removal And Installation Remove the bucket. (See BUCKET on Page 40-140-1.) Lower the boom/arm to the ground. Figure 40-170-1
Figure 40-170-3
P-38236
Remove the bucket/auxiliary hoses (Item 1) [Figure 40170-2] & [Figure 40-170-3] from both sides of the boom.
P-382733
Support the boom with a chain hoist (Item 1) [Figure 40170-1]. With the engine off, the start key in the run position and the left console lowered, move the joysticks to relieve hydraulic pressure. Figure 40-170-2
1
P-38237
40-130-1
ARM (CONTD) Removal And Installation (Contd)
Remove the bolt (Item 1) [Figure 40-170-5] and washer from the rod end of the arm cylinder. Figure 40-170-6
Figure 40-170-4
P-38239
P-38235
Install a chain hoist (Item 1) [Figure 40-170-4] on the arm. Figure 40-170-5
P-38238
40-130-2
ARM (CONTD) Removal And Installation (Contd) Figure 40-170-7
Figure 40-170-9
P-38242
1
P-38240
Remove the shims (Item 1) [Figure 40-170-9] from both sides of the cylinder rod end. Figure 40-170-10
Place a block (item 1) [Figure 40-170-7] under the arm cylinder. Figure 40-170-8 1
1
P-38243
P-38241
Remove the arm pivot pin nut (Item 1) [Figure 40-17010] and washer. Installation: Tighten the nut until it is seated against the boom. Do not overtighten the nut and deflect the boom mounting plates. The arm must pivot freely.
Remove the rod end retaining pin (Item 1) [Figure 40170-8].
40-130-3
ARM (CONTD) Removal And Installation (Contd) Figure 40-170-11
Figure 40-170-13
P-38271
P-38244
Remove the bushing (Item 1) [Figure 40-170-13] from both sides of the arm. Installation: Install the bushing until it is flush with the outside of the arm.
Remove the pivot pin (Item 1) [Figure 40-170-11]. Figure 40-170-12
P-38245
Move the arm away from the boom. Remove the shims (Item 1) [Figure 40-170-12] from both sides of the arm. Bushing Removal And Installation
40-130-4
BUCKET Removal And Installation Stop the excavator on a flat level surface. Put the bucket on the ground. Figure 40-140-1
Figure 40-140-3
2 3 1 1
1
P-32832
1 Remove the pins (Item 1) [Figure 40-140-3]. Retract the bucket link (Item 2) and raise the arm (Item 3) [Figure 40-140-3].
P-32913
Figure 40-140-4 Remove the cotter pins (Item 1) [Figure 40-140-1] from both pins. Figure 40-140-2 2 2
1 1 1
P-32833
Installation: The pins (Item 1) must seat against the antirotation stops (Item 2) [Figure 40-140-4].
P-32831
Remove the washers (Item 1) [Figure 40-140-2] from both pins.
40-140-1
40-140-2
REAR COVER Removal And Installation Figure 40-150-1
Figure 40-150-3
P-36384
P-36385
Support the cover and remove the gas strut (Item 1) [Figure 40-150-3].
Figure 40-150-2
P-36386
Remove the retainer clip (Item 1) [Figure 40-150-1] & [Figure 40-150-2] from the top and bottom of the gas strut.
40-150-1
REAR COVER (CONTD) Removal And Installation (Contd) Figure 40-150-4
Figure 40-150-6
1
P-36389
Figure 40-150-7
P-36387
Figure 40-150-5
1 1
P-36390
P-36388
Have an assistant support the cover, and remove the left and right hinge pins (Item 1) [Figure 40-150-6] & [Figure 40-150-7]. Remove the cover
Remove the cotter pin (Item 1) [Figure 40-150-4] & [Figure 40-150-5] and washer from the left and right hinge pins.
40-150-2
RIGHT SIDE COVER Removal And Installation Open the right side cover. Figure 40-160-8
Figure 40-160-10
P-35017
Figure 40-160-11
P-35016
Figure 40-160-9 1
1
P-35018
Remove the retainer clip (Item 1) [Figure 40-160-10] & [Figure 40-160-11] from the bottom of the gas strut.
P-35019
Support the cover and remove the gas strut.
Remove the retainer clip (Item 1) [Figure 40-160-8] & [Figure 40-160-9] from the top of the gas strut.
40-160-1
RIGHT SIDE COVER (CONTD) Removal And Installation (Contd) Figure 40-160-12
Figure 40-160-14
P-35159
Figure 40-160-15
P-35156
Figure 40-160-13
P-35158
P-35157
Have an assistant support the cover, and remove the front and rear hinge pins (Item 1) [Figure 40-160-14] & [Figure 40-160-15]. Remove the cover.
Remove the cotter pin (Item 1) [Figure 40-160-12] & [Figure 40-160-13] from the front and rear hinge pins.
40-160-2
RIGHT SIDE COVER (CONT) Removal And Installation (Contd) Figure 40-160-16 1 1
P-40595
Remove the four bolts (Item 1) and washers from the dust seal (Item 2) [Figure 40-160-16]. Remove the dust seal. Figure 40-160-17 1
P-40593
Remove the two bolts (Item 1) and washers from the bracket (Item 2) [Figure 40-160-17]. Remove the bracket. Remove the right side cover.
40-160-3
40-160-4
COUNTERWEIGHT Removal And Installation
Figure 40-170-1 COUNTERWEIGHT BRACKET
MS1571
Build the service lifting bracket [Figure 40-170-1] used to remove and install the counterweight. Remove the rear cover. (See REAR COVER on Page 40150-1.) Figure 40-170-2
P-40148
Remove the two bolts (Item 1) [Figure 40-170-2] and washers from both rear legs of the support bracket.
40-170-1
COUNTERWEIGHT (CONTD) Removal And Installation (Contd) Figure 40-170-3 2 1
Figure 40-170-5
2
P-40182
P-40187
Install a chain hoist (Item 1) [Figure 40-170-5] on the counterweight service lifting bracket. NOTE: Use a lifting device of sufficient capacity. Raise the hoist until the weight of the counterweight is supported by the hoist. Figure 40-170-6
Install the counterweight service lifting bracket (Item 1) [Figure 40-170-3] on the counterweight. Figure 40-170-4
1 1
P-40186
P-40183
Use two bolts (Item 2) [Figure 40-170-3] 16 mm x 35 mm MC Grade 8,8 and one bolt (Item 1) [Figure 40-170-4] 20 mm x 35 mm MC Grade 8,8 to fasten the lifting bracket to the counterweight.
Remove the lock nut (Item 1) [Figure 40-170-6] washers and bolt from the bottom of the counterweight.
40-170-2
COUNTERWEIGHT (CONTD) Removal And Installation (Contd) Figure 40-170-7
P-40184
Remove the reflector (Item 1) [Figure 40-170-7] from both sides of the counterweight. NOTE: The reflectors are held on by an adhesive. Clean and dry the surface before installing new reflectors. Figure 40-170-8
P-40181
Remove the bolt (Item 1) [Figure 40-170-8] and washer from both sides of the counterweight. Raise the hoist and remove the counterweight.
40-170-3
40-170-4
ELECTRICAL SYSTEM AND ANALYSIS ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1 Alternator Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-18 Capacitor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-17 Charging System Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-6 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-10 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-5 Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-8 Removal And Installation (S/N 522311001 & Above) . . . . . . . . . . . 50-30-1 Removal And Installation (S/N 528911001 & Above And 528611001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-3 Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-16 Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-17 Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-16 Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-16 BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . 50-20-4 BATTERY DISCONNECT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1 ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 50-10-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2 Fuse And Relay Location (S/N 522311001 & Above) . . . . . . . . . . . 50-10-3 Fuse And Relay Location (S/N 528911001 & Above And S/N 528611001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-5 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1 FRONT CAB LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1 FUEL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1 E-Prom Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
DRIVE SYSTEM ELECTRICAL SYSTEM AND ANALYSIS ELECTRICAL SYSTEM & ANALYSIS ENGINE SERVICE
SPECIFICATIONS
50-01
442 Excavator Service Manual50-0
ELECTRICAL SYSTEM AND ANALYSIS (CONTD) STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-40-1 Assembly (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-14 Disassembly (All Models). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4 Inspection And Repair (All Models) . . . . . . . . . . . . . . . . . . . . . . . . 50-40-12 Parts Identification (All Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3 Removal And Installation (S/N 522311001 & Above). . . . . . . . . . . . 50-40-1 Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1 TWO SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1 WIPER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1
50-02
WIRING SCHEMATIC
[C] Sheet 2 of 4
442 EXCAVATOR (S/N 522311001 AND ABOVE) (PRINTED APRIL 2005) V-0173
sw 2,5 sw 2,5
/3.4 [F] /3.3 Sheet 2 & 3 of 4 /3.1
(Sheet 1 of 4)
2
FB FA FA FB
sw 4,0
30 15
K01
/2.2 0 15 I I I I 15 I I 30
HR32-E01
rt 2,5
F1
5 , 2 l b / w s
F2
F5
104
ge gn/sw 10 5
F6
ge
B1 A4
F7 S3
IIIII I 0 ge
[D] Sheet 1 of 4 /1.6

ge 133
K3
K2
K1
ge
ge
S1
[A] Sheet 2 /2.4 of 4
100
0 , 4 w s
54 19 17 50A 0 , 4 t r 8 X2 4
0 , 4 t r
133
0 , 1 t r 0 , 1 e g / t r
120
XMNT
ge
Item
Ampere
Assigned to
2
0 , 4 t r 0 , 6 w s
85 87
87a
ge/gn
F1 F2 F3 F4 F5 F6 F7 F8 F9
15 20 15 15 10 15 10 5 -
Interior light, radio, immobilizer, rotating beacon Socket, refueling pump, additional heating (option) Working floodlight, front Working floodlight, rear Horn, switch light, immobilizer Heater fan
Wiper/washer system Wish/wash system
G1
D+ G+ B+
5 , 2 l b / w s
9 10 8 9 XB1 8
XK1 4 4 XK1 3 3 XK1 2 2 XRADIO XRADIO 7
XK1
13 13
5 , 2 t r
sw
Fuses
FA
FB
XM1 5 5
7 X2 3 5 , 2 l b / w s 1 XM1 1
6
X2
gn/sw gn/gr gn/bl
[B] Sheet 2/2.44 of
5 X2 1
1.15 [D] 131 Sheet/4.7 1 of 4 [E] 5 , Sheet 2 t 3 of 4 r
S16
9 1 A2 C1 A3 A1
S11
3 5 10
2 6 7 9 gn/vi
5 XK1 5
5 , 2 t r
Thermostat 31
gn/sw
bl/rt
ge
12 XM2 12
ge
11 XM2
7 XM1 7
6 6
86 XB1
30 10
K3
bl/sw
gn/vi
bl
1,0 sw
6 XK1 6
B2
B10
B3
4 L+ R+ 30 L- R-
rt 1 1
5 , 2 t r
gn/sw gn/gr gn/bl
bl/sw
gn/vi
br/gn
bl/rt
XMGE
2 XMGE 2
7 XMNT 7
15
e g / t r
t r
XM2
15 15
bl
B1
31 XRADIO 8
ge/gn
sw 4,0 + 30
M5
243 3 M 1
+ M -
50a M 31 0 , 6 r b
1 2
br 2,5
B-
G2
M1
M7
M
S30
2 1
M4
2 4
M XK1 1 1 XK1 11 12 XK1 11 12
Control module signal input Additional heating (option) Additional heating (option) Seat with electrical heating Working (option) floodlight(s) (option) Working floodlight(s) (option) Main fuse Pre-heating
31
Y10
2
1 2
0 , 6 r b
S0
5 , 2 r b r b r b
FA FB
30 60
br
br
br
r b
YMK
HR32-E02
HR32-E03
Relay
Position
Function Pre-heat relay Working floodlight , front Working floodlight , rear

Air not Conditione assigned r
K 01 K1
Designation
Device Power supply Generator Fuse Fuse Battery Battery disconnecting switch Start-up system Pre-heat/ starter switch Starter
Designation
Device Shut-off Shut-off Interior light Fuse Interior light

Socket, refueling pump
Designation
Device Horn Fuse Horn Fuse, horn button Solenoid valve, immobilizer Heater fan/ air conditioner Air conditioner switch Relay Pressure switch air conditioner Magnetic coupling compressor Fuse
Designation
Device Heater fan Heater fan switch Wash/ wipe system Washer pump Wash/ wipe switch Fuse Wiper motor Radio Radio Loudspeaker Loudspeaker
K2
G1 FA FB G2 SO S1 M1
Y1 F1 E21 F2 M7 X1
F5 B10 S12 Y10 S16 K3 S30 YMK F6
M6 S3 M5 S11 F7 M4 B1 B2 B3
K3
Fuse Refueling pump Socket
V-0173 (3-21-05)
br 2,5
br 2,5
5 , 2 r b
1 X0
br
br
br
br
br
br/ws
gn
br 2,5
50b
Y1
1 1
E21
X1
S12
M6
WIRING SCHEMATIC
(Sheet 2 of 4)
ge 1,0
[C] Sheet 1 of 4 15 15/1.3
[A] Sheet 1 of 4 100 100/1.1

bl
F8
F8
130 /3.1
F8 130 2.15
[F] Sheet 1 of 4 104

ge 1,0 104 1.10 ge1,0 ge1,0 10 5 10 5
104 1.10 11 11
ge 1,0
ge
1
ge
1
ge
ge
sw
XB1
sw
sw
XM1
S33
S31
2
S32
1 2
104 1.10
104 1.10 ge1,0 10 5 ge1,0
104 1.10
XB1
S30
10 5
rt/ws
rt
bl 0,5
10
rt/sw
rt/gn
rt/bl
S9
9 1 31 9 1 31
S5 S5A
9 1 31
S6
9 31 1
S8
9
31
S15
1
X1:2 X1:1 X1:3 X1:5 BE1 X3:18 BE1 X2:6 BE1 X3:20 BE1 X3:3
BE1 X3:4 BE1 X3:5 BE1 X3:19 BE1 X3:17 BE1 X3:6
BE1 X3:36 2 2
XB1 3 3 XB1 4 4 XB1 5 5 XB1
rt/ge 0,5
ge 1,0 gn/ws/vi 0,5
gn/ge 0,5
ge 1,0
sw/vi 0,5
gn/rt 0,5
rt/sw 0,5
rt/gn 0,5
bl/ws 0,5
rt/ws 0,5
X1:4
BE1
gn 0,5
vi/ws
[B] 6 XM1 Sheet 6 1 of 4 120 120/1.3

sw 6,0
XM1
3 XM2 3
1
XM2
2 XM1 2
4 4
4 XM2 4 XM2
5 5 6 XM2 6
7 XM2 7 8 XM2 8
BE1 X3:21
BE1 X3:22
BE1 X3:23
BE1 X3:24
gn/ge
rt/ws
vi/ws
gn
bl/ws
sw/vi
rt/ws 0,5
rt/bl 0,5
BE1 X3:9
BE1 X3:14
BE1 X3:16
BE1 X3:25
BE1 X3:12
gn/ws/vi
BE1 X2:3
gn/rt
BE1 X2:5
BE1 X2:4
ge
86
30
sw 6,0
gn
rt/ws
85
87
gn
rt
bl/rt
XMNT
XMNT
XB1
7 7
XM2
9 9
XM2
3 3
br/ge
XB1 14 14 1
K01
R1
S5
S4
2
S7
2
B2
2
B1
2
B20
2
B7
1
gn
rt
bl/rt
br/ge
1
ge
Y5
br br br br br br br br br
br
1 2 2
H10
Y11
2
Y4
2
br
HR32-E04
HR32-E05
br
br
br
br/ge 0,5
BE1 X2:2
gn/rt 0,5
bl/rt 0,5
gn 0,5
HR32-E06
Designation
Device Check module Control module Pre-heat Pre-heat relay Glow plugs
Designation
Device Display units Oil pressure switch Maintenance, air filter Hydraulic oil filter Coolant temperature Fuel gauge transmitter Hydraulic oil level Fuse
Designation
Device Load warning sensor Fuse Load warning signal
Designation
Device Pressure switch travel Pressure switch forward/left Pressure switch reverse/left Pressure switch forward/right Pressure switch reverse/right
Designation
Device
Load warning device Shut-off - load warning device Travel
Designation
Device
Float position, breaker
BE1 K01 R1
S5 S4 S7 B2 B1 B20 F8
F8 B7
S33 S31 S32 S30
S9
S5A S5 Y5 S6 H10
Fast/ slow Valve, fast Travel alarm Travel alarm
S8 Y11 S15 Y4
Float position Valve float position Breaker Valve breaker
V-0173 (3-21-05)
WIRING SCHEMATIC
(Sheet 3 of 4)
S17
9
rt/bl
ge
XB1 S21
2
bl/sw
S29
1
bl/ge rt/sw
10
ge 2,5
ge 1,0
11
11
ge 1,0
ge 1,0
ge 1,0
ge 1,0
F9
5
F3
F4
S25
2
bl/rt
XB1
15 10
ge 86 2
3 1
10
rt
5
110 /4.9
[E] Sheet 1 of 4 [F] 131 Sheet 1 of 4 104
F1 131 1.6 104 1.10
5 5
bl/sw 0,5
7 7 XB2
rt/sw 0,5
12 12
bl/ge 0,5
16 XB1 XB1 16
bl/rt 0,5
3 3
rt/bl 0,5
9
XB2
XB2
31
gr/sw 0,5
gr/rt 0,5
rt 2,5
rt 2,5
BE1 X3:31
BE1 X3:32
BE1 X3:11
BE1 X3:26
BE1 X3:30
GRN/YEL
XB1
14
XM2
17
86 30
86
30
K1
X
BE1 X2:7 BE1 X2:8
BE1 X2:1 BE1 X2:13 BE1 X2:10
K2
85 87 87a
85 87 87a
Y
bl/sw bl/ge rt/sw rt/bl bl/rt
XK1 8 XK1 10
22
XK1 7 XK1 9 7
9
gr/sw
gr/sw
gr/rt
gr/rt
XM2
10 10
XK1 14 14
gr/sw
bl/sw
bl/ge
rt/sw
bl/rt
gr/rt
gr/rt
gr/rt
16
18
13
13
gr/sw
vi/ws
1
XM2
16
XM2
18
XB1
13
XM2
13
10
XM2
BRN
Y18
2
br
Y19
2
br
Y3
2
br
Y12
2
br br
E4
1 2
1 2
E5
E6
1 2
1 2
E8
E7
1 2
2
vi/ws
gr/rt
br
br
br
br
br
br
HR32-E07
br
br
Desig-nation Designation
Device Joystick
Pushbutton additional control circuit Valve additional control circuit Valve additional control circuit Working hydraulics Armrest switch Working hydraulics
Designation
Device
High torque swing drive High torque swing drive Valve high drive Option Option torque swing
Designation
Device Working floodlights Fuse Working floodlights Relay Working floodlight front Fuse Working floodlight front Fuse
S21S21 Y18Y18 Y19Y19 S29S29 Y3 Y3
S25 Y12 S17
F9 S10 K1 E4 F3 E5 F4
II I 0
/6.2
S10
S4
9
31
E3
HR32-E08
Designation
Device Relay Working floodlight rear Working floodlight rear Boom-mounted work. floodlight Switch rotating beacon Rotating beacon
ISO/STD Valve Solenoid ISO/STD Valve Solenoid
K2 E6 E8 E7 S4 E3
X Y
V-0173 (3-21-05)
Control module
WIRING SCHEMATIC
13 14 15 16 17 18 High torque swing drive Valve additional control circuit 2 -----
Cable colors black red brown blue white yellow green grey beige black / red black / blue black / white black / green black / yellow black / white / green black / grey black / violet black / brown red / black red / white red / yellow red / blue red / green red / brown brown / red brown / white brown / yellow brown / green blue / red blue / brown blue / white blue / yellow blue / black white / yellow white / grey yellow / black yellow / green green / red green / white green / violet green / grey green / blue green / black grey / black grey / red violet / white green / white / red green / black / white green / white / violet orange blue / green blue / yellow / green Terminal Significance 30/49 15 31 D+/61 56a 15
(Sheet 4 of 4)
X3 Signal inlets
1 2 3 4 5 6 7 8 9 10 11 12
HR32-E15
--Oil pressure switch Air filter contamination Hydraulic oil filter contamination Hydraulic oil level switch --Load warning switch -Armrest switch Breaker switch -Quick slow switch -Back-up alarm switch Tank transmitter Ground Coolant temperature Load control Pressure switch travel forward left Pressure switch travel reverse left Pressure switch travel forward right Pressure switch travel reverse right Float position switch High torque swing drive Proximity switch boom Proximity switch intermediate boom Option Option Additional control circuit pushbutton Additional control circuit pushbutton ---Load warning signal --
54 L R 49a C2 G
13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37
X1 Power supply
1 2 3 4 5 6 7 8 9 Power supply terminal 30 Power supply terminal 30 Power supply terminal 30 Ground Power supply terminal 15 -----
17/31b
56b 3
X2 Signal outlets
1 2 3 4 5 6 7 8
9 10 11 12
Working hydraulics Breaker Quick slow Float position Back-up alarm Pre-glow Valve additional control circuit Valve additional control circuit
--Option Boom cut-off Intermediate boom cut-off
Battery, positive, reverse, flasher Glow starter, positive Ground, negative Generator, working hour meter High beam Switched positive output Oil pressure - engine Switch forward - rectifier Board check system Brake lights, stop light switch Additional valve Flasher left, flasher check, terminal C Flasher right Parking brake - charge indicator light Flasher switch Flasher indicator light Fuel level gauge Warning buzzer Axle lock Temperature indicator Hand brake switch - cabin lamp Steering inversion 4-wheel steering - crab 4-wheel steering - round Hydr.oil cooler / transmitter / engine Warning lamp pre-glow / wiper motor V-belt check, valve-breaker Horn Hydraulic pressure Diesel fuel heat., charge press. (fuel) Air filter check Armrest switch - pilot control Electr. engine shut-off, wiper motor Low beam Light switch Heater fan switch - motor Hydr. filter clogging indicator Engine oil temperature light (Deutz) Hydraulic oil temperature Windscreen wiper Heater fan Heater fan Heater fan Side marker lamp left Side marker lamp right, panel lamps / working floodlights Rotating beacon Cooling water level Engine oil level Hydraulic oil level Slew limitation Wiper switch Steering lock angle rear
X4 Interface
Unassigned !!!
V-0173 (3-21-05)
WIRING SCHEMATIC
442 EXCAVATOR
(S/N 528611001 AND ABOVE) (S/N 528911001 AND ABOVE)
(PRINTED NOVEMBER 2007)
BLK RED Fuse F1 10A [A]

See Page 2 of 5
V-0616 Sheet 1 of 5
X30 3
X30 4
X30 5
BLK RED [B]

See Page 5 of 5
RED 30 BLK BLK BLK Key Switch
Fuel Gauge
GRY /BLU
Temperature Gauge
Boom Load Indicator Gauge BRN
[C]
See Page 3 of 5
86
30 K02 Switch Power RED Off Run Glow Start
58
15
58
15
BLK
58
15
Q
BLK P1 31 WHT BRN
85
87
50A
17 19 54
15
31 P1
31 31 BRN
p
P1
3 31 31 WHT X7:5 BE1
RED
BLK/BLU
BLK
RED
X1:5 BE1
X1:1 BE1
X1:2 BE1
X1:3 BE1
X7:1 BE1
X7:2 BE1
X7:3 BE1
X7:4 BE1
BE1 X3:20 8 X2 X30 BLU 1 4 RED X2 BLK/BLU 7 3 X2:6 X2 VIO/WHT 5 1 YEL BE1 6 XM1 VIO/WHT 6 GRN X1:4 BE1 X3:18 BE1 X3:3 BE1 X3:4 BLU/WHT BE1 X3:17 BLK/VIO BE1 X3:19 RED/WHT BE1 X3:5 YEL/GRN BE1 X3:6 GRN/WHT/VIO 2 XM2 2 XM2 3 XM1 Fuse FA 40A 3 XM2 1 1 XM2 4 4 4 XM1 4 6 6 5 XM2 5 BLU/WHT BLK/VIO RED/WHT GRN GRN/WHT/VIO BRN BRN XMO T GRN 6 6 Oil Pressure Switch P Air Filter P Switch Fuel Level Sender Q Engine Temperature Switch BRN Hyd. Oil P Filter Switch BRN YEL/GRN BRN Hyd. Oil Level BRN 7 X31 8 X31 2 X31 3 X31 5 X31 6 X31 BE1
BLK
2 XM1 2 XM1
5 5 XM1
1 1
BLK/BLU
Fuse FB 50A BLU
86
RED
30 K02 Starter
86
30 K03 Engine Heater
85 RED RED
87
85
87
WHT
BLK
BLK
BLK
BRN
BLK
2 2 + D+ Battery 12 Volt Alternator _ BLK
XMOT W BLK BLK B+
10 10
9 XMOT 9
XMOT
7 7
XMOT
30
M
31
50a 50b
B-
Starter
Fuel Rack Advanc e Solenoi d BRN
Fuel Shut-off Solenoi d
Engine Intake Heater
BRN
X31
BRN
X31
X31
BRN
Battery Disconnect Switch
X31
X31
V-0616 (10-15-07)
YEL Q
WIRING SCHEMATIC
442 EXCAVATOR
30 15
BLK RED Fuse F2 15A [A]

See Page 1 of 5
V-0617 Sheet 2 of 5
Fuse F6 15A Fuse F7 10A YEL YEL YEL YEL YEL YEL Heater Motor Switch 10 Off Low Med Hi 5 3 Wiper Washer Switch A1 9 7 6 2 BRN/BLK GRN/BLU GRN/VIO BLU/BLK BLU [D]
See Page 3 of 5
Fuse F8 15A
Fuse F9 15A
10
A/C ON/OFF Switch
B1
A4
RED/YEL
BLU/RED
9 YEL
8 2 7
1 GRN/BLK
C1 A3 A2
RED
RED
YEL
YEL
X2 2 BLU/RED
K3 85 GRN
A/C Relay 87 87a
YEL BLK
Power Plug 12 V
YEL/BLK
86
30
GRN/GRY
GRN/BLK
YEL/GRN
BRN
XM1 13 XK1 13 XM2 12 12 7 XB2 1 1 XB2 8 8 XB2 9 9 XM2
XB1 XB1 8 XB1 8 9 9
10 10 4 XK1 3 XK1 XK1 4 3 1 2 XK1 1 2 5 XK1 5 6 XK1 6
15 15
11 XK1 11 XK1
B6 BRN/BLK RED/YEL 1 P 2 2 YEL BRN GRN BRN GRN Pressure Switch GRN/VIO BLU/BLK YEL Horn Switch S12 1 GRN/GRY GRN/BLU GRN/BLK BLU
Speaker (Optional)
BRN
YEL BLK
Speaker B7 (Optional)
BRN/GRN
E21
BRN
_ BRN
BRN
BRN
BRN
BRN
X31 1
X31 4
BRN
X31
X31
X31
X31 18
X31 2
X31 2
X31 3
BRN
X31 4
BRN
S34
M4
31
X31 5
X31 6
V-0617 (10-15-07)
BRN
Interior Light And Switch
+ M
M7 Fuel Pump B10 Horn
Thermostat Switch T YMK
Compressor Clutch 1
4 2 3
+
Heater Fan Motor M5
53
31b 53a 7 4 34 5 B1 6 Radio (Optional)
M
M6
M Washer
Pump
Wiper Pump
BRN 12 12
XM2 11
XM1 15
X31 20
X31 21
WIRING SCHEMATIC
442 EXCAVATOR
V-0618 Sheet 3 of 5
30 15 Fuse F11 5A BLK RED Fuse F10 5A YEL Fuse F12 5A
[C]
See Page 1 of 5
[D]
See Page 2 of 5
[D]
See Page 2 of 5
[D]
See Page 2 of 5
[D]
See Page 2 of 5
[D]
See Page 2 of 5
YEL 10 S9 9 1 5 Load Warning S5 Device 9 Switch 10 5 Two Speed Switch S6 9 1 10 5 Travel Alarm Switch S8 9 1 10 5 10 Float Position S15 Switch 9 5 Breaker Switch 1
BLU/RED
GRN/RED
RED/YEL
YEL
YEL
X3:9 BE1
X3:14 BE1
X3:16 BE1
GRN
X3:25 BE1
X3:12 BE1
BRN/YEL
X3:11 BE1
BLU/YEL
BRN/YEL
GRN/RED
RED/WHT
RED/GRN
RED/BLU
RED/BLK
BLU/RED
BLU/YEL
BE1 X3:21
BE1 X3:22
BE1 X3:23
BE1 X3:24
BE1 X3:36
BE1 X2:3 RED
BE1 X2:5 GRN
BE1 X2:4
BE1 X2:2
BE1 X2:1
1 XB1 1
2 XB1 2 RED/BLK RED/BLU XB1
3 XB1 3 RED/GRN
4 XB1 4 RED/WHT
5 5
7 XM2 7 XM2
8 XB1 8
7 XM2 7
9 XM2 9 BLU/RED
3 XB1 3
14 14 BRN/YEL
13 XB1 13 XB1
12 XB1 12
BLU/YEL
GRN/RED
2 P 1 Pressure Switch Forward Left BRN P
2 1 Pressure Switch Reverse Left P
2 1 Pressure Switch Forward Right P
2 1 Pressure Switch Reverse Right
2 B7 P 1 U 3 Y5 Load Warning Sensor
1 2 BRN
Two Speed Solenoid
1 Travel Alarm 2 H10 BRN Y11
1 2 BRN
Float Position Solenoid
1 Y4 2 BRN
Breaker Solenoid
1 Y3 2 BRN Auxiliary Hydraulics Solenoid S29
BLU/YEL
RED
YEL
YEL
GRN
1 2
YEL Armrest Switch
BRN
X31 10
X31
X31 11
X31 12
X31
X31
V-0618 (10-15-07)
YEL 11 11
WIRING SCHEMATIC
442 EXCAVATOR
(PRINTED NOVEMBER 2007) 30 15 Fuse F13 5A BLK RED
V-0619 Sheet 4 of 5
YEL 3 YEL YEL Additional Control Circuit Switch (On 1 Joystick) 1 3 Additional Control Circuit Switch (On 1 Joystick) 1 Swing Brake Switch 2 BLU/GRN 1 High Torque Swing Drive 10 S17 9 1 5 Optional
S21 2
S20 2 GRN/BLK BLU/WHT
S22 2
S24
S25 2 BLU/RED
BLU/BLK
16 XB2 16 XB2
RED/BLK
RED/BLK
5 XB2 5
7 7 RED/BLK
18 XB1 18 GRN/BLK XB2
11 XB2 BLU/WHT RED/BLK 11
13 13
1 XB2 1 BLU/GRN XB1 BLU/RED
RED/BLU 16 16 3 XB2 3 RED/BLU XM2 RED/BLU 20 XB1 17 X3:30 BE1
X3:31 BE1
BLU/BLK
X3:32 BE1
X3:13 BE1
X3:27 BE1
X3:28 BE1
X3:29 BE1
X3:26 BE1
X3:15 BE1 GRN/YEL
BLU/GRN
GRN/BLK
RED/BLK
BLU/WHT
RED/BLK
16 XM2 16 BLU/BLK XM2
18 18
19 XM2 XM3
1 XM3 1 BLU/WHT RED/BLK
2 2
17 XM2 17 BLU/GRN XB2
BLU/RED
BLU/BLK
RED/BLU
17 17 BLU/RED
22 XM2 22 RED/BLU XM2
YEL/BLK 21 XM2
BE1 X2:7
BE1 X2:8
BE1 X2:9
BE1 X2:11
BE1 X2:12
BE1 X2:14
BE1 X2:13
BE1 X2:10
BE1 X2:15
14
RED/BLK
1 Y18 2 BRN
Additional Control Circuit Solenoid
1 Y19 2 BRN
1 Y23 2 BRN
1 Y24 2 BRN
1 Y14 2
Swing Brake Solenoid
1 Y12 2
High Torque Swing Drive Solenoid
1 Y25 2 Optional Solenoid
BRN
X31 13
X31 14
X31 15
X31 16
X31 17
X31
X31 24
V-0619 (10-15-07)
WIRING SCHEMATIC
442 EXCAVATOR
30 15
V-0620 Sheet 5 of 5
BLK RED Fuse F14 10A Fuse F3 5A [D]
See Page 2 of 5
Fuse F4 15A [D] [D] RED

See Page 2 of 5 See Page 2 of 5
Fuse F5 15A
10 YEL YEL S4 9 2 XB2 2 YEL 1
5 Beacon Light
10 8 6
YEL 3 Light Switch 9 2 1 GRN/RED
[B] 85 87 87a 85 87 87a

See Page 1 of 5
YEL/RED
BRN/RED
BRN
GRN/RED
BRN/YEL
GRN/YEL
GRN/BLU
VIO/WHT
86 K9 85 87
30
Front Light Relay 87a
86 K9 85 87
30
15 XB2 XB2
4 XB2 4 BRN/RED YEL/RED
6 XB2 6
10 XB2 10 BRN/YEL
12 XB2 12 GRN/RED
14 14
Rear Light Relay 87a
GRN/BLK
5 XM3 5 BRN/RED YEL/RED XM3
4 XM3 4
3 XM3 3 BRN/YEL
6 XM3 6 GRN/RED
7 XK1 7 GRN/YEL
14 14 VIO/WHT XK1
GRN/RED
GRN/RED
GRN/YEL
8 XK1 8 GRN/RED
10 10 XK1
GRN/BLK
7 XK1 7 GRN/BLK GRN/BLK
9 XK1 9
BRN
_
Arm
_ BRN BRN BRN BRN Arm Solenoid Rear Lights BRN X31 19
YEL/RED
GRN/RED
GRN/RED Boom Light
X31 20 X31 6 BRN
X31 21
X31 22
X31 23
X31 7
X31 8
X31 8 X31 9
BRN
Front Lights
BRN
BRN
BRN
X31 9
X31 10
BRN
GRN/RED 10 10
S18
Reach Limit Switch
GRN/BLK
10
5 K8
86
30
86 K9
30
RED
RED
V-0620 (10-15-07)
ELECTRICAL SYSTEM INFORMATION 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.
WARNING
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operators Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or W-2003-00903 death.
PROBLEM
Battery will not take a charge. Alternator will not charge. Starter will not turn the engine. 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.
CAUSE
1, 2, 3, 4, 5 1, 2, 5 2, 3, 4, 6, 7, 8, 9
50-10-1
ELECTRICAL SYSTEM INFORMATION (CONTD) Description Figure 50-10-1 Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.
W-2065-1296
WARNING
P-32706
Figure 50-10-2
P-32701
The excavator has a 12 volt, negative ground electrical system. The electrical system is protected by fuses located in the right console and beside the battery [Figure 50-10-1] & [Figure 50-10-2]. The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found before starting the engine again. The battery cables must be clean and tight. Check the electrolyte level in the battery. Add distilled water as needed. Remove acid or corrosion from the battery and cables with a sodium bicarbonate and water solution.
50-10-2
ELECTRICAL SYSTEM INFORMATION (CONTD) Fuse And Relay Location (S/N 522311001 & Above) Figure 50-10-3
Figure 50-10-5
1 1
B-16658
2
P-32706
The location and sizes are shown below and [Figure 5010-4] & [Figure 50-10-5].
To check or replace the fuses in the right console, remove the three screws (Item 1) and remove the cover (Item 2) [Figure 50-10-3]. Figure 50-10-4
REF. 1 2 3 4 5 6 7 8 9 K1 K2 K3
DESCRIPTION Interior light, radio Auxiliary power outlet Front lights Rear work lights Horn Heater fan motor Wiper/Washer Control module signal input Optional work lights and heating Front work lights Rear work lights Air conditioning
AMPERAGE. 5 20 15 15 10 15 10 5 relay relay relay
Always replace fuses with the same type and capacity.

P-32707
50-10-3
ELECTRICAL SYSTEM INFORMATION (CONTD) Fuse And Relay Location (S/N 522311001 & Above) (Contd) Figure 50-10-6
Figure 50-10-8
P-32705
Remove the covers (Item 1) [Figure 50-10-8] for access to the two fuses.
P-32701
Figure 50-10-9 To check or replace fuses beside the battery, pull up on and remove the floor mat (Item 1) [Figure 50-10-6]. Figure 50-10-7
1
B-16659
The location and sizes are shown below [Figure 50-108] & [Figure 50-10-9].
P-32702
Remove the battery compartment cover (Item 1) [Figure 50-10-7].
REF. 1 (FA) 2 (FB) 3 (K01)
DESCRIPTION Main fuse Pre-Heat Pre-Heat
AMPERAGE.
30 60 relay
50-10-4
ELECTRICAL SYSTEM INFORMATION (CONTD) Fuse And Relay Location (S/N 528911001 & Above And S/N 528611001 & Above) Figure 50-10-10
Figure 50-10-12
2
B-23196
The location and sizes are shown below [Figure 50-1011] & [Figure 50-10-12].
P-32706
REF. To check or replace the fuses in the right console, remove the screws (Item 1) and remove the cover (Item 2) [Figure 50-10-10]. Figure 50-10-11 1 2 3 4 5 6 7 8 9 10 11
P-58260
DESCRIPTION Key switch, interior light, security ignition (If equipped) Aux power outlet, radio, heater Rotating beacon (If equipped) Flood light (Front) Flood light (Back) Fuel pump Horn, panel light, security ignition (If equipped) Heater fan Wiper/washer, radio Hyd. oil level, hyd functions, overload warning Travel pressure switch Main hyd. system Left and right joystick Air conditioning box Flood light (Front) Flood light (Rear) Open
AMPER AGE 10A 15A 10A 15S 15A 15A 10A 15A 15A 5A 5A 5A 5A 10A Relay Relay Relay Relay
12 13 14 K1 K2 K3
K01 Switch power
50-10-5
ELECTRICAL SYSTEM INFORMATION (CONTD) Fuse And Relay Location (S/N 528911001 & Above And S/N 528611001 & Above) (Contd) Figure 50-10-13
Figure 50-10-15
1
P-32705
Remove the covers (Item 1) for access to the two fuses [Figure 50-10-15].
P-32701
Figure 50-10-16 To check or replace fuses beside the battery, pull up on and remove the floor mat (Item 1) [Figure 50-10-13]. Figure 50-10-14
B-23197
The location and sizes are shown below (Item 1) [Figure 50-10-15] & [Figure 50-10-16].
P-32702
REF. Remove the battery compartment cover (Item 1) [Figure 50-10-14]. 1 (FA) 2 (FB) 3 (K03)
DESCRIPTION Main fuse Pre-Heat Intake air heat
AMPERAGE 40 40 relay
50-10-6
ELECTRICAL SYSTEM INFORMATION (CONTD) Fuse And Relay Location (S/N 528911001 & Above And S/N 528611001 & Above) (Contd) Open the right side cover. Figure 50-10-17
P-56417
Figure 50-10-18
P-56416
The location is shown above [Figure 50-10-17] & [Figure 50-10-18]. REF. 1 (K02) DESCRIPTION Starter, additional fueling AMPERAGE Relay
Always replace relays with the same type and capacity.
50-10-7
50-10-8
BATTERY Servicing The battery is located under the cab floor. Figure 50-20-1
Figure 50-20-3
1
P-32703
P-32701
The battery cables (Item 1) [Figure 50-20-3] 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 battery saver grease to prevent corrosion.
Pull up on and remove the floormat (Item 1) [Figure 5020-1]. Figure 50-20-2
P-32702
50-20-1
BATTERY (CONTD) Servicing (Contd) Figure 50-20-4
Removal And Installation Figure 50-20-5
P-32701 P9590
Pull up on and remove the floormat (Item 1) [Figure 5020-5]. Clean the battery terminals and cable ends even when installing a new battery [Figure 50-20-4]. 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. If electrolyte level is lower than 1/2 inch (13 mm) above the plates, add distilled water only. Put Battery Saver or grease on the battery terminals and cable ends to prevent corrosion.
P-32702
Figure 50-20-6
WARNING
Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes. If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.
W-2065-1296
50-20-2
BATTERY (CONTD) Removal And Installation (Contd) Figure 50-20-7
Figure 50-20-8 2 1 1
1
P-32704
P-32703
Remove the nuts (Item 1) and remove the hold down clamp (Item 2) [Figure 50-20-8]. Remove the battery.
Disconnect the negative (-) cable (Item 1) [Figure 50-207] first. Disconnect the positive (+) cable (Item 2) [Figure 50-207].
Always clean the terminals and the cable ends. Install the battery. Install the hold down clamp and tighten the bolts. Connect the battery cables. Connect the negative (-) cable (Item 1) [Figure 50-20-7] last to prevent sparks.
WARNING
W-2065-1296
50-20-3
BATTERY (CONTD) Using A Booster Battery (Jump Starting) If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operators seat and one person to connect and disconnect the battery cables. Be sure the key switch is OFF. The booster battery must be 12 volt. Figure 50-20-9
WARNING
W-2065-1296
WARNING
Keep arcs, sparks flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.
P-32701
Pull up on and remove the floor mat (Item 1) [Figure 5020-9]. Figure 50-20-10
Do not jump start or charge a frozen or damaged battery. Warm battery to 60F (16C) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging. Battery gas can explode and cause serious injury.
W-2066-1296
P-32702
50-20-4
BATTERY (CONTD) Using A Booster Battery (Jump Starting) (Contd) Figure 50-20-11 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
IMPORTANT
P-32708
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 50-20-11] of the excavator battery. Connect the end of the second cable to the negative (-) terminal of the booster battery. Connect the other end of the same cable to the excavator frame (Item 2) [Figure 50-20-11] (away from the battery). NOTE: See Cold Temperature Starting Procedure, in the correct Operation & Maintenance Manual. Start the engine. After the engine has started, remove the ground (-) cable first (Item 2) [Figure 50-20-11]. Disconnect the cable from the excavator battery (Item 1) [Figure 50-20-11].
IMPORTANT
If jump starting the excavator from a second machine: When jump starting the excavator from a battery installed in a second machine is NOT running while using the glow plugs. High voltage spikes from a running machine can burn out the glow plugs.
I-2060-0195
50-20-5
50-20-6
ALTERNATOR Removal And Installation (S/N 522311001 & Above) Disconnect the battery. (See BATTERY on Page 50-201.) Open the right side cover. Figure 50-30-1
Figure 50-30-3
P-36917
Remove the clamp (Item 1) [Figure 50-30-3]. Figure 50-30-4 1
P-36915
1 Remove the clamp (Item 1) [Figure 50-30-1]. Figure 50-30-2
P-36918
Remove the air tube (Item 1) [Figure 50-30-4] from the air intake and slide the tube towards the rear of the excavator. 1 1
P-36916
Loosen the two clamps (Item 1) [Figure 50-30-2].
50-30-1
ALTERNATOR (CONTD) Removal And Installation (S/N 522311001 & Above) (Contd) Figure 50-30-5
Figure 50-30-7
2 1
P-36919 B-16596
Remove the nuts (Item 1) [Figure 50-30-5] from the alternator studs. Remove the wire harness from both studs. Disconnect the wire connector (Item 2) [Figure 50-30-5] from the back of the alternator. Figure 50-30-6
Loosen the adjustment bolt (Item 1) [Figure 50-30-7]. Loosen the mount bolts (Item 2) [Figure 50-30-7] and remove the alternator belt. Remove the two mount bolts and remove the alternator.
1 1
P-36920
Remove the bolts (Item 1) [Figure 50-30-6] from the lower radiator hose clamps. Reposition the hose to gain clearance to remove the alternator.
50-30-2
ALTERNATOR (CONTD) Removal And Installation (S/N 528911001 & Above And 528611001 & Above) Disconnect the battery. (See BATTERY on Page 50-201.) Open the right side cover. Figure 50-30-8
Figure 50-30-10
P-63300
Loosen the clamp (Item 1) [Figure 50-30-10]. Figure 50-30-11
P-63298
Remove the clamp (Item 1) [Figure 50-30-8]. Figure 50-30-9
P-63301
Remove the air tube (Item 1) [Figure 50-30-11] from the air intake and filter housing. Reposition the air tube.
P-63299
Loosen the clamp (Item 1) [Figure 50-30-9].
50-30-3
ALTERNATOR (CONTD) Removal And Installation (S/N 528911001 & Above And 528611001 & Above) (Contd) Figure 50-30-12
Figure 50-30-14
1 2 1
1
P-63453
P-58800
Remove the 4 bolts, washers, and spacers (Item 1) from the guard (Item 2) [Figure 50-30-14]. Relocate the guard. Figure 50-30-15
Disconnect the wire connector (Item 1) [Figure 50-30-12] from the alternator. Remove the nuts and wire connectors (Item 2) [Figure 50-30-12]. Figure 50-30-13 1 2
1
P-58799
1 Remove the 2 bolts (Item 1) from the alternator (Item 2) [Figure 50-30-15]. 2
P-58320
NOTE: The engine, fan and pulley are shown removed for photo clarity. Remove the alternator.
Loosen the bolt (Item 1). Remove the belt (Item 2) [Figure 50-30-13].
50-30-4
ALTERNATOR (CONTD) Parts Identification
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
Nut Wave Washer Bushing Screw Bracket Bearing Cover Rotor Slip Ring Cover Stator Rectifier Cover Washer Nut Brushes Regulator Capacitor 7 4 5 6
10 6 9 1514 14 3 8 4 13 12 4 11 4 3 14 1 14 16 14 15 15 15
3 1 2
17
4 4 18
B23285
50-30-5
ALTERNATOR (CONTD) Alternator Identification Figure 50-30-16
ALTERNATOR (CONT'D) Charging System Check
IMPORTANT
Damage to the alternator can occur if: Engine is operated with battery cables disconnected. Battery cables are connected when using a fast charger or when welding on the excavator. (Remove both cables from the battery.) Extra battery cables (booster cables) are connected wrong.
I-2023-1285
P-63399
If the charging system malfunctions check the following: Check the condition and tension of the fan/fuel pump drive belt. (See FAN/FUEL PUMP BELT on Page 10-1401) If belt is worn or deteriorated replace. Inspect the alternator wiring harness and connectors at alternator. Harness and connectors must be clean and tight. Check the electrolyte level in the battery. Add distilled water as needed. (Does not apply to maintenance free batteries.)
The back cover has been removed to show alternator rectifier assembly [Figure 50-30-16]. Figure 50-30-17
2 Verify the charge of the battery. Make sure battery is fully charged. Disconnect the battery cables (negative first, then positive). Inspect the cable clamps and battery posts for corrosion. Remove acid or corrosion from the battery and cables with a sodium bicarbonate and water solution. Put grease on the cable ends and battery terminals to prevent corrosion. Reconnect the cables. Make sure all wiring harness leads are connected. Turn all accessories OFF
P-63310
The alternator contains field diodes (Item 1) [Figure 5030-16] a capacitor (Item 1) and brush holder (Item 2) [Figure 50-30-17].
50-30-6
Figure 50-30-18
ALTERNATOR (CONTD) Charging System Check (Contd)
WARNING
Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame. Do not jump start or charge a frozen or damaged battery. Warm battery to 60F. (16C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging. Battery gas can explode and cause serious injury.
W-2066-1296
3 1
P-63302
Connect the positive lead from the voltmeter to the B+ terminal (Item 1) on the alternator. Connect the negative lead from the voltmeter to the alternator housing (ground) (Item 2) [Figure 50-30-18]. If the reading on the voltmeter is lower than battery voltage or has a zero reading, check and make repairs to the wiring between the B+ terminal of the alternator and the battery. Connect the positive lead from the voltmeter to the D+ terminal (Item 3). Connect the negative lead from the voltmeter to the alternator housing (ground) (Item 2) [Figure 50-30-18]. If the reading on the voltmeter is zero check the alternator.
Figure 50-30-19
WARNING
W-2065-1296
P-32703
Run the engine at rated speed. Check to make sure that all accessories are turned OFF. Connect the positive lead of the voltmeter to the positive terminal (Item 1) of the battery. Connect the negative lead of the volt meter to the negative terminal (Item 2) [Figure 50-30-19]. If the reading on the voltmeter is 15 volts or more, disassembly the alternator and check the components.
50-30-7
ALTERNATOR (CONT'D) Rectifier Continuity (Diode) Test NOTE: The photos may appear different. The procedure is the same. Figure 50-30-20
Figure 50-30-22
P-63613
1 2
P-63611
Reverse the ohmmeter leads. Read the ohmmeter. There must be resistance in one direction and an open in the other. If the readings are the same, replace the rectifier bridge. Repeat this step for the other diodes [Figure 5030-22]. Figure 50-30-23
Unsolder the stator coil at the connections (Item 1) to the rectifier bridge. Remove the stator (Item 2) [Figure 5030-20]. NOTE: Bend phase lead-out wires as little as possible. Figure 50-30-21 1
2 1
P-63615
P-63612
Check the negative diodes in the rectifier bridge. Connect the negative lead of the ohmmeter to the surface of the diode plate (Item 1) that is not painted. Connect the positive lead of the ohm meter to one of the leads for the negative diodes (Item 2) [Figure 50-30-23] The negative diodes are the diodes on the side of the rectifier bridge opposite the B+ terminal.
Test the positive diodes in the rectifier bridge. Connect the negative lead of the ohmmeter to the output B+ terminal (Item 1). Connect the positive lead of the ohm meter to one of the leads (Item 2) [Figure 50-30-21] for the positive diodes. The positive diodes are the diodes closest to the B+ terminal.
50-30-8
ALTERNATOR (CONT'D) Rectifier Continuity (Diode) Test (Contd) Figure 50-30-24
P-63614
Reverse the ohmmeter leads. Read the ohmmeter. There must be resistance in one direction and an open in the other. If the readings are the same, replace the rectifier bridge. Repeat this step for the other diodes [Figure 5030-24].
50-30-9
ALTERNATOR (CONT'D) Disassembly Figure 50-30-25
Figure 50-30-27
P-63380

P-63378
Figure 50-30-28 Remove the nut (Item 1) [Figure 50-30-25]. Figure 50-30-26 1
P-63381
Remove the pulley sheave (Item 1) [Figure 50-30-28].

P-63379
50-30-10
ALTERNATOR (CONT'D) Disassembly (Contd) Figure 50-30-29
Figure 50-30-31
P-63384

P-63382
Figure 50-30-32 Remove the pulley sheave (Item 1) [Figure 50-30-29]. Figure 50-30-30 1
P-63385
Remove the cooling fins (Item 1) [Figure 50-30-32].

P-63383
50-30-11
Figure 50-30-35
2 3 1
P-63388
1 Remove the 3 nuts (Item 1) [Figure 50-30-35].

P-63386
Figure 50-30-36 Disconnect the wire (Item 1). Remove the bolt (Item 2). Remove the capacitor (Item 3) [Figure 50-30-33]. Figure 50-30-34
1 1
P-63389
Remove the washers (Item 1) [Figure 50-30-36].

P-63387
Remove the 2 bolts (Item 1) and brush holder (Item 2) [Figure 50-30-34].
50-30-12
Figure 50-30-39
1 1 1
P-63392
Remove the face plate (Item 1) [Figure 50-30-39].

P-63390
Figure 50-30-40 Remove the 4 screws (Item 1) [Figure 50-30-37]. Figure 50-30-38
1 1
P-63395
P-63391
Align the notch with the tab on the cover (Item 1) [Figure 50-30-40].
50-30-13
Figure 50-30-43
2 1
1 1
P-63397
P-63394
Remove the bearings (Item 1) and plate (Item 2) [Figure 50-30-43]. Figure 50-30-44
Remove the rotor (Item 1) [Figure 50-30-41]. Figure 50-30-42
1
P-63398
P-63396
Remove the cover (Item 1) [Figure 50-30-42].
50-30-14
Figure 50-30-47
1 2 1
P-63399
Unsolder the 3 wires (Item 1) [Figure 50-30-47].

P-63403
Remove the rectifier (Item 2) [Figure 50-30-47]. Remove the stator (Item 1) [Figure 50-30-45]. Figure 50-30-46 1 1 Figure 50-30-48
P-63400 P-63402
Remove the bushing (Item 1) [Figure 50-30-48]. Remove the bushing (Item 1) [Figure 50-30-46].
50-30-15
Stator Ground Test Figure 50-30-51
P-63529 P-63401
Remove the bushing (Item 1) [Figure 50-30-49]. Stator Continuity Test Use an ohmmeter to test the stator. Figure 50-30-50
Touch one probe to a bare stator lead and the other probe to the bare metal surface of the stator [Figure 5030-51]. There should be no continuity. Replace the stator if there is continuity. Rotor Continuity Test Figure 50-30-52
P-63528
Touch the probes to two of the bare stator wires [Figure 50-30-50]. Move one of the probes to the third wire.
P-63307
Touch the probes to the slip rings [Figure 50-30-52]. The ohmmeter should read between 3.0 - 4.0 ohms. The readings should be the same. If there is no continuity replace the rotor. If there is no continuity, replace the stator.
50-30-16
ALTERNATOR (CONTD) Rotor Ground Test Figure 50-30-53
P-63308
Touch one probe to one of the slip rings and the other probe to the rotor shaft [Figure 50-30-53]. There should be no continuity. Replace the rotor if there is continuity. Capacitor Continuity Test Figure 50-30-54
P-63610
Check the capacitor for continuity between the mounting tab (Item 1) and the lead (Item 2) [Figure 50-30-54]. If there is continuity the capacitor is bad. Check the capacitor by connecting an ohmmeter between the mounting tab and the lead. The ohmmeter will initially show movement and then return to indicating no continuity as the capacitor is charged. Discharge the capacitor by grounding the lead to the tab before installation.
50-30-17
ALTERNATOR (CONTD) Assembly Figure 50-30-55
Figure 50-30-57
1 1 2
P-63399
P-63401
Install the rectifier (Item 1). Solder the 3 wires (Item 2) [Figure 50-30-57]. Figure 50-30-58
Install the bushing (Item 1) [Figure 50-30-55]. Figure 50-30-56 1 1
P-63402
P-63400
Install the bushing (Item 1) [Figure 50-30-58].
50-30-18
ALTERNATOR (CONTD) Assembly (Contd) Figure 50-30-59
Figure 50-30-61
1 2 2
P-63397
P-63403
Install the plate (Item 1) and 2 bearings (Item 2) [Figure 50-30-61]. Figure 50-30-62
Install the stator (Item 1) [Figure 50-30-59]. Figure 50-30-60
1 1
P-63396
P-63398
Install the cover (Item 1) [Figure 50-30-62].
Install the 2 screws (Item 1) [Figure 50-30-60].
50-30-19
ALTERNATOR (CONTD) Assembly (Contd)
Figure 50-30-65
1 Figure 50-30-63
1 Install the face plate (Item 1) [Figure 50-30-65].

P-63395
P-63392
Figure 50-30-66 Align the tab on the cover (Item 1) with the notch in the rectifier (Item 2) [Figure 50-30-63]. Figure 50-30-64
1 1
P-63404
Install the 4 screws (Item 1) [Figure 50-30-66].

P-63394
Install the rotor (Item 1) [Figure 50-30-64].
50-30-20
Figure 50-30-69
1 1 Install the 3 nuts (Item 1) [Figure 50-30-69].

P-63390 P-63388
Figure 50-30-70 Install the 4 screws (Item 1) [Figure 50-30-67]. Figure 50-30-68 1 2
P-63387
1 Install the washers (Item 1) [Figure 50-30-68].
P-63389
Install the brush holder (Item 1) with 2 bolts (Item 2) [Figure 50-30-70].
50-30-21
Figure 50-30-73
1 3
P-63386
P-63384
Install the washer (Item 1) [Figure 50-30-73]. Figure 50-30-74
Install the capacitor (Item 1) with the screw (Item 2). Connect the wire (Item 3) [Figure 50-30-71]. Figure 50-30-72 1 1
P-63383
Install the spacer (Item 1) [Figure 50-30-74].

P-63385
Install the cooling fin (Item 1) [Figure 50-30-72].
50-30-22
Figure 50-30-77
P-63380

P-63382
Figure 50-30-78 Install the pulley sheave (Item 1) [Figure 50-30-75]. Figure 50-30-76
1 1
P-63379

P-63381
Install the pulley sheave (Item 1) [Figure 50-30-76].
50-30-23
P-63378
Install the nut (Item 1) [Figure 50-30-79].
50-30-24
50-30-25
50-30-26
STARTER Removal And Installation (S/N 522311001 & Above) The engine is shown removed for photo clarity. Shut off the battery disconnect switch. (See Servicing on Page 50-20-1.) Remove the muffler. ((See MUFFLER (S/N 522311001 & ABOVE) on Page 60-20-1.).) Figure 50-40-1 1 2 1
STARTER (CONTD) Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above) Remove the muffler. ((See MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 60-211.).) Disconnect the battery. (See Servicing on Page 50-20-1.) Figure 50-40-2
2 2
P-61453 P-38196
Disconnect the wires (Item 1) [Figure 50-40-1]. Remove the three bolts (Item 2) [Figure 50-40-1]. Remove the starter.
Remove the three bolts (Item 1) and shield (Item 2) [Figure 50-40-2]. Figure 50-40-3
P-61452
Remove the wires (Item 1) [Figure 50-40-3] from the starter.
50-40-1
Figure 50-40-4
P-61451
Remove the two bolts (Item 1) [Figure 50-40-4] from the starter. Remove the starter.
50-40-2
STARTER (CONTD) Parts Identification (All Models)
16 3 2 1 14 15 16 2
18
18
13 3 4 5 17 7 2 16
2 18 2 16 22
24 23 11
6 9 10
11 11
12
16 21
20
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
Magnetic Switch Washer Nut Clamp Screw Bearing Bolt Housing Snap Ring Collar Bushing Pinion Plate Yoke Pivot Seal Shaft Gear Armature Frame Brush Holder Retainer Cover Cap
19 13
B-23284
50-40-3
STARTER (CONTD) Disassembly (All Models) Figure 50-40-5
Figure 50-40-7
P-63314
P-63312
Remove the frame (Item 1) [Figure 50-40-7] from the 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 5040-5] for ease of assembly. Figure 50-40-6
1
P-63315
1 1 Remove the cap (Item 1) from the cover (Item 2) [Figure 50-40-8].
P-63313
Remove the bolts (Item 1) [Figure 50-40-6].
50-40-4
STARTER (CONTD) Disassembly (All Models) (Contd) Figure 50-40-9
Figure 50-40-11
1
P-63318
P-63316
Remove the armature (Item 1) [Figure 50-40-11] from the frame. Figure 50-40-12
Remove the retainer (Item 1) [Figure 50-40-9] and washer. Figure 50-40-10
P-63319
1
P-63317
The brushes are non-replaceable. If the brushes are worn, remove the wire (Item 1) from the brush holder (Item 2) [Figure 50-40-12] and replace the brush holder.
50-40-5
STARTER (CONTD) Disassembly (All Models) (Contd) Figure 50-40-13 1
Figure 50-40-15
3 2 1 1 1 Remove the spring (Item 1), poppet (Item 2) and flange (Item 3) [Figure 50-40-15]. Figure 50-40-16 Remove the screws (Item 1) [Figure 50-40-13] from the housing. Figure 50-40-14
P-63324
P-63321
1 1
P-63327

P-63322
Remove the starter housing (Item 1) [Figure 50-40-14] from the magnetic switch housing.
50-40-6
Figure 50-40-19
P-63333
1 Install the tube (Item 1) [Figure 50-40-19] over the retainer, and tap gently. Figure 50-40-20 Remove the pinion (Item 1) [Figure 50-40-17]. Figure 50-40-18 2 1 1.5 (38 mm)
P-63328
P-63334
0.675 (17 mm)
P-63335
Press the collar (Item 1) down to gain access to the snap ring (Item 2) [Figure 50-40-20]. Remove the snap ring.
In order to remove the snap ring from the pinion shaft, a tube 0.675 inches (17 mm) in diameter by 1.5 inches (38 mm) in length is needed [Figure 50-40-18].
50-40-7
Figure 50-40-23
2 1
P-63339
2 1
P-63337
Press down on the over running clutch (Item 1) [Figure 50-40-23]. Remove the snap ring (Item 2) [Figure 50-40-23].
Remove the collar (Item 1) and pinion (Item 2) [Figure 50-40-21]. Figure 50-40-22
Figure 50-40-24
4 3 2 1
1
P-63338
P-63340
Remove the yoke (Item 1) [Figure 50-40-22].
Remove the snap ring retainer (Item 1), yoke retainer (Item 2), spring retainer (Item 3) and spring (Item 4) [Figure 50-40-24].
50-40-8
Figure 50-40-27
P-63341

P-63342
Figure 50-40-28 Remove the plate (Item 1) [Figure 50-40-25]. Figure 50-40-26 1
P-63345

P-63343
Remove the gears (Item 1) [Figure 50-40-26].
50-40-9
Figure 50-40-31
P-63348
2 Remove the washer (Item 1) [Figure 50-40-31].

P-63344
Figure 50-40-32 Remove the shaft assembly (Item 1) from the gear assembly (Item 2) [Figure 50-40-29]. Figure 50-40-30
1
P-63349
Remove the gear (Item 1) [Figure 50-40-32].

P-63347
Remove the bushing (Item 1) [Figure 50-40-30].
50-40-10
Figure 50-40-35
P-63364

P-63363
Figure 50-40-36 Remove the bushing (Item 1) [Figure 50-40-33]. Figure 50-40-34 1 1
P-63377
1
P-63350
Remove the bushing (Item 1) [Figure 50-40-36].
Remove the seals (Item 1) [Figure 50-40-34].
50-40-11
STARTER (CONTD) Inspection And Repair (All Models) Inspect the brush cover for discoloration, indicating the starter has been overheated. Inspect the pinion teeth for wear and damage. Figure 50-40-37
Figure 50-40-39
P-63368
Armature Winding Continuity Test: Use a circuit tester, touch the probes to two commutator segments [Figure 50-40-39]. There must be continuity at any point. If there is no continuity, the winding is open-circuited, replace the armature.
B-14455
Figure 50-40-40
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 50-40-37]. A short-circuited armature causes the blade to vibrate and be attracted to the core. An armature which is short-circuited must be replaced. Figure 50-40-38
B-14458
Commutator Run-Out Test: Check the commutator runout as shown in [Figure 50-40-40]. Service Limit - 0.020 inch (0,4 mm) If the commutator exceeds the service limit, repair as needed.
P-63367
Armature Winding Ground Test: Use a circuit tester, touch one probe to a commutator segment and the other probe to the armature core [Figure 50-40-38]. There should be no continuity. If there is continuity, the armature is grounded and must be replaced.
50-40-12
STARTER (CONTD) Inspection And Repair (All Models) (Contd) Figure 50-40-41
Figure 50-40-42
P-63369
B-14460
Measure the segment mica depth (Item 1) [Figure 50-4041]. Service Limit - 0.008 inch (0,2 mm)
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 50-4042]. There should be no continuity. If there is continuity, the field windings are grounded. Replace the field windings. Figure 50-40-43
If it is worn, replace the armature. Check the commutator surface for burned spots which usually indicates an open-circuit, and correct it using #400 sand paper. Check the field windings for wear and damage. Check all the connections for clean and tight solder joints.
P-63375
Field Windings Continuity Test: Use a circuit tester, touch one probe to the wire and the other probe to the brush [Figure 50-40-43]. There must be continuity. If there is no continuity, the field windings are open-circuited. Replace the yoke if the field windings have an open circuit. 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.
50-40-13
STARTER (CONTD) Inspection And Repair (All Models) (Contd) Figure 50-40-44
Figure 50-40-46
P-63377

N-15059
Figure 50-40-47 Brush Holder Insulation Test: Use a circuit tester, touch one probe to the positive brush holder plate and the other probe to the holder plate [Figure 50-40-44]. There should be no continuity. If there is continuity, replace or repair. Assembly (All Models) Figure 50-40-45 1
1 Install the bearing (Item 1) [Figure 50-40-47].
P-63364
P-63332
Inspect the over running clutch (Item 1) [Figure 50-4045], it must rotate freely in the direction of the starter rotation and locked in the opposite rotation.
50-40-14
STARTER (CONTD) Assembly (All Models) (Contd) Figure 50-40-48
Figure 50-40-50
1 1
P-63348
1
P-63350
Install the gear (Item 1) [Figure 50-40-50]. Figure 50-40-51
Install the seals (Item 1) [Figure 50-40-48]. Figure 50-40-49
1 1
P-63348

P-63363
50-40-15
Figure 50-40-54
1 Install the washer (Item 1) [Figure 50-40-54].

P-63347
P-63345
Figure 50-40-55 Install the bushing (Item 1) [Figure 50-40-52] in the shaft assembly. Figure 50-40-53
1 1
P-63341

P-63344
Install the shaft assembly (Item 1) [Figure 50-40-53].
50-40-16
Figure 50-40-58
1 2 3 4
P-63340
P-63343
Install the spring (Item 1), spring retainer (Item 2), yoke retainer (Item 3) and snap ring retainer (Item 4) [Figure 50-40-58]. Figure 50-40-59
Install the gears (Item 1) [Figure 50-40-56]. Figure 50-40-57
1 2
1
P-63339 P-63342
Press down on the snap ring retainer (Item 1) and install the snap ring (Item 2) [Figure 50-40-59]. Install the plate (Item 1) [Figure 50-40-57].
50-40-17
Figure 50-40-62
P-63334
1 Install the snap ring (Item 1) [Figure 50-40-62].

P-63338
Figure 50-40-63 Install the yoke (Item 1) [Figure 50-40-60]. Figure 50-40-61 1
P-63332
1 2
P-63337
Install the collar (Item 1) [Figure 50-40-63] over the snap ring.
Install the pinion (Item 1) and collar (Item 2) [Figure 5040-61].
50-40-18
Figure 50-40-66
1 2 1 3
P-63324
3
P-63329
Install the flange (Item 1), poppet (Item 2) and spring (Item 3) [Figure 50-40-66].
Align the notch (Item 1) with the tab (Item 2). Install the pinion (Item 3) [Figure 50-40-64]. Figure 50-40-65
P-63327
50-40-19
Figure 50-40-69
1 1
P-63322
P-63326
Install the magnetic switch housing (Item 1) [Figure 5040-69]. Figure 50-40-70
Figure 50-40-68 1
1 1
P-63321 P-63325
Install the screws (Item 1) [Figure 50-40-70]. The end of the poppet (Item 1) [Figure 50-40-67] must fit over the end of the yoke (Item 1) [Figure 50-40-68].
50-40-20
Figure 50-40-73
2 2
1
P-63376
P-63320
Install the armature (Item 1). Remove the punches (Item 2) [Figure 50-40-73]. Figure 50-40-74
Solder the wire (Item 1) [Figure 50-40-71] if the brush holder assembly has been replaced. Figure 50-40-72
1
P-63317
Install the cover (Item 1) [Figure 50-40-74].

P-63365
Push the brushes into the brush holders. Use small punches to hold the brushes in place [Figure 50-40-72].
50-40-21
Figure 50-40-77
P-63314
Install the frame (Item 1) [Figure 50-40-77].

P-63316
Figure 50-40-78 Install the washer and retainer (Item 1) [Figure 50-4075]. Figure 50-40-76
1 1
P-63313
1 Install the bolts (Item 1) [Figure 50-40-78].

P-63315
Install the cap (Item 1) [Figure 50-40-76].
50-40-22
P-63312
Install the cable (Item 1) [Figure 50-40-79] on the terminal.
50-40-23
50-40-24
STARTER (S/N 528911001 & ABOVE & S/N 528611001 & ABOVE) Removal And Installation Remove the muffler. (See MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 60-211.) Disconnect the battery. (See BATTERY on Page 50-201.) Figure 50-41-80
Figure 50-41-82
P-61451
1 Remove the two bolts (Item 1) [Figure 50-41-82] from the starter. 2 Remove the starter.
P-61453
Remove the three bolts (Item 1) and shield (Item 2) [Figure 50-41-80]. Figure 50-41-81
P-61452
Remove the wires (Item 1) [Figure 50-41-81] from the starter.
50-41-1
50-41-2
FRONT CAB LIGHT Removal And Installation Figure 50-50-1
Figure 50-50-2
1 1
P-36367
Figure 50-50-3
P-36352
Remove the bolt (Item 1) [Figure 50-50-1] nut and flat washer.
P-36368
Installation: Align the notch (Item 1) [Figure 50-50-2] on the bolt with the notch (Item 1) [Figure 50-50-3] in the mount bracket. Tighten the bolt enough to prevent the light from pivoting in the bracket. NOTE: Do not overtighten the bolt. The housing may be damaged.
50-50-1
FRONT CAB LIGHT (CONTD) Removal And Installation Figure 50-50-4
Disassembly And Assembly Figure 50-50-5
P-36354 P-36353
Remove the two bushings (Item 1) [Figure 50-50-5]. Unplug the wire connector (Item 1) [Figure 50-50-4]. Installation: The wire connector can only be plugged in one way. Figure 50-50-6
P-36356
Loosen the four screws (Item 1) [Figure 50-50-6].
50-50-2
FRONT CAB LIGHT (CONTD) Disassembly And Assembly (Contd) Figure 50-50-7
Figure 50-50-9
P-36360
1
P-36357
Squeeze the ends of the retainer clip (Item 1) [Figure 5050-9] and pivot the retainer clip to the side. Figure 50-50-10
Remove the four screws (Item 1) and cover (Item 2) [Figure 50-50-7]. 1 Figure 50-50-8
P-36362
2 Remove the bulb (Item 1) [Figure 50-50-10].

P-36359
Disconnect the red wire (Item 1) from the white wire (Item 2). Remove the black wire (Item 3) [Figure 50-50-8] from the housing.
NOTE: Do not touch the bulb. If the bulb needs to be cleaned use a clean lint free cloth. Any dirt or oil on the bulb will shorten the service life of the bulb.
50-50-3
FRONT CAB LIGHT (CONTD) Disassembly And Assembly (Contd) Figure 50-50-11
2
P-36363
Figure 50-50-12
P-36364
Installation: Align the notches (Item 1 & 2) [Figure 5050-11] on the bulb with the notches (Item 1 & 2) [Figure 50-50-12] in the housing
50-50-4
TWO SPEED SWITCH Removal And Installation Turn the battery disconnect switch to the off position. Figure 50-60-1
Figure 50-60-3
2
P-63442
Press in on the tab (Item 1) [Figure 50-60-3]. (Both ends) 1

P-63440
Figure 50-60-4
The two-speed switch (Item 1) [Figure 50-60-1] is located on the right console. Raise the panel (Item 2) [Figure 50-60-1]. Figure 50-60-2 1
P-63443
Remove the two speed switch (Item 1) [Figure 50-60-4].
1 1
P-63441
Disconnect the 2 wire connectors (Item 1) [Figure 50-602].
50-60-1
50-60-2
FUEL LEVEL SENDER Removal And Installation Disconnect the negative battery cable. (See BATTERY on Page 50-20-1.) Remove the rear cover. (See REAR COVER on Page 40150-1.) Figure 50-70-1
P-33730
Remove the power wire (Item 1) and ground wire (Item 2) [Figure 50-70-1]. Figure 50-70-2
P-33729
Remove the four bolts (Item 1) [Figure 50-70-2]. Remove the sender.
50-70-1
50-70-2
WIPER MOTOR Removal And Installation Figure 50-80-1
Figure 50-80-3
1 1
P-36373
Remove the wiper arm (Item 1) [Figure 50-80-3].

P-36371
Figure 50-80-4 Open the cover (Item 1) [Figure 50-80-1]. Figure 50-80-2
1 1
2
P-36374
P-36372
Remove the nut (Item 1) and spacer (Item 2) [Figure 5080-4].
Remove the nut (Item 1) [Figure 50-80-2] and washer.
50-80-1
WIPER MOTOR (CONTD) Removal And Installation (Contd) Figure 50-80-5
Figure 50-80-7
P-36378

P-36376
Figure 50-80-8 Remove the two screws (Item 1) [Figure 50-80-5] from the cover. Figure 50-80-6 1
1
P-36379
Remove the two bolts (Item 1) [Figure 50-80-8].

P-36377
Figure 50-80-9
P-36380
Remove the wiper motor (Item 1) [Figure 50-80-9].

BATTERY DISCONNECT SWITCH Removal And Installation Disconnect the battery. (See Servicing on Page 50-20-1.) Figure 50-90-1
Figure 50-90-3
1 1 1 1 Mark and remove the six hoses (Item 1) [Figure 50-903]. Install caps and plugs.
P-35919 P-35921
Figure 50-90-4
Remove the four screws (Item 1) [Figure 50-90-1]. Raise the left console. Figure 50-90-2 2
P-40672
Remove the dust covers (Item 1) [Figure 50-90-4].
P-35920
Remove the three screws (Item 1) [Figure 50-90-2]. Remove the lower console cover (Item 2) [Figure 50-902].
50-90-1
BATTERY DISCONNECT SWITCH (CONTD) Removal And Installation (Contd) Figure 50-90-5
P-40673
Remove the two nuts (Item 1) and cables (Item 2) [Figure 50-90-5]. Figure 50-90-6
P-40660
Remove the key (Item 1) and two bolts (Item 2) [Figure 50-90-6] and locknuts. Remove the switch.
50-90-2
INSTRUMENT PANEL Removal And Installation Figure 50-100-1
Figure 50-100-3
1 1
P-40667
P-32715
Loosen the wire harness screws and remove the wire harness (Item 1) [Figure 50-100-3]. Figure 50-100-4
Remove the screw (Item 1) [Figure 50-100-1]. Figure 50-100-2 1 1 1 1
1
P-40666
P-40668
Remove the two wire harness connectors (Item 1) [Figure 50-100-4]. Remove the instrument panel.
Tip the instrument panel back and remove the gauge light harness connectors (Item 1) [Figure 50-100-2].
50-100-1
INSTRUMENT PANEL (CONTD) E-Prom Information Figure 50-100-5
P-40664
Figure 50-100-6
P-40665
The E-prom (Item 1) [Figure 50-100-5] & [Figure 50100-6] is located on the back of the instrument panel. The E-prom is not dealer serviceable and the complete instrument panel must be sent to Bobcat Company for service.
50-100-2
ENGINE SERVICE AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1 ENGINE (S/N 522311001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1 ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) . . 60-61-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-61-1 ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) . . 60-50-1 Checking the Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3 Engine Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1 Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-15 Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-7 Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9 Fuel Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-21 Fuel Injector, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-18 Fuel Injector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-19 Fuel Shutoff Solenoid Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5 Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . 60-50-6 Glow Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4 Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-24 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-23 ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-1 Aneroid Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-34 Checking the Manifold Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-3 Engine Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-1 Fuel Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-17 Fuel Injector, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-14 Fuel Injector Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-15 Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 60-51-13 Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-10 Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-7 Fuel Injection Pump Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-9 Fuel Shutoff Solenoid Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-5 Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . 60-51-6 Manifold Heater Removal And Installation. . . . . . . . . . . . . . . . . . . . . . 60-51-4 Thermostat, Oil Pressure Control Valves & Heater Connections. . . . 60-51-31 Timing Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-19 Timing Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-22 Timing Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-20 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-28 Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-51-29 Continued On Next Page
DRIVE SYSTEM
ENGINE SERVICE
ENGINE SERVICE
SPECIFICATIONS
ENGINE SERVICE (CONTD) FLYWHEEL (S/N 522311001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1 Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1 FLYWHEEL (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) . .60-71-1 Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-71-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-71-1 MUFFLER (S/N 522311001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-1 MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) . . . 60-21-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-21-1 RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) . . . . . . . . . . . . . . . . 60-40-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1 RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1 Hydraulic Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . 60-41-5 Hydraulic Check Valve Disassembly And Assembly . . . . . . . . . . . . . . . . 60-41-6 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-41-1
60-02
ENGINE SERVICE (CONTD) RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE). . . . . . . . . . 60-80-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-9 Balancing Shaft Bearing, Checking (If Equipped) . . . . . . . . . . . . . . . . . 60-80-50 Balancing Shaft Bearing, Removal And Installation. . . . . . . . . . . . . . . . 60-80-51 Camshaft Bearing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-48 Camshaft Bearing, Removal And Installation . . . . . . . . . . . . . . . . . . . . 60-80-49 Connecting Rod, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-58 Control Rod Guide Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-52 Crankshaft, Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-56 Cylinder, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-47 Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-68 Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-65 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-2 Deutz Engine Tools Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1 Front Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-71 Front Cover Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-70 Piston, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-61 Piston Installation On The Connecting Rod . . . . . . . . . . . . . . . . . . . . . . 60-80-64 Piston Pin, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-62 Piston Rings Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-63 Rear Cover Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 60-80-54 Rocker Arm And Bracket, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-69 Turbo Charger Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-80-72 Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-66 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-67
60-03
ENGINE SERVICE (CONTD) RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-9 Camshaft Bearing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-29 Camshaft Bearing, Removal And Installation. . . . . . . . . . . . . . . . . . . . . 60-81-30 Connecting Rod, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-41 Control Rod Guide Bushing Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-33 Control Rod Guide Bushing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-31 Crankshaft, Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-39 Crankshaft Gear Mounting Bolt Torque Procedure . . . . . . . . . . . . . . . . 60-81-72 Cylinder, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-28 Cylinder Head Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-51 Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-48 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-2 Deutz Engine Tools Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-1 Front Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-60 Front Cover Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-54 Piston, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-44 Piston Installation On The Connecting Rod . . . . . . . . . . . . . . . . . . . . . . 60-81-47 Piston Pin, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-45 Piston Rings Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-46 Rear Cover Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 60-81-38 Rocker Arm And Bracket, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-53 Turbo Charger Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . 60-81-70 Valves, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-49 Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-81-50 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
60-04
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 Slow cranking speed. Engine will not start. Difficult to start. No power from engine. Engine is mis-firing. Too much fuel consumption. Black exhaust. Blue/white exhaust. Low oil pressure. Engine knocking. Engine running rough. Vibration. High oil pressure warning. Overheating. Too much crankcase pressure. Poor compression. Start and stop 1, 2, 3, 4 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28 10, 12,13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 46, 47 4, 31, 32, 33, 34, 35, 37, 38, 39, 45, 48 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 49 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 49 2, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43 4, 33, 36 10, 12, 13, 15, 16, 20, 21, 32, 40, 44, 47 22, 27, 29, 46 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 49 9, 10, 11 CAUSE
60-10-1
TROUBLESHOOTING (CONTD) Chart (Contd) KEY TO CORRECT THE CAUSE 1. Battery capacity low. 2. Bad electrical connections. 3. Faulty starter motor. 4. Incorrect grade of oil. 5. Low cranking speed. 6. Fuel tank empty. 7. Faulty stop control operation. 8. Plugged fuel line. 9. Plugged fuel filter. 10. Restriction in the air cleaner. 11. Air in the fuel system. 12. Faulty fuel injection pump. 13. Faulty fuel injectors. 14. Broken injection pump drive. 15. Incorrect injection pump timing. 16. Incorrect valve timing. 17. Poor compression. 18. Plugged fuel tank vent. 19. Incorrect grade of fuel. 20. Exhaust pipe restriction. 21. Cylinder head gasket leaking. 22. Overheating. 23. Cold running. 24. Incorrect tappet adjustment. 25. Sticking valves. 26. Incorrect high pressure fuel lines. 27. Worn cylinder bores. 28. Worn valves and seat. 29. Broken, worn or sticking piston rings. 30. Worn valve stems or guides. 31. Worn or damaged bearings. 32. Not enough oil in the oil pan. 33. Switch/sensor is defective. 34. Oil pump worn. 35. Pressure relief valve is sticking open. 36. Pressure relief valve is sticking closed. 37. Broken relief valve spring. 38. Faulty suction pipe. 39. Plugged oil filter. 40. Piston seizure. 41. Incorrect piston height. 42. Faulty engine mounting. 43. Incorrect alignment of flywheel. 44. Faulty thermostat. 45. Plugged oil cooler 46. Plugged PCV system 47. Damaged valve stem oil deflectors. 48. Plugged oil pump pipe strainer. 49. Broken valve spring.
60-10-2
MUFFLER (S/N 522311001 & ABOVE) Removal And Installation Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Remove the rear cover. (See REAR COVER on Page 40150-1.) Figure 60-20-1
Figure 60-20-3
P-35232
Remove the four bolts (Item 1) [Figure 60-20-3]. 1 Figure 60-20-4
P-35231
Remove the two bolts (Item 1) [Figure 60-20-1] and hose clamps. Figure 60-20-2
P-38128
Figure 60-20-5 1
P-35231
P-38129
Remove the two pump mount bolts (Item 1) [Figure 6020-4] and [Figure 60-20-5] and washers.
60-20-1
MUFFLER (S/N 522311001 & ABOVE) (CONTD) Removal And Installation (Contd) Installation: Tighten the bolts to 125-140 ft.-lb. (170-190 Nm) torque. Slide the pump away from the engine. Figure 60-20-6
Figure 60-20-8
P-40472
Remove the clamp (Item 1) [Figure 60-20-8]. 1 Reposition the tubeline (Item 2) [Figure 60-20-8] for clearance when removing the muffler. Figure 60-20-9
P-40474
Remove the clamp (Item 1) [Figure 60-20-6]. 1 Figure 60-20-7
P-40471
1
P-40473
Remove the three nuts (Item 1) [Figure 60-20-9].
Remove the bolt (Item 1) [Figure 60-20-7], spacer and nut. Remove the bolt (Item 2) [Figure 60-20-7] and nut.
60-20-2
MUFFLER (S/N 522311001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 60-20-10
Figure 60-20-12
1 1 Figure 60-20-13
P-40469
P-40467
Remove the bolts (Item 1) [Figure 60-20-10] and nuts. Figure 60-20-11 2 1 1
3 3
P-40468
Remove the four bolts (Item 1) [Figure 60-20-12] & [Figure 60-20-13] and washers.
P-40470
Remove the muffler from the mount.
Remove the bolt (Item 1), washer wire harness clamp and nut. Reposition the wire harness (Item 2) [Figure 6020-11] to prevent damage to the harness when removing the muffler. Remove the bolts (Item 3) [Figure 60-20-11] and washers. Installation: Apply medium strength thread adhesive (Loctite 242) to the bolt threads. Tighten the bolts to 33 ft.-lb. (45 Nm) torque. Remove the muffler and mount assembly.
60-20-3
60-20-4
MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Removal And Installation Figure 60-21-1
Figure 60-21-3
P-58447
1 Remove the bolts (Item 1) [Figure 60-21-2] & [Figure 60-21-3] and washers.
P-58445
Remove the muffler. Remove the nuts (Item 1) [Figure 60-21-1]. Figure 60-21-2
P-58446
60-21-1
MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 60-21-4
P-58448
Remove the gasket (Item 1) [Figure 60-21-4] from the turbo. NOTE: Plug the turbo to prevent any contamination from entering the engine. Figure 60-21-5 1
1 1
P-58449
Remove the bolts (Item 1) and washers. Remove the mount [Figure 60-21-5].
60-21-2
AIR CLEANER Removal And Installation Open the right side cover.
Figure 60-30-3
1 Figure 60-30-1 1 2
3 2
P-33726
Figure 60-30-4 5
P-33724
Remove the wire harness (Item 1) [Figure 60-30-1]. Loosen the clamps (Item 2). Remove the tube (Item 3) [Figure 60-30-1] and elbows. NOTE: Plug the intake to keep contamination out of the engine. Loosen the clamp (Item 4) and remove the air intake (Item 5) [Figure 60-30-1]. Figure 60-30-2 Slide the air cleaner (Item 1) [Figure 60-30-3] & [Figure 60-30-4] out the front of the excavator. 1 1
P-33727
P-33725
Remove the clamp (Item 1) [Figure 60-30-2].
60-30-1
60-30-2
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) Removal And Installation
NOTE: The plug is located next to the alternator mount bracket. Drain the coolant from the engine.
Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Remove the right side cover. (See RIGHT SIDE COVER on Page 40-160-1.) Remove the air conditioning condenser. (See CONDENSER (S/N 522311001 & ABOVE) on Page 70150-1 or See CONDENSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 70-151-1.) Figure 60-40-1
Figure 60-40-3
1 1
P-36921
Loosen the hose clamps (Item 1) [Figure 60-40-3] and remove the hoses from the radiator/oil cooler. Figure 60-40-4 1 1
P-38640
Remove the eleven bolts (Item 1) [Figure 60-40-1] and washers. 2 Remove the cover (Item 2) [Figure 60-40-1]. Figure 60-40-2 1
P-36922
Cut and remove the cable tie (Item 1) [Figure 60-40-4] from the lower radiator hose. NOTE: The lower hose will be removed with the radiator. Loosen the hose clamp (Item 2) [Figure 60-40-4] and remove the hose from the engine.
P-32849
Remove the plug (Item 1) [Figure 60-40-2] from the back side of the engine block.
60-40-1
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 60-40-5
Position the hose and bracket (Item 2) [Figure 60-40-6] towards the rear of the excavator. Reinstall the bolt (Item 1) [Figure 60-40-6]. Figure 60-40-7
2 1
P-36923
P-36925
Remove the hose (Item 1) [Figure 60-40-5]. Remove the top oil hose (Item 2) [Figure 60-40-5].
Remove the bottom oil hose (Item 1) [Figure 60-40-7].
IMPORTANT
I-2003-0888
Figure 60-40-6
P-36924
60-40-2
Figure 60-40-10
2 1
P-36928
Install a lifting chain and hoist on the lifting brackets [Figure 60-40-10].
P-36926
Figure 60-40-9
2 1
P-36927
Remove the top fan shroud mount bolts (Item 1) [Figure 60-40-8] & [Figure 60-40-9] from both sides. Install lifting brackets (Item 2) [Figure 60-40-8] & [Figure 60-40-9] on the bolts, and reinstall the bolts.
60-40-3
Remove the three bolts (Item 1) [Figure 60-40-11], [Figure 60-40-12] & [Figure 60-40-13] and washers. Figure 60-40-14
1 1
P-36930 P-36932
Figure 60-40-15 Figure 60-40-12
P-36929 P-36933
Figure 60-40-13
Remove the two radiator mount bolts (Item 1) [Figure 6040-14] & [Figure 60-40-15] and washers.
P-36934
60-40-4
RADIATOR/OIL COOLER (S/N 522311001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 60-40-16 2
Figure 60-40-18
P-36936
1
P-36935
Remove the top condenser bolts (Item 1) [Figure 60-4018] and washers. Remove the mount. NOTE: The receiver/dryer will be removed with the mount.
Remove the hose (Item 1) and wire harness (Item 2) [Figure 60-40-16] from the receiver/dryer. Figure 60-40-17
P-36937
Remove the bottom condenser bolts (Item 1) [Figure 6040-17] and washers.
60-40-5
Figure 60-40-21
P-36940
1 Raise the hoist and slide the radiator towards the front of the excavator. Remove the fan guard (Item 1) [Figure 60-40-21]. Remove the radiator.
P-36938
Figure 60-40-20
2
P-36939
Remove the two bolts (Item 1) [Figure 60-40-19] & [Figure 60-40-20] and washers. Remove the plate (Item 2) [Figure 60-40-20].
60-40-6
Figure 60-40-24
1 1
1
P-38010
Remove the bolts (Item 1) [Figure 60-40-24] and washers.

P-36941
Figure 60-40-23
Loosen the hose clamp and remove the lower radiator hose. Figure 60-40-25
1
P-36942
P-38011
Remove the washers (Item 1) [Figure 60-40-22] & [Figure 60-40-23] from the radiator mount.
Remove the bolts (Item 1) [Figure 60-40-25] and washers from both sides of the fan shroud.
60-40-7
P-38012
Remove the fan shroud (Item 1) [Figure 60-40-26].
60-40-8
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Removal And Installation Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Drain the engine oil. (See Replacing Oil And Filter on Page 10-90-2.) Figure 60-41-1
Figure 60-41-3
P-58451
Install the drain hose (Item 1) [Figure 60-41-3]. Tighten the hose until oil starts to drain from the radiator.
IMPORTANT
I-2003-0888
P-38640
Remove the eleven bolts (Item 1) [Figure 60-41-1] and washers. Remove the cover (Item 2) [Figure 60-41-1]. Figure 60-41-2
P-58450
Remove the cap (Item 1) [Figure 60-41-2] from the bottom of the cooler.
60-41-1
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 60-41-4 2
Figure 60-41-6
2 1
P-58453
1 3
P-58452
Remove the bolt (Item 1) and clamp. Remove the lower hydraulic cooler hose (Item 2) [Figure 60-41-6]. Figure 60-41-7
Remove the plug (Item 1) [Figure 60-41-4] and washer to assist draining the radiator. Install the plug and washer. Remove the drain hose after the radiator is drained. 1 Remove the upper hydraulic cooler hose (Item 2) and upper radiator hose (Item 3) [Figure 60-41-4]. Figure 60-41-5 1 1
P-58455
Remove the six bolts (Item 1) [Figure 60-41-7] and washers. (Three per side)
P-58454
Remove the tie strap (Item 1). Remove the lower radiator hose (Item 2) [Figure 60-41-5].
60-41-2
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 60-41-8
Figure 60-41-10
4 1
P-58459
3
P-58457
Tilt the radiator/cooler towards the front of the excavator and position the fan shroud over the fan [Figure 60-4110]. Figure 60-41-11
Remove the top bolt (Item 1) and washer. Remove the washer (Item 2) [Figure 60-41-8] from between the mount and bracket. Remove the four bolts (Item 3) [Figure 60-41-8], washers, and spacers. Rotate and remove the fan guard (Item 4) [Figure 60-418]. Figure 60-41-9
1 1
P-58460
Remove the fan bolts (Item 1) [Figure 60-41-11].
1 1
P-58458
Remove the bolts (Item 1) [Figure 60-41-9] and washers from the bottom of the radiator / oil cooler.
60-41-3
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 60-41-12
Figure 60-41-14
P-58464
Separate the radiator / oil cooler from the condenser mount and remove the cooler [Figure 60-41-14].
P-58461
Tilt the fan shroud forward and remove the fan (Item 1) [Figure 60-41-12]. Figure 60-41-13
P-58462
Remove the shroud (Item 1) [Figure 60-41-13].
60-41-4
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Hydraulic Check Valve Removal And Installation Figure 60-41-15 1
Figure 60-41-16
1
P-58465
Remove the bypass hose (Item 1) [Figure 60-41-16].

P-58452
Figure 60-41-17
There is a 14.5 PSI (1 bar) check valve (Item 1) [Figure 60-41-15] installed on the top of the oil cooler. The valve removal is shown with the radiator / oil cooler removed. The procedure can be done with the cooler installed in the excavator.
IMPORTANT
I-2003-0888
1
P-58466
Remove the check valve (Item 1) [Figure 60-41-17].
60-41-5
RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Hydraulic Check Valve Disassembly And Assembly Figure 60-41-18
P-58467
Remove the fitting (Item 1) [Figure 60-41-18]. Figure 60-41-19
P-58468
Remove the spring seat (Item 1), spring (Item 2), check valve (Item 3), and O-ring (Item 4) from the check valve body (Item 5) [Figure 60-41-19].
60-41-6
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) Engine Compression Checking Check and adjust the valve clearance as needed. (See Valve Clearance Adjustment on Page 60-50-23) The tools listed will be needed to do the following procedure: MEL 10630 - Engine Compression Tester MEL 1489 - Compression Test Adapter
Figure 60-50-2
IMPORTANT
Do not bend the high pressure fuel injection tubes when removing or installing them.
I-2029-0289
P-63087
Remove the valve cover [Figure 60-50-2]. Installation: Tighten the bolts to 6-7 ft.-lb. (8-10 Nm) torque. Figure 60-50-3
Figure 60-50-1
P-63086
P-63089
Disconnect the wire harness (Item 1) [Figure 60-50-1] from the fuel shut off solenoid.
Remove the fuel injector lines from the fuel pump and fuel injector [Figure 60-50-3]. Installation: Preload the injector cap nuts to 4 ft.-lb. (5 Nm) torque. Final tighten the nuts to 18-21 ft.-lb. (2528,5 Nm) torque. NOTE: Do not rebend or reuse fuel injector lines.
60-50-1
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Engine Compression Checking (Contd) Figure 60-50-4
Figure 60-50-6
P-63091
Install the injector retainer and bolt [Figure 60-50-6].

P-61842
Figure 60-50-7
Remove the injector [Figure 60-50-4]. Installation: Tighten the injector to 12-15 ft.-lb. (16-21 Nm) torque. Figure 60-50-5 1
P-63092
Connect the compression gauge (Item 1) [Figure 60-507] to the adapter. Turn the engine with the starter at 200 to 300 RPM. Run the test for each cylinder two times at 5 to 10 seconds each time and take the average reading. The correct compression of the engine is 406-479 PSI (28-33 bar) with no more than 15% difference between the cylinders.
P-63090
Install the compression adapter tool [Figure 60-50-5].
60-50-2
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Checking the Glow Plugs Not Available at Time of Print
60-50-3
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Glow Plug Removal And Installation Figure 60-50-8
P-63087
P-61843
Remove the glow plugs [Figure 60-50-9]. Installation: Tighten the glow plugs to 13-16 ft.-lb. (1822 Nm) torque.
60-50-4
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Shutoff Solenoid Checking Not Available at Time of Print
60-50-5
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Shutoff Solenoid Removal And Installation Figure 60-50-10
Figure 60-50-12
P-61950
Remove the solenoid [Figure 60-50-12].

P-63086
Installation: Press and hold the control rod in the stop position. Install the solenoid.
Disconnect the wire harness [Figure 60-50-10]. Figure 60-50-11
P-61951
Remove the two bolts [Figure 60-50-11]. Installation: Tighten the bolts to 15 ft.-lb. (21 Nm) torque.
60-50-6
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injection Pump Removal
Remove the fuel injector lines from the fuel pump and fuel injectors [Figure 60-50-14]. Installation: Preload the injector cap nuts to 4 ft.-lb. (5 Nm). Final tighten the bolts to 18-21 ft.-lb. (25-28,5 Nm) torque. NOTE: Do not rebend or reuse fuel injector lines. Figure 60-50-15
IMPORTANT
Do not attempt to maintain or adjust unless you are trained and have the correct equipment.
I-2028-0289
The injection pump(s) contain parts which have a very close tolerance and its operation has a direct effect on the performance of the engine. Figure 60-50-13
P-63093
Remove the bolts [Figure 60-50-15].
P-63087
P-63089
60-50-7
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injection Pump Removal (Contd) Figure 60-50-16
Figure 60-50-18
P-61849
Remove the tappet and shim(s) [Figure 60-50-18].

P-63094
Remove the flange [Figure 60-50-16]. Figure 60-50-17
P-63101
Remove the injection pump and shims [Figure 60-5017]. NOTE: The shim(s) are used to time the injection pump, keep the same thickness for each injection pump.
60-50-8
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injection Pump Timing Figure 60-50-19
Figure 60-50-21
P-61922
P-61920
Turn the locking tool. Move the control rod to the stop position by pressing in on the setscrew [Figure 60-5021]. Figure 60-50-22
Install the control rod locking tool (MEL-XXX) [Figure 6050-19]. Figure 60-50-20
P-61923
P-61921
Install the graduated disc MEL XXX on the flywheel flange [Figure 60-50-22].
Measure and record the distance from the locking tool to the stop position of the control rod [Figure 60-50-20]. Measure and record the distance from the locking tool to the start position of the control rod. The difference in the distance between the start and stop position is the control rod travel. The allowable range for control rod travel is 0.669-0.689 in. (17-17,5 mm)
60-50-9
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injection Pump Timing (Contd) Figure 60-50-23
Figure 60-50-25
P-61926
Set the graduated disc to zero before TDC. [Figure 6050-25].

P-61924
Install the pointer MEL XXX [Figure 60-50-23]. Install the TDC measuring bar MEL XXX and washers MEL XXX. Install a dial indicator on the measuring bar. Turn the crankshaft in the direction of engine rotation until the dial indicator reaches its reversal point. Figure 60-50-24
Turn the crankshaft in the direction of engine rotation approximately 90. Figure 60-50-26
P-61927
Turn the crankshaft against direction of engine rotation to 0.315 (8 mm) before TDC. The dial indicator reads zero [Figure 60-50-26].
P-61925
Set the dial indicator to zero [Figure 60-50-24]. Turn the crankshaft in the direction of engine rotation approximately 90. Turn the crankshaft against the direction of engine rotation to 0.315 in. (8 mm) before TDC. The dial indicator reads zero.
60-50-10
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injection Pump Timing (Cont'd) Record the measurement on the disc (Determined value). Divide the measurement by 2 (Actual value). Turn the crankshaft until the actual value is reached on the disc. Figure 60-50-27
Figure 60-50-29
P-61930
Install the tappet [Figure 60-50-29]. The fuel pump opening pressure and type of camshaft are stamped on the engine rating plate. Figure 60-50-30
P-61928
Example: 50 (Determined value) divided by 2 = 25 (Actual value) [Figure 60-50-27]. Figure 60-50-28
P-61931
Install a dial indicator on the measuring device MEL XXX. Set the dial to zero [Figure 60-50-30].
P-61929
Loosen the two screws and reset the graduated disc to zero [Figure 60-50-28].
60-50-11
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injection Pump Timing (Cont'd) Figure 60-50-31
Figure 60-50-33
P-61934
Measure and record dimension L [Figure 60-50-33].

P-61932
Enter the measurement in Table 1 [Figure 60-50-34 on Page 13]. Example: -116.26 mm-
Position the tappet, of the injector pump to be timed, on the base circle. Turn the crankshaft 180 opposite the direction of engine rotation [Figure 60-50-31]. Figure 60-50-32
P-61933
Carefully install the measuring device [Figure 60-50-32].
60-50-12
Figure 60-50-35
P-61935
Reset the dial indicator to -0- [Figure 60-50-35]. NOTE: Do not change the direction of rotation after the pre-stroke position has been reached. Turn the crankshaft in the direction of the engine rotation until the dial indicator reaches the pre-stroke dimension (See Table 1 [Figure 60-50-34]). Example: Commencement of delivery -9Camshaft type -CPrestroke -4.63 mmFigure 60-50-36
P-61937
B-23278
Read the actual commencement of delivery [Figure 6050-36]. Record in Table 1 [Figure 60-50-34]. Example: -8-
60-50-13
Figure 60-50-39
P-63102
Select the proper shim as follows [Figure 60-50-39]:

P-61938
Example: The injection cylinder 3 is to be replaced. Procedure: Read off EP code for cylinder 3 from nameplate under column EP, e.g. 070. (Reading sequence: line 1=cyl 1, line 2=cyl 2, etc. Take corrected injection pump installation dimension (Ek) from Table 3 [Figure 60-50-34 on Page 13] according to EP code. e.g. 111.725 mm Take code for injection pump length (A) from new injection pump. e.g. 53. Take standard dimension of injection pump (Lo) from Table 1 [Figure 60-50-34 on Page 13], e.g. 109 mm. Determine theoretical shim thickness (Ts): Ts = Ek-(Lo+A/100) Ts = 111.725 mm - (109 mm +53/100 mm) Ts = 2.195 mm = Ss 2.2 mm
Read the code for injection pump length -A- [Figure 6050-37]. Enter in Table 1 [Figure 60-50-34 on Page 13]. Example: -53Figure 60-50-38
P-63098
Remove the dial indicator [Figure 60-50-38].
Select shim thickness (S) according to Table 2 [Figure 60-50-34 on Page 13]. Ts 2.195 mm = Ss 2.2 mm Repeat the procedure for each injection pump.
60-50-14
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injection Pump Installation Figure 60-50-40
Figure 60-50-42
P-63101
Carefully install the linkage lever into the control rod [Figure 60-50-42].
P-63099
Figure 60-50-43 Install the proper shim on the tappet [Figure 60-50-40]. NOTE: To determine the proper shim see . Figure 60-50-41
P-63094
Install the flange [Figure 60-50-43]. NOTE: The chamfer on the flange must face the injection pump.
P-63100
Turn the injection pump linkage to the middle position [Figure 60-50-41]. Position the roller tappet on the base circle. Lightly oil the O-rings on the injector pump and crankcase bore.
60-50-15
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injection Pump Installation (Cont'd) Figure 60-50-44
Figure 60-50-46
P-63097
Turn the injection carefully counter-clockwise until it stops [Figure 60-50-46].

P-63095
Figure 60-50-47 Install the bolts [Figure 60-50-44]. Tighten the bolts to 4 ft.-lb. (5 Nm) torque. Figure 60-50-45
P-63093
Tighten the bolts as follows [Figure 60-50-47]: Initial torque60 Second stage torque5 ft.-lb. (7 Nm) Third stage torque7 ft.-lb. (10 Nm) Final stage torque22 ft.-lb. (30 Nm) NOTE: Alternately torque the bolts starting with the outer bolt.
P-63096
Loosen the bolts 60 [Figure 60-50-45].
60-50-16
Figure 60-50-50
P-61955
Loosen the injector clamp bolts [Figure 60-50-50].

P-61957
Installation: Tighten the injector clamp bolts to 12-15 ft.lb. (16-21 Nm) torque. Figure 60-50-51
Remove the fuel return lines [Figure 60-50-48]. NOTE: Do not reuse the fuel return lines. Figure 60-50-49
P-61954
P-61956
Remove the injector high pressure fuel lines [Figure 6050-51]. Installation: Install a new seal on the fuel lines and hand tighten. NOTE: Do not rebend or reuse the fuel injector lines.
Remove the fuel line cap nuts [Figure 60-50-49]. Installation: Preload the cap nuts to 4 ft.-lb. (5 Nm) torque. Tighten the cap nuts to 18-21 ft.-lb. (25-28,5 Nm) torque.
60-50-17
Fuel Injector, Checking
IMPORTANT
Do not disassemble or test the fuel injector nozzles unless you have the correct service and testing tools.
WARNING
P-61953
Remove the fuel injector clamps and bolts [Figure 60-5052]. Figure 60-50-53
W-2072-0496
The tools listed will be needed to do the following procedure: OEM1064 - Injection Nozzle Test OEM1065 - Accessory Set Figure 60-50-54
P-61952
Remove the injectors [Figure 60-50-53]. Installation: Lightly grease the seal on the injectors.
B-8971
NOTE: The return line fitting must face the exhaust side.
Connect the nozzle to the test pump, in a down position [Figure 60-50-54]. Operate the test pump until the nozzle valve opens: Injection Pressure:3625-3741 PSI. (250-258 bar)
60-50-18
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injector Disassembly Figure 60-50-55
Figure 60-50-57
1 2 3 4 6 5
CD-15333
Disassemble the parts as shown in [Figure 60-50-57].

MC-2177
Check nozzles spray pattern [Figure 60-50-55]: The spray pattern must be uniform from all four holes of the nozzle. The nozzles are dirty or defective: If the spray pattern is not uniform. If fuel drips from the end of the nozzle. If the spray is a solid stream instead of a mist.
1. Nozzle Cap Nut 2. Injector Nozzle 3. Adapter 4. Thrust Pin 5. Spring 6. Shim(s) Wash all the parts in clean diesel fuel and blow dry using compressed air. Figure 60-50-58
Figure 60-50-56
CD-15334
The nozzle needle and body [Figure 60-50-58] are lapped together and can not be exchanged with other nozzle parts.
CD-15332
DO NOT touch the nozzle needle with your fingers. Remove the nozzle cap nut [Figure 60-50-56]. When the nozzle body is held in the upright position, the needle should by its own weight slide slowly and smoothly on its seat [Figure 60-50-58].
60-50-19
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injector Disassembly (Contd) NOTE: If the nozzle needle does not slide smoothly, wash the injector nozzle parts again in clean diesel fuel. Blow dry with compressed air. Redo the procedure again. Replace the injectors as needed. Wash all new injectors in clean diesel fuel before installation. Figure 60-50-59
CD-15335
Check the seat surface of the adapter for wear. Make sure the centering pins are in place [Figure 60-50-59].
60-50-20
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injector Assembly Figure 60-50-60
Figure 60-50-62
CD-15338
Install the thrust pin with the centering collar facing toward the compression spring [Figure 60-50-62].
CD-15336
Figure 60-50-63 Install the shim(s) [Figure 60-50-60]. The injector opening pressure is adjusted by selecting the correct amount of shim(s). A thicker shim will increase the opening pressure at the injector nozzle. Figure 60-50-61
CD-15339
Install the adapter with the centering pins toward the thrust pin [Figure 60-50-63].
CD-15337
Install the compression spring [Figure 60-50-61].
60-50-21
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Fuel Injector Assembly (Cont'd) Figure 60-50-64
Figure 60-50-66
CD-15342
Tighten the cap nut to 29-37 ft.-lb. (40-50 Nm) torque [Figure 60-50-66].
CD-15340
Install the injector nozzle, make sure the center bore fits over the centering pins of the adapter [Figure 60-50-64]. NOTE: Be careful that the nozzle needle does not fall out of the nozzle body. Figure 60-50-65
Check the injector nozzle on the nozzle tester before installation. (See Fuel Injector, Checking on Page 60-5018.)
CD-15341
Install the nozzle cap nut [Figure 60-50-65].
60-50-22
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Valve Clearance Adjustment Make the valve clearance adjustment with the engine stopped and cold. Remove the valve cover and crankcase breather. Figure 60-50-67
Figure 60-50-69
CRANKSHAFT POSITION ONE Turn crankshaft until valves of cylinder No. 1 Over lap CRANKSHAFT POSITION TWO Turn crankshaft further by one complete revolution
(360)
DO NOT ADJUST ADJUST
MC-2174
Use the following sequence as shown in [Figure 60-5069] to set the valve clearance. Turn the crankshaft until the valves of cylinder No. 1 over-lap [Figure 60-50-69]. Turn the crankshaft by one complete revolution (360) and set the other valves. Figure 60-50-70
P-61964
When installing the valve cover bolts, tighten the bolts to 6-7 ft.-lb. (8-10 Nm) torque [Figure 60-50-67]. Figure 60-50-68
P-63103
P-63104
Loosen the locknut and turn the set screw until the clearance is correct [Figure 60-50-70]. Intake - 0.012 inch (0.3 mm) Exhaust - 0.020 inch (0.5 mm) Tighten the locknut to 13-16 ft.-lb. (18-22 Nm) torque.
When installing the crankcase breather bolts, tighten the bolts to 6-7 ft.-lb. (8-10 Nm) torque [Figure 60-50-68].
60-50-23
ENGINE COMPONENTS AND TESTING (S/N 522311001 & ABOVE) (CONTD) Thermostat Figure 60-50-71
P-63105
Press down on the thermostat and remove from the housing [Figure 60-50-71]. Installation: Press down and turn the thermostat into the housing. NOTE: The yoke must engage the housing.
60-50-24
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Engine Compression Checking Check and adjust the valve clearance as needed. (See Valve Clearance Adjustment on Page 60-51-28.) The tools listed will be needed to do the following procedure: MEL 10630 - Engine Compression Tester MEL 1433 - Compression Test Adapter Warm the engine. Clean the area around the fuel injection pump and injectors. Figure 60-51-1
IMPORTANT
I-2029-0289
Installation: Tighten the fuel line nuts to 10-12 ft.-lb. (13.5 - 16.5 Nm) torque. Figure 60-51-3
1
P-58312
Remove the bolt (Item 1) [Figure 60-51-3] and injector retainer.

P-58310
Installation: Tighten the bolt to 16 ft.-lb. (21 Nm) torque.
Disconnect the wire harness (Item 1) [Figure 60-51-1] from the fuel shutoff solenoid. Figure 60-51-2
P-58311
Remove the high pressure fuel line (Item 1) [Figure 6051-2] from the fuel pump and fuel injector.
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Engine Compression Checking (Contd) Figure 60-51-4
Figure 60-51-6
P-56716
Install the injector retainer (Item 1) [Figure 60-51-6] and bolt.

P-58313
Figure 60-51-7
Remove the injector (Item 1) [Figure 60-51-4]. Figure 60-51-5
1
P-56717
Connect the compression gauge (Item 1) [Figure 60-517] to the adapter.

P-56715
Install the compression adapter tool MEL-1433 [Figure 60-51-5].
Turn the engine with the starter at 200 to 300 RPM. Run the test for each cylinder two times at 5 to 10 seconds each time and take the average reading. The correct compression of the engine is 319 - 392 PSI (22 - 27 bar) with no more than 15% difference between the cylinders.
60-51-2
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Checking the Manifold Heater Open the right side cover. Figure 60-51-8
Figure 60-51-9
1 2
P-58328
Connect one lead from the multimeter to the terminal (Item 1) [Figure 60-51-9]. Connect the other lead to the base of the heater (Item 2) [Figure 60-51-9].
P-58327
The reading must be approximately 0.5 ohms. Remove the nut, washer and wire harness (Item 1) [Figure 60-51-8] from the manifold heater. Use a multimeter to measure the resistance of the heater. If the resistance is zero ohms, the heater has a short circuit and must be replaced. If the resistance is infinite, the coil of the heater is broken and the heater must be replaced.
60-51-3
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Manifold Heater Removal And Installation Figure 60-51-10
Figure 60-51-12
P-58330
Remove the copper washer (Item 1) [Figure 60-51-12].
P-58327
Remove the nut, washer and wire harness (Item 1) [Figure 60-51-10] and second washer. Figure 60-51-11
P-58329
Remove the heater (Item 1) [Figure 60-51-11].
60-51-4
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Shutoff Solenoid Checking Figure 60-51-13
P-58310
Disconnect the wire harness (Item 1) [Figure 60-51-13] from the fuel shutoff solenoid. Use a multi meter to measure the resistance of the fuel shutoff solenoid. Figure 60-51-14
P-58316
Connect the meter leads (Item 1) [Figure 60-51-14] to the terminals. The reading must be approximately 3.5 ohms. If the resistance is zero ohms the solenoid has a short circuit. If the resistance is infinite, the coil in the solenoid is broken.
60-51-5
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Shutoff Solenoid Removal And Installation
Figure 60-51-17
1 Figure 60-51-15
2 3
P-58318
Remove the O-ring (Item 1) [Figure 60-51-17]. Check the solenoid spring (Item 2) and linkage (Item 3) [Figure 60-51-17]. NOTE: When installing the fuel shutoff solenoid in the engine, the linkage (Item 3) [Figure 60-51-17] must engage the fuel control rack.
P-58310
Disconnect the wire harness (Item 1) [Figure 60-51-15]. Figure 60-51-16
2 3
P-58317
Cut and remove the cable tie (Item 1). Remove the two bolts (Item 2) and remove the solenoid (Item 3) [Figure 60-51-16]. Installation: Tighten the bolts to 10-12 ft.-lb. (13.5-16.3 Nm) torque.
60-51-6
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injection Pump Removal
Figure 60-51-19
IMPORTANT
Do not attempt to maintain or adjust unless you are trained and have the correct equipment.
I-2028-0289
The injection pump(s) contain parts which have a very close tolerance and its operation has a direct effect on the performance of the engine. Figure 60-51-18
P-58311
Use a flare nut wrench (Item 1) [Figure 60-51-19] to loosen the high pressure fuel line nut. Figure 60-51-20
2 1 1
P5282
Remove the fuel tubeline (Item 1) to the fuel injection pumps (Item 2) [Figure 60-51-18]. Disconnect the respective high pressure fuel line (Item 3) [Figure 60-51-18] from the injection pump to be removed and fuel injector.
P5281
Remove the two mounting nuts (Item 1) [Figure 60-5120] from the injection pump.
IMPORTANT
60-51-7
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injection Pump Removal (Contd) Figure 60-51-21
Figure 60-51-23
P-56990
Install the tappet into its respective bore [Figure 60-5123].

P5283
Remove the fuel injection pump (Item 1) [Figure 60-5121]. Remove the shim (Item 2) [Figure 60-51-21]. NOTE: The shim(s) are used to time the injection pump, keep the same thickness for each injection pump. Figure 60-51-22
P5279
Use a magnet to remove the injection pump tappet [Figure 60-51-22]. Inspect the tappet for wear or damage, replace as needed.
60-51-8
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injection Pump Timing The fuel injection pump does not need to be timed if the tappet, shim(s) and the camshaft are not changed. Figure 60-51-24
Measured Depth 2.29 inch. (58.16 mm) Difference0.070 inch. (1,78 mm) Determine the number of shim(s) needed to get the correct installation height. Figure 60-51-26
P-56994
P-56991
Install the appropriate number of shims on the engine block surface. [Figure 60-51-26].
Install a depth micrometer (Item 1) [Figure 60-51-24] and record the measurement. Figure 60-51-25
Tappet
MC-2175
Measure the distance between the engine block surface (without shim) and surface of the tappet [Figure 60-5125]. Installation dimension of the injection pump is 2.36 inch (60 mm). EXAMPLE: Specifications: Installation Depth2.36 inch. (60 mm)
60-51-9
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injection Pump Installation Figure 60-51-27
Figure 60-51-29
P-56995
Use the centering pin MEL-1467 to remove the press-in plug (Item 1) [Figure 60-51-29] from the injection pump.
P-56988
Figure 60-51-30
Remove the plug from the engine block. Install control rack locating pin MEL-1459 (Item 1) [Figure 60-51-27]. Figure 60-51-28
2
B-23275
P-56989
Install the centering pin (Item 1) into the injection pump and into the control lever (Item 2). Align the marks (Item 3) [Figure 60-51-30] on the pump body and the control lever. Make sure the control lever is in the center position.
Rotate the camshaft until the tappet stroke is at B.D.C. [Figure 60-51-28]. Tighten the locating pin.
60-51-10
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injection Pump Installation (Cont'd) Install the injection pump into the engine block. Make sure the control lever goes into the slot on the fuel control rack. Install the two nuts. Figure 60-51-31
Figure 60-51-33
P-56999
Install the press in plug [Figure 60-51-33]. Figure 60-51-34
P-56997
Tighten the mounting nuts to 15 ft.-lb. (21 Nm) torque [Figure 60-51-31]. Figure 60-51-32
P-58000
Remove the locating pin [Figure 60-51-34].
P-56998
Remove the centering pin [Figure 60-51-32].
60-51-11
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injection Pump Installation (Cont'd) Figure 60-51-35
Figure 60-51-37
P5285
Install new washers (Item 1) [Figure 60-51-37] on the fuel line bolts.
P-58001
Install the fuel line on the injection pumps and tighten to 20-23 ft.-lb. (27-31 Nm) torque.
Install the plug [Figure 60-51-35]. Tighten the plug to 14 ft.-lb. (18 Nm) torque. Install the high pressure fuel line. Figure 60-51-36
P-58311
Tighten the fuel line nut (Item 1) to 10-12 ft.-lb. (13,5 16,5 Nm) torque [Figure 60-51-36].
60-51-12
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injector Removal And Installation Figure 60-51-38
Figure 60-51-39
1
P-58312
Remove the bolt (Item 1) [Figure 60-51-39] and holddown clamp from the fuel injector.
P-58311
Installation: Tighten the bolt to 16 ft.-lb. (21 Nm) torque. Figure 60-51-40
Remove the high pressure fuel line (Item 1) [Figure 6051-38] from fuel injector to be removed and fuel injection pump.
IMPORTANT
Installation: Tighten the fuel line nut to 10-12 ft.-lb. (13,5-16,5 Nm) torque.
P-58313
Remove the fuel injector (Item 1) [Figure 60-51-40].
60-51-13
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injector Removal And Installation (Contd) Figure 60-51-41
Figure 60-51-42
1
B-8971
Connect the nozzle to the test pump, in a down position [Figure 60-51-42].
P-58314
Operate the test pump until the nozzle valve opens: Injection Pressure:3045-3161 PSI. (210-218 bar)
Remove the washer (Item 1) [Figure 60-51-41] from the injector. Fuel Injector, Checking
IMPORTANT
Do not disassemble or test the fuel injector nozzles unless you have the correct service and testing tools.
WARNING
W-2072-0496
The tools listed will be needed to do the following procedure: OEM1064 - Injection Nozzle Test OEM1065 - Accessory Set
60-51-14
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injector Disassembly Figure 60-51-43
Figure 60-51-45
1 2 3 4 6 5
CD-15333
Disassemble the parts as shown in [Figure 60-51-45]. 1. Nozzle Cap Nut 2. Injector Nozzle 3. Adapter 4. Thrust Pin 5. Spring 6. Shim(s) Wash all the parts in clean diesel fuel and blow dry using compressed air. Figure 60-51-46
MC-2177
Check nozzles spray pattern [Figure 60-51-43]: The spray pattern must be uniform from all four holes of the nozzle. The nozzles are dirty or defective: If the spray pattern is not uniform. If fuel drips from the end of the nozzle. If the spray is a solid stream instead of a mist.
Figure 60-51-44
CD-15334
The nozzle needle and body [Figure 60-51-46] are lapped together and can not be exchanged with other nozzle parts.
CD-15332
DO NOT touch the nozzle needle with your fingers. When the nozzle body is held in the upright position, the needle should by its own weight slide slowly and smoothly on its seat [Figure 60-51-46].
Remove the nozzle cap nut [Figure 60-51-44].
60-51-15
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injector Disassembly (Contd) NOTE: If the nozzle needle does not slide smoothly, wash the injector nozzle parts again in clean diesel fuel. Blow dry with compressed air. Redo the procedure again. Replace the injectors as needed. Wash all new injectors in clean diesel fuel before installation. Figure 60-51-47
CD-15335
Check the seat surface of the adapter for wear. Make sure the centering pins are in place [Figure 60-51-47].
60-51-16
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injector Assembly Figure 60-51-48
Figure 60-51-50
CD-15338
Install the thrust pin with the centering collar facing toward the compression spring [Figure 60-51-50].
CD-15336
Figure 60-51-51
Install the shim(s) [Figure 60-51-48]. The injector opening pressure is adjusted by selecting the correct amount of shim(s). A thicker shim will increase the opening pressure at the injector nozzle. Figure 60-51-49
CD-15339
Install the adapter with the centering pins toward the thrust pin [Figure 60-51-51].
CD-15337
Install the compression spring [Figure 60-51-49].
60-51-17
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Fuel Injector Assembly (Cont'd) Figure 60-51-52
Figure 60-51-54
CD-15342
Tighten the cap nut to 29-37 ft.-lb. (40-50 Nm) torque [Figure 60-51-54].
CD-15340
Install the injector nozzle, make sure the center bore fits over the centering pins of the adapter [Figure 60-51-52]. NOTE: Be careful that the nozzle needle does not fall out of the nozzle body. Figure 60-51-53
Check the injector nozzle on the nozzle tester before installation. (See Fuel Injector, Checking on Page 60-5114.)
CD-15341
Install the nozzle cap nut [Figure 60-51-53].
60-51-18
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Timing Belt Inspection NOTE: The timing belt is maintenance free. Timing belts that are in operation do not need to be re-tensioned. The timing belt, belt tensioner and mount bolt must be replaced every 3000 operating hours or every 5 years. A repair kit is available. NOTE: If the timing belt has to be removed before 200 hours of engine operation, the timing belt can be re-used and re-tensioned according to the procedure listed. To do the following procedure you need the following tool: ME-1552 - Torx Bit Figure 60-51-55
Figure 60-51-56
P-58326
Check the timing belt, sprockets and tensioner for wear, cracks or damage [Figure 60-51-56]. Check the timing belt in detail for the following conditions, replace as needed. 1. 2. 3. 4. 5. 6. 7. Oil deposits Hardened back rubber surfaces Cracked Badly worn teeth Missing tooth Side of belt badly worn Side of belt cracked
3 2
P-58315
Remove the bolts (Item 1) [Figure 60-51-55] from the timing belt inspection cover. Remove the torx bolt (Item 2) [Figure 60-51-55]. Remove the cover (Item 3) [Figure 60-51-55].
60-51-19
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Timing Belt Removal NOTE: The timing belt can be replaced in the excavator. The procedure is shown with the engine removed for photo clarity. To remove the belt with the engine installed, remove the radiator/oil cooler. (See RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 60-41-1.) Remove the bolts (Item 1) [Figure 60-51-55 on Page 19] from the timing belt inspection cover. Remove the torx bolt (Item 2) [Figure 60-51-55 on Page 19]. Remove the cover (Item 3) [Figure 60-51-55 on Page 19]. Figure 60-51-57
Figure 60-51-58
1
P-58798
Remove the shield (Item 1) [Figure 60-51-58]. Figure 60-51-59
2 1
2
P-58797
P-58800
Disconnect the wire harness (Item 1) [Figure 60-51-59] from the alternator. Remove the nuts and wire harness (Item 2) [Figure 6051-59].
Remove the bolts (Item 1) from the V-belt pulley (Item 2) [Figure 60-51-57]. Remove the V-belt pulley.
60-51-20
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Timing Belt Removal (Contd) Figure 60-51-60
Figure 60-51-62
1
P-58802
2
P-58799
Loosen the belt tensioner mounting bolt (Item 1) [Figure 60-51-62]. Loosen the belt tensioner. Remove the timing belt.
Remove the two bolts (Item 1). Remove the fan mount/ alternator assembly (Item 2) [Figure 60-51-60]. Figure 60-51-61
P-58801
Remove the bolts (Item 1) and remove the cover (Item 2) [Figure 60-51-61].
60-51-21
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Timing Belt Installation Figure 60-51-63
Figure 60-51-65
P-58805
The crankshaft plug is located at the front of the engine block (Item 1) [Figure 60-51-65] on the exhaust manifold side.
P9575
Remove the plug. The camshaft plug is located at the rear of the engine block (Item 1) [Figure 60-51-63] on the fuel injection pump side. NOTE: Remove the fuel injectors from the cylinder head. (See Fuel Injector Removal And Installation on Page 60-51-13). This will allow the crankshaft turn easier for timing belt installation. Remove the plug. Rotate the camshaft until the notch in the camshaft can be seen through the plug hole. Figure 60-51-64
B-14401
Figure 60-51-66
Rotate the crankshaft until the flat spot on the crankshaft throw (Item 1) can be seen through the plug hole. Turn the crankshaft back a small amount. Install the timing tool (Item 2) [Figure 60-51-66] and tighten.
P-58804
Install the timing tool MEL-1458 (Item 1) [Figure 60-5164] and tighten.
60-51-22
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Timing Belt Installation (Contd) Figure 60-51-67
Figure 60-51-69
1
P5630
Measure the distance from the edge of the belt to the front cover surface [Figure 60-51-69].
P-58806
Figure 60-51-70
Rotate the crankshaft until it hits the timing tool (Item 1) [Figure 60-51-67] and stops. Figure 60-51-68
P5632
Using the dimension, align the timing belt to make sure it is at an equal distance from the front cover [Figure 6051-70].
P5301
Loosen the nut at the camshaft gear using MEL-1466 Tool [Figure 60-51-68]. Install the new timing belt.
60-51-23
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Timing Belt Installation (Cont'd) Figure 60-51-71
Figure 60-51-73 1
2
N-18866
With a torque degree wheel (Item 1) [Figure 60-51-73] tighten the camshaft bolt an additional 210.
N-18863
Remove the camshaft and crankshaft locating pins. Figure 60-51-74
Install the belt tension tool MEL-1460 (Item 1) [Figure 60-51-71]. Turn the idler tensioner pulley in counterclockwise direction to obtain a scale reading of 3.0-3.5. Tighten the idler tensioner pulley nut (Item 2) [Figure 60-51-71] to 14-17 ft.-lb. (19-23 Nm) torque. Remove the belt tension tool. Figure 60-51-72
N-18864
Mark the crankshaft pulley (Item 1) [Figure 60-51-74]. Make four complete crankshaft revolutions in a clockwise direction of engine rotation. Bring the mark on the crankshaft pulley back to the same position.
N-18867
Initially tighten camshaft bolt to 22 ft.-lb. (30 Nm) [Figure 60-51-72].
60-51-24
Figure 60-51-77
2
N-18865
1
N-18852
Measure the belt tension. The reading should be 6.5-9.5 [Figure 60-51-77]. NOTE: If the specified scale reading is not obtained, repeat the installation procedure starting with [Figure 60-51-63 on Page 22]. Remove the belt tension tool. NOTE: See Valve Timing before installing the timing belt cover. (See Valve Timing, Checking on Page 60-51-29) Figure 60-51-78
Install the belt tension tool (Item 1) [Figure 60-51-75]. NOTE: The belt tension tool may touch the governor linkage cover (Item 2) [Figure 60-51-75], but will not affect the belt tightening procedure. Figure 60-51-76
N-18853 P-58801
Check the position of the belt tension tool (Item 1) [Figure 60-51-76] on the belt.
Install the belt cover (Item 1) [Figure 60-51-78] and tighten the bolts.
60-51-25
Figure 60-51-81
2 1
P-58798
Install the shield (Item 1) [Figure 60-51-81]. Figure 60-51-82

P-58799
Install the fan mount/alternator assembly (Item 1) and bolts (Item 2) [Figure 60-51-79]. Figure 60-51-80
P-58797
1 Install the V-belt pulleys (Item 1) [Figure 60-51-82]. Tighten the bolts to 28-34 ft.-lb. (38-46 Nm) torque.
P-58800
Install the wire harness (Item 1) [Figure 60-51-80] on the alternator.
60-51-26
P-58315
Install the timing belt inspection cover (Item 1) [Figure 60-51-83] and tighten the bolts.
60-51-27
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Valve Clearance Adjustment Make the valve clearance adjustment with engine stopped and cold. Remove the valve cover. Figure 60-51-84
Figure 60-51-86
P-56712
Loosen the locknut and turn the set screw until the clearance is correct [Figure 60-51-86]. Intake - 0.012 inch (0.3 mm) Exhaust - 0.020 inch (0.5 mm) Tighten the locknut to 13-16 ft.-lb. (18-22 Nm) torque.
P-56714
When installing the valve cover bolts, tighten to 75 in.-lb. (8.5 Nm) torque [Figure 60-51-84]. Figure 60-51-85
CRANKSHAFT POSITION ONE Turn crankshaft until valves of cylinder No. 1 Overlap DO NOT ADJUST CRANKSHAFT POSITION TWO Turn crankshaft further by one complete revolution (360) ADJUST
F L Y W H E E L
F L Y W H E E L
MC-2174
Use the following sequence as shown in [Figure 60-5185] to set the valve clearance. Turn the crankshaft until the valves of cylinder No. 1 overlap [Figure 60-51-84]. Turn the crankshaft by one complete revolution (360) and set the other valves.
60-51-28
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Valve Timing, Checking Figure 60-51-87
Figure 60-51-89
P-56710
1 At the crankshaft pulley bolt, install a torque wrench and turn the engine in the direction of rotation to 30 ft.-lb. (40 Nm) torque [Figure 60-51-89].
P-58319
Remove the camshaft access plug (Item 1) [Figure 6051-87]. Rotate the crankshaft/camshaft until the notch in the camshaft can be seen through the plug hole. Figure 60-51-88
Remove the torque wrench, DO NOT change the crankshaft position. Figure 60-51-90
1
P-58320
Remove the crankshaft access plug (Item 1) [Figure 6051-90].

P-58443
Install the timing tool (Item 1) [Figure 60-51-88].
NOTE: The access plug is located on the front of the crankcase, below the turbocharger and just above the right side front engine mount.
60-51-29
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Valve Timing, Checking, (Contd) Figure 60-51-91
P-58444
Turn the crankshaft timing tool MEL-1458 (Item 1) [Figure 60-51-91] into the crankcase until it makes slight contact with the crankshaft. Mark the position of the timing tool. The valve timing is correct if the timing tool can be turned into the crankcase another 3/4 to 2-1/4 turns until it stops. If the timing tool can not be turned into the crankcase the required turns, the camshaft (valve timing) setting will have to be redone.
60-51-30
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Thermostat, Oil Pressure Control Valves & Heater Connections Figure 60-51-92
Figure 60-51-94 1
2 3
4 1 5 6
B-14310
Remove the plug and O-ring (Item 1) [Figure 60-51-92]. Remove the thermostat and spring assembly (Item 1) [Figure 60-51-94] from the engine block.
P-58322
Figure 60-51-93
Installation: Install the plug and tighten to 82 ft.-lb. (111 Nm) torque. Remove the plug and O-ring (Item 2) [Figure 60-51-93] and remove the spring and oil pressure control valve (Item 2) [Figure 60-51-94] from the engine block. Installation: Install the plug and tighten to 82 ft.-lb. (111 Nm) torque. 3 Remove the heater hose, fitting (Item 3) [Figure 60-5193], and O-ring (Item 3) [Figure 60-51-94]. Installation: Install the fitting and tighten to 82 ft.-lb. (111 Nm) torque.
P-58324
2 4
Remove the plug and O-ring (Item 4) [Figure 60-51-93] Remove the spring and oil pressure control valve (Item 4) [Figure 60-51-94] from the engine block. Installation: Install the plug and tighten to 82 ft.-lb. (111 Nm) torque. Remove the heater hose, fitting (Item 5) [Figure 60-5193], and O-ring (Item 5) [Figure 60-51-94]. Remove the valve and spring (Item 6) [Figure 60-51-94] from the engine block. Installation: Install the fitting and/or plug and tighten to 82 ft.-lb. (111 Nm) torque. NOTE: Be sure the valve and spring (Item 6) [Figure 60-51-94] is installed as shown.
60-51-31
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Thermostat, Oil Pressure Control Valves & Heater Connections (Cont'd) Figure 60-51-95
Installation: See Thermostat, Oil Pressure Control Valves & Heater Connections on page 31. [Figure 6051-94] for location on the engine block. Figure 60-51-97 1 2 3
2 1
N-18871
N-18868
Remove the thermostat spring (Item 1) from the thermostat (Item 2) [Figure 60-51-95], inspect all parts and replace as needed. Installation: See Thermostat, Oil Pressure Control Valves & Heater Connections on page 31. [Figure 6051-94 on Page 31] for location on the engine block. Figure 60-51-96
Replace the O-ring (Item 1). Remove the spring (Item 2) from the oil pressure control valve (Item 3) [Figure 6051-97]. The spring is marked with a red mark, for proper installation. If the red mark is missing, the spring coil diameter is 0.055 inch (1,4 mm). Installation: See Thermostat, Oil Pressure Control Valves & Heater Connections on page 31. [Figure 6051-94 on Page 31] for location on the engine block.
3 1 2
N-18869
Remove the spring (Item 1) from the oil pressure control valve (Item 2). Replace the O-ring (Item 3) [Figure 6051-96]. The spring is marked with a yellow mark, for proper installation. If the yellow mark is missing, the spring coil diameter is 0.047 inch (1,2 mm).
60-51-32
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Thermostat, Oil Pressure Control Valves & Heater Connections (Cont'd) Figure 60-51-98
N-18872
Remove the spring (Item 1) from the valve (Item 2) [Figure 60-51-98]. The spring is marked with a blue mark, for proper installation. If the blue mark is missing, the spring coil diameter is 0..039 inch (1,0 mm). Installation: See Thermostat, Oil Pressure Control Valves & Heater Connections on page 31. [Figure 6051-94 on Page 31] for location on the engine block.
60-51-33
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Aneroid Device Description The aneroid device is used to control exhaust smoke during acceleration or when a sudden load is placed on a turbo-charged engine. This is accomplished by delaying the fuel control rack from moving into the higher fuel setting until the turbo-charger has time to provided sufficient intake manifold pressure to assure the correct air fuel mixture to the combustion chambers. If the intake manifold pressure is low, the fuel delivery will be reduced to prevent exhaust smoke. Once the intake manifold pressure has reached a predetermined pressure, the aneroid device will allow the injection pump control rack to move to a higher fuel setting and enable the engine to produce more power, while controlling exhaust smoke output. The only time the aneroid device should be tested or adjusted is if excessive loss of engine RPM is evident when a hydraulic pump load is applied to the engine. This condition can occur when two hydraulic functions are required at the same time (one of these functions must work the gear pump). Example: engaging the swing circuit and the blade circuit at the same time. Testing Use the following information to determine if the aneroid needs adjustment: NOTE: Two people will be required for doing this procedure. One person must stay in the excavator cab to operate the machine, the second person to monitor gauges at the engine. Before checking the aneroid function, make sure that the engine is operating correctly. Make sure the fuel filters are clean and fuel lines are not restricting fuel flow. Are the air filters clean and no damage to the intake system. Check to make sure the engine speed control lever is adjusted to reach its maximum stop so full engine RPM is available. Check exhaust system for leaks, damage or restrictions.
WARNING
Rotating fan blade can cause serious injury or death. Keep away from fan and moving parts. Do not operate with guard removed. Hot surfaces can cause injury. Do not touch. Allow to cool before servicing.
W-2521-0106
The following components will be needed for testing the aneroid device for proper function: Fuel Pressure Gauge - 0 - 30 PSI (0 - 60 HG) Boost Pressure Gauge (must also fabricate an adapter to go from the gauge threads to fit into the manifold threads) Infrared Heat Sensor [must read a minimum 1000 F. (538 C.)] Photo tach
Figure 60-51-99
P-58327
WARNING
Turbochargers, operate at high speed and high temperatures. Keep fingers, tools and other objects away from the inlet and outlet ports. Avoid contact with hot surfaces.
W-2257-1196
Remove the nut, washer and wire harness (Item 1) [Figure 60-51-8] from the manifold heater and remove the manifold heater. (Tape the end of the manifold heater wire so that it does not ground out during the test.) Install an adapter and the Boost Pressure Gauge into the manifold heater opening.
60-51-34
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Aneroid Device (Contd) Testing (Contd) Figure 60-51-100
1. Bring the engine to high idle (approximately 2400 RPM) and verify the engine speed with the photo tach. 2. Check fuel pressure, the fuel pressure should be between 8 - 12 PSI (0,55 - 0,82 bar). This will be difficult to read as the pressure gauge will be pulsing due to the transfer pump. 3. Read the intake manifold pressure. The reading should be between 9 - 12 PSI (0,62 - 0,82 bar) or 20 - 24 HG. If these readings can be obtained, the engine is operating properly, continue to step 4. If these readings can not be obtained, further engine evaluation is needed to determine fuel restrictions, air restrictions, etc.. 4. Take an exhaust temperature reading at 2 - 3 in. from the exhaust outlet of the turbo-charger. The temperature should be between 850 - 900 F. (455 482 C.)
P-56410A
5. Have the operator in the cab raise the boom and the blade fully until both the relief valves goes over relief. 6. The second person should note the manifold pressure, the fuel pressure and monitor the engine RPM. 7. If the manifold pressure starts to drop off and the engine RPM starts to fall, and black exhaust smoke is present, this is an indication that an adjustment to the aneroid is needed. (IF the engine pulls down for a short period of time and then start to recover without producing black smoke, the aneroid is set correctly.) 8. Decrease engine RPM, lower boom fully and lower blade to the ground. Stop the engine and remove the key. 9. If aneroid adjustment is needed, proceed to the adjustment procedure. If no adjustment is needed, remove the gauges and reinstall all the existing components.
Disconnect the fuel line (Item 1) [Figure 60-51-98] at the filter and install the fuel pressure gauge at this location. This test must be done with the engine and the hydraulic fluid at operating temperature, 150 F. (66 C.).
WARNING
Turbochargers, operate at high speed and high temperatures. Keep fingers, tools and other objects away from the inlet and outlet ports. Avoid contact with hot surfaces.
W-2257-1196
WARNING
Rotating fan blade can cause serious injury or death. Keep away from fan and moving parts. Do not operate with guard removed. Hot surfaces can cause injury. Do not touch. Allow to cool before servicing.
W-2521-0106
With the second person in the excavator cab, start the engine and bring the excavator to operating temperature.
60-51-35
ENGINE COMPONENTS AND TESTING (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Aneroid Device (Contd) Adjustment The aneroid is located in the fuel filter housing. There are two lock nuts and adjustment screws on the filter housing. Make sure you are adjusting the correct screw as shown below. Figure 60-51-101 1 2 1
Once the correct adjustment has been reached, the engine will pull down for a short period of time and will start to recover without producing black smoke.
When adjustment is complete: remove all test equipment and reinstall all the original components that were previously removed. Start the engine and run at high idle for a few minutes. Return engine to low idle and stop the engine. Check for leaks and repair or replace as necessary.
1
P-56410B
NOTE: Before making any adjustment, mark the adjustment screw so that it can be returned to the original setting if required. Loosen the lock nut (Item 1) [Figure 60-51-101] and turn the adjustment screw DO NOT adjust (Item 2) [Figure 60-51-101]. Turn the adjustment screw IN 1/2 turn and tighten the lock nut (Item 1) [Figure 60-51-101]. Repeat the test procedure. Decrease engine RPM, lower boom fully and lower blade to the ground. Stop the engine and remove the key If further adjustment is needed, Loosen the lock nut (Item 1) [Figure 60-51-101] and turn the adjustment screw an additional 1/2 turn IN. Tighten the lock nut. Repeat this procedure until the correct adjustment is reached. DO NOT turn the adjustmrnt screw IN more than five full turns. If adjustment is not possible before the five full turns, return the adjustment screw to the original setting and contact your Bobcat dealer.
60-51-36
ENGINE (S/N 522311001 & ABOVE) Removal And Installation Drain the hydraulic reservoir. (See Replacing The Hydraulic Oil on Page 10-100-2.) Disconnect the battery. (See BATTERY on Page 50-201.) Remove the right side cover. (See RIGHT SIDE COVER on Page 40-160-1.) Remove the muffler. (See MUFFLER (S/N 522311001 & ABOVE) on Page 60-20-1.) Discharge the air conditioning system. (See SYSTEM CHARGING AND RECLAMATION on Page 70-130-1.) Remove the air conditioning condenser. (See CONDENSER (S/N 522311001 & ABOVE) on Page 70150-1 or See CONDENSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 70-151-1.) Figure 60-60-1
Figure 60-60-2 2
1
P-36935
Remove the hose (Item 1) and wire harness (Item 2) [Figure 60-60-2] from the receiver/dryer. Figure 60-60-3
1 1 1
P-36937
P-38639
Remove the two bottom condenser mount bolts (Item 1) [Figure 60-60-3] and washers.
Remove the eleven bolts (Item 1) and bottom panel (Item 2) [Figure 60-60-1].
60-60-1
ENGINE (S/N 522311001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 60-60-4
Figure 60-60-6
1 1
P-35232
Remove the four bolts (Item 1) [Figure 60-60-6].

P-36936
Figure 60-60-7 Remove the two top condenser mount bolts (Item 1) [Figure 60-60-4] and washers. Remove the mount. NOTE: The receiver/dryer will be removed with the mount. Figure 60-60-5 1
P-38128
Figure 60-60-8
P-35231
Loosen the clamp (Item 1) [Figure 60-60-5]. Rotate the clamp to provide clearance to the suction fitting bolts. 1
P-38129
Remove the two pump mount bolts (Item 1) [Figure 6060-7] and [Figure 60-60-8] and washers.
60-60-2
ENGINE (S/N 522311001 & ABOVE) (CONTD) Removal And Installation (Contd) Installation: Tighten the bolts to 125-140 ft.-lb. (170-190 Nm) torque. Slide the pump away from the engine. Figure 60-60-9
Figure 60-60-11
P-38134
1 Remove the radiator overflow hose (Item 1) [Figure 6060-11]. 2 Remove the top oil cover hose (Item 2) [Figure 60-6011].
P-38138
Remove the test fitting (Item 1) and hose (Item 2) [Figure 60-60-9] from the gear pump. Figure 60-60-10
IMPORTANT
1 Figure 60-60-12
I-2003-0888
2 2
P-38139
Remove the top bolt (Item 1) and two bottom bolts (Item 2) [Figure 60-60-10]. Installation: Tighten the bolts to 22-26 ft.-lb. (30-35 Nm) torque. Slide the pump away from the engine. Remove the bolt (Item 1) [Figure 60-60-12]. Reposition the hose (Item 2) [Figure 60-60-12] towards the bottom of the engine.
P-36924
60-60-3
Figure 60-60-15
2 1
P-38135
P-36925
Remove the top heater hose (Item 1) and both air conditioning hoses (Item 2) [Figure 60-60-15]. Disconnect the electrical connector (Item 3). Remove the ground wire (Item 4) [Figure 60-60-15] from the air conditioning pump. Figure 60-60-16
Remove the bottom oil cooler hose (Item 1) [Figure 6060-13]. Figure 60-60-14
2 1 1
P-32849
P-38136
Remove the plug (Item 1) [Figure 60-60-14] from the back side of the engine block. NOTE: The plug is located next to the alternator mount bracket. Drain the coolant from the engine.
Disconnect the two wiring connectors (Item 1) Remove the bottom heater hose (Item 2) [Figure 60-60-16].
60-60-4
Figure 60-60-19
2 2
P-38141
Remove the return fuel line (Item 1) [Figure 60-60-19].

P-38137
Cut and remove the cable tie (Item 2) [Figure 60-60-19]. Remove the fuel line (Item 1) [Figure 60-60-17]. Remove the engine ground/fuel line clamp bolt (Item 2) [Figure 60-60-17]. Figure 60-60-18 1 3 Figure 60-60-20
2 2
P-38142
1
P-38140
Remove the two bolts (Item 1) and remove the right side cover striker (Item 2) [Figure 60-60-20].
Remove the bolt (Item 1) [Figure 60-60-18]. Cut and remove the cable tie (Item 2) [Figure 60-60-18]. Remove the wire (Item 3) [Figure 60-60-18] from the glow plug terminal.
60-60-5
ENGINE (S/N 522311001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 60-60-21 2
Figure 60-60-23
1 1
P-38145
P-38143
Remove the battery cable (Item 1) [Figure 60-60-23] from the starter. Figure 60-60-24
Remove the bolt (Item 1) from the fuel line/engine speed control cable (Item 2) [Figure 60-60-21]. Figure 60-60-22
1 2
P-36915
P-38144
Loosen the clamps (Item 1) and remove the air intake hose (Item 2) [Figure 60-60-24].
Remove the engine speed control cable (Item 1) [Figure 60-60-22]. Loosen the cable mount nut (Item 2) [Figure 60-60-22] and remove the cable from the mount.
60-60-6
Figure 60-60-27
1 1
P-38152
P-38146
Disconnect both ends of the auxiliary hydraulic direct to tank line (Item 1) [Figure 60-60-26] & [Figure 60-60-27]. Reposition the line to gain clearance for removing the engine.
Remove the bolt (Item 1) [Figure 60-60-25] and remove the hose clamps. Figure 60-60-26
P-38151
60-60-7
Figure 60-60-30
1
P-38150
P-38147
Install a hoist on the engine lift mounts (Item 1) [Figure 60-60-30]. Figure 60-60-31
Remove the front two engine mount bolts (Item 1) [Figure 60-60-28]. Installation: Tighten the bolts to 48-55 ft.-lb. (65-75 Nm) torque. Figure 60-60-29
P-38153
Remove the engine [Figure 60-60-31].
P-38148
Remove the rear two engine mount bolts (Item 1) [Figure 60-60-29]. Installation: Tighten the bolts to 48-55 ft.-lb. (65-75 Nm) torque.
60-60-8
P-38154
Remove the four engine mount spacers (Item 1) [Figure 60-60-32].
60-60-9
60-60-10
ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Removal And Installation Disconnect the battery. (See BATTERY on Page 50-201.) Remove the muffler. (See MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 60-211.) Remove the hydraulic piston pump and gear pump. ( See HYDRAULIC PISTON PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 20-52-1 and See HYDRAULIC GEAR PUMP (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 20-531.) Remove the radiator/oil cooler. (See RADIATOR/OIL COOLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 60-41-1.) Figure 60-61-1
Figure 60-61-3
1
P-58671
Mark and remove the heater hoses (Item 1). Remove the bolt and ground strap (Item 2) [Figure 60-61-3]. Figure 60-61-4
1 1 1 2
1
P-58669
P-58672
Mark and remove the engine coolant hoses (Item 1) [Figure 60-61-1]. Figure 60-61-2
Remove the three cable ties (Item 1). Loosen the hose clamp (Item 2) [Figure 60-61-4] and remove the return fuel line.
P-58670
Remove the bolt (Item 1) [Figure 60-61-2].

ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 60-61-5 2
Figure 60-61-7
1 2 3
P-56395
Remove the nut, washer and wire harness (Item 1) [Figure 60-61-7] from the intake air heater.
P-58673
Figure 60-61-8 Disconnect the wire harness (Item 1). Remove the cable ties (Item 2). Loosen the hose clamp (Item 3) [Figure 6061-5] and remove the fuel line. Figure 60-61-6 3 1 1
2
P-58675
1 1
P-58674
Remove the speed control cable retainer (Item 1). Loosen the nut (Item 2) and remove the cable (Item 3) [Figure 60-61-8].
Remove the three cable ties (Item 1) [Figure 60-61-6].
60-61-2
ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 60-61-9
Figure 60-61-11 1
3 2
P-58677
P-58676
Loosen the A/C compressor bolts (Item 1) and remove the belt. Disconnect the wire harness (Item 2). Remove the bolt, nut and ground wire (Item 3) [Figure 60-61-11]. Figure 60-61-12
Remove the cable tie (Item 1) [Figure 60-61-9] from the A/C hoses. Figure 60-61-10
1
P-58679
P-58678
Remove the bolts (Item 1) [Figure 60-61-12] and washers. Reposition the A/C compressor and mount. NOTE: Do not allow the hoses to support the compressor.
Remove the bolts (Item 1) [Figure 60-61-10] and right side cover latch.
60-61-3
Figure 60-61-15
2 2 2 1 2 2
P-58682
1 2
2
P-58680
Remove the nut, washer, and positive (+) battery cable (Item 1) from the starter. Remove the three cable ties (Item 2) [Figure 60-61-15] from the back side of the engine block. Figure 60-61-16
Loosen the clamps (Item 1) and remove the air intake hose. Remove the cable ties (Item 2) [Figure 60-61-13]. NOTE: Plug the air intake to prevent contamination from entering the engine. Figure 60-61-14
1 1
P-58684
Remove the front two engine mount bolts (Item 2) [Figure 60-61-16].
P-58681
Installation: Tighten the bolts to 48-55 ft.-lb. (65-75 Nm) torque.
Remove the cable tie (Item 1) [Figure 60-61-14] from the A/C wire harness.
60-61-4
Figure 60-61-19
P-58687
1 Install lifting brackets (Item 1) [Figure 60-61-19] on the rear of the engine.
P-58683
Figure 60-61-20 Remove the rear two engine mount bolts (Item 1) [Figure 60-61-17]. Installation: Tighten the bolts to 48-55 ft.-lb. (65-75 Nm) torque. Figure 60-61-18
P-58688
1 Install a hoist on the lifting brackets [Figure 60-61-20]. Remove the engine.
P-58686
Install lifting brackets (Item 1) [Figure 60-61-18] on the front of the engine cradle.
60-61-5
P-58689
Remove the four washers (Item 1) [Figure 60-61-21] from the engine mounts.
60-61-6
FLYWHEEL (S/N 522311001 & ABOVE) Removal And Installation Remove the engine. (See ENGINE (S/N 522311001 & ABOVE) on Page 60-60-1.) Mark the flywheel cover to engine block for ease of assembly.
Figure 60-70-3 1
1 Figure 60-70-1 1
1 1 1 1 1 Remove the plugs (Item 1) [Figure 60-70-3]. Mark the flywheel to crankshaft. Figure 60-70-4 1 1
P-38181
P-38272
Remove the nine bolts (Item 1) [Figure 60-70-1]. Installation: Apply medium strength thread adhesive (Loctite 242) to the bolt threads. Tighten the bolts to 33 ft.-lb. (45 Nm) torque. Figure 60-70-2 1
P-38180
2 1 1 1 1
Remove the bolts (Item 1) [Figure 60-70-4]. Installation: Tighten the bolts as follows: 10. 30-45 mm long 15-22 ft.-lb. (20-30 Nm) 50-85 mm long 22-30 ft.-lb. (30-40 Nm) 11. 60
P-38182
12. 30 mm long 30 35-85 mm long 60 Remove the flywheel.
Remove the bolts (Item 1) and pump coupler (Item 2) [Figure 60-70-2]. Installation: Apply medium strength thread adhesive (Loctite 242) to the bolt threads. Tighten the bolts to 36 ft.-lb. (49 Nm) torque.
60-70-1
FLYWHEEL (S/N 522311001 & ABOVE) (CONTD) Flywheel Ring Gear
WARNING
W-2019-1285
Figure 60-70-5 1
P-38179
The ring gear on the flywheel is an interference fit. Heat the ring gear (Item 1) [Figure 60-70-5] 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 450-500F (232-260C). Fit the ring gear over the flywheel. Make sure the gear is seated correctly.
60-70-2
FLYWHEEL (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Removal And Installation Remove the muffler and muffler mount. (See MUFFLER (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 60-21-1). Remove the hydraulic piston pump. (See Removal And Installation on Page 20-52-13.)
Installation: Apply thread adhesive (Loctite 242) to the bolt threads. Tighten the bolts to 15-18 ft.-lb. (20-25 Nm) torque. Mark the flywheel to crankshaft. Figure 60-71-3
1 Mark the flywheel cover to engine block for ease of assembly. Figure 60-71-1
1 1
P-58649
1 1
Remove the bolts (Item 1) [Figure 60-71-3]. Installation: Do not reuse the bolts. Install new bolts and tighten the bolts to 22 ft.-lb. (30 Nm) torque. Torque the bolts an additional 60. 1
P-58646
Final torque the bolts an additional 30. Remove the eight bolts (Item 1) [Figure 60-71-1]. Installation: Apply thread adhesive (Loctite 242) to the bolt threads. Tighten the bolts to 30-37 ft.-lb. (40-50 Nm) torque. Figure 60-71-2 Remove the flywheel.
1 1
P-58648
Remove the bolts (Item 1) and pump coupler (Item 2) [Figure 60-71-2].
60-71-1
FLYWHEEL (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Flywheel Ring Gear
WARNING
W-2019-1285
Figure 60-71-4 1
P-38179
The ring gear on the flywheel is an interference fit. Heat the ring gear (Item 1) [Figure 60-71-4] 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 450-500F (232-260C). Fit the ring gear over the flywheel. Make sure the gear is seated correctly.
60-71-2
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) Deutz Engine Tools Identification Chart
B-23276
60-80-1
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Disassembly Remove the engine. Mount the engine on a suitable engine stand. Remove the starter. (See Removal And Installation (S/N 522311001 & Above) on Page 50-40-1.) Remove the alternator. (See Removal And Installation (S/ N 522311001 & Above) on Page 50-30-1.) Drain the oil from the engine oil pan. Remove the turbocharger. See Turbo Charger Removal and Installation on page 72. Remove the shut off solenoid.
Figure 60-80-1
P-61844
Remove the rocker arms and brackets [Figure 60-80-1]. Figure 60-80-2 Remove the fuel injectors. (See Fuel Injection Pump Removal on Page 60-50-7.) Remove the overflow valve. Remove the exhaust manifold. Remove the intake manifold. Remove the oil filter. Remove the fuel filter. Remove the fuel pump.
P-61845
Remove the water pump. Remove the oil cooler. Remove the valve cover. Remove the glow plugs. Remove the push rods [Figure 60-80-2]. Figure 60-80-3
P-61846
Remove the air intake manifold [Figure 60-80-3].

RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Disassembly (Cont'd) Figure 60-80-4
Figure 60-80-6
P-61849
Remove the injection pump roller tappets [Figure 60-806] and shims.
P-61847
Figure 60-80-7 Remove the cylinder head bolts. Remove the cylinder head [Figure 60-80-4]. Figure 60-80-5
P-61850
Remove the dipstick [Figure 60-80-7].

P-61848
Remove the fuel injection pumps [Figure 60-80-5]. Remove the shims. (If installed)
60-80-3
Figure 60-80-10
P-61853
Remove the oil pan [Figure 60-80-10].

P-61851
Figure 60-80-11
Remove the cover [Figure 60-80-8]. Figure 60-80-9
P-61854
Remove the oil suction pipe [Figure 60-80-11].

P-61852
Remove the housing [Figure 60-80-9].
60-80-4
Figure 60-80-14
P-61857
Remove the front cover [Figure 60-80-14].

P-61855
To disassemble and assemble the front cover. See Front Cover Disassembly on page 70. Remove the flywheel. (See Removal And Installation on Page 60-70-1.) Figure 60-80-15
Remove the connecting rod bolts [Figure 60-80-12]. Remove all the piston/connecting rod assemblies from the engine block. To check the piston/connecting rod assembly. See Piston Installation On The Connecting Rod on page 64. Figure 60-80-13
P-61858
Remove the rear cover [Figure 60-80-15].

P-61856
To install a new rear seal and inspect the cover. See Rear Cover Seal Removal And Installation on page 54.
Remove the pulley [Figure 60-80-13].
60-80-5
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Disassembly (Cont'd) Mark the location of each main bearing cap so it will be installed in the original position. Figure 60-80-16
Figure 60-80-18
P-61861
Remove the thrust rings and upper half of the main bearings [Figure 60-80-18]. Figure 60-80-19
P-61859
Remove the main bearing caps bolts [Figure 60-80-16]. Remove the main bearing caps. Figure 60-80-17
P-61862
Install the balancing shaft drive gears [Figure 60-80-19]. (If equipped)
P-61860
Remove the crankshaft [Figure 60-80-17]. Check the crankshaft specifications. See Crankshaft, Checking on page 56.
60-80-6
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) Disassembly (Cont'd) Figure 60-80-20
Figure 60-80-22
P-61865
Remove the governor drive gear [Figure 60-80-22].

P-61863
Figure 60-80-23
Remove the balancing shaft thrust washers [Figure 6080-20]. (If equipped) Figure 60-80-21
P-61866
Remove the camshaft [Figure 60-80-23].
P-61864
Remove the balancing shafts [Figure 60-80-21]. (If equipped).
60-80-7
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) Disassembly (Cont'd) Figure 60-80-24
Figure 60-80-26
P-61869
Remove the oil spray nozzles [Figure 60-80-26].

P-61867
Remove the guide sleeve and control rod [Figure 60-8024]. Figure 60-80-25
P-61868
Remove the tappets from the engine block [Figure 6080-25].
60-80-8
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Assembly Figure 60-80-27
Figure 60-80-29
P-61872
Install the camshaft [Figure 60-80-29].

P-61870
Figure 60-80-30
Install the oil spray nozzles [Figure 60-80-27]. NOTE: Check the oil parts for obstructions. Figure 60-80-28
P-61873
Install the upper main bearing halves [Figure 60-80-30].
P-61871
Install the tappets [Figure 60-80-28].
60-80-9
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Assembly (Cont'd) Figure 60-80-31
Figure 60-80-33
P-56920
Figure 60-80-34
P-61874
Install the other main bearing half into the main bearing caps [Figure 60-80-31]. Figure 60-80-32
P-56921
Measure the bearing journal width at the crankshaft [Figure 60-80-33] & [Figure 60-80-34]. Specifications: Journal Width Std. . . . . . . . . . . . . . . . . .1.417-1.419 inch. (36,0-36,04 mm) Limit for O/S . . . . . . . . . . . . . . . . 1.435 inch. (36,44 mm) Determine the end play for the crankshaft. Specifications: Std. End Play. . . . . . . . . . . . . . . . . . . . .0.004-0.012 inch. (0,10-0,30 mm) Use new thrust washers as needed to get the correct end play.
P-61875
Install the thrust bearings halves on the main bearing cap [Figure 60-80-32]. Measure the width of the thrust washers/main bearing cap [Figure 60-80-32].
60-80-10
Figure 60-80-37
P-61878
Lubricate the thrust washer (with tab) with grease and install them on the main bearing cap [Figure 60-80-37].
P-61876
Install the crankshaft into the engine block [Figure 60-8035]. NOTE: Align the marks on the crankshaft and camshaft. Figure 60-80-36
NOTE: The wear surface of the thrust washer must face the crank web. Figure 60-80-38
P-61879
Install the main bearing/thrust washer assembly [Figure 60-80-38].

P-61877
Lubricate the thrust washer (without tab) with grease and install them on the main bearing cap [Figure 60-80-36]. NOTE: The wear surface of the thrust washer must face the crank web.
NOTE: The main bearing cap No. 1, at the flywheel end, the chamfer must be towards the flywheel end.
60-80-11
If the engine is equipped with balancing shafts use Figure 60-80-41 through Figure 60-80-63. Figure 60-80-41
P-61882 P-61880
Remove the plugs [Figure 60-80-41]. Install the main bearing caps/main bearing assembly [Figure 60-80-39]. Install the caps in the original locations. Figure 60-80-40 Figure 60-80-42
P-61883
Install the balancing shaft [Figure 60-80-42].

P-61881
NOTE: The weights must be positioned toward the oil pan sealing surface.
Tighten the main bearing cap bolts as follows [Figure 6080-40]: Initial Torque . . . . . . . . . . . . . . . . . . . . 22 ft.-lb. (30 Nm) 1st Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
60-80-12
Figure 60-80-45
P-61886
Tighten the bolt to 21 ft.-lb. (29 Nm) torque [Figure 6080-45].

P-61884
Figure 60-80-46 Turn the adjusting pin in as far as possible [Figure 6080-43]. NOTE: The bore of the balancing shaft must align with the crankcase bore. Figure 60-80-44
P-61887
Turn the crankshaft until the #1 cylinder is at TDC [Figure 60-80-46]. NOTE: TDC is reached when the mark on the crankshaft aligns with the centerline of the crankshaft and camshaft [Figure 60-80-46].
P-61885
Install the thrust washer [Figure 60-80-44]. NOTE: Align the thrust washer with the shaft axis.
60-80-13
Figure 60-80-49
P-61890
Turn the crankshaft clockwise until the crankshaft and idler gears have moved three teeth [Figure 60-80-49].
P-61888
Figure 60-80-50 Install the idler gear [Figure 60-80-47]. NOTE: The teeth on the idler gear must mesh with the teeth on the crankshaft gear. Figure 60-80-48
P-61891
Turn the crankshaft until the bores are in line [Figure 6080-50].
P-61889
Mark the teeth on the idler gear and crankshaft gear [Figure 60-80-48].
60-80-14
Figure 60-80-53
P-61894
Install the second balancing shaft [Figure 60-80-53].

P-61892
NOTE: Install the weights toward the oil pan sealing surface. Figure 60-80-54
Install the bearing journal [Figure 60-80-51]. NOTE: Turn the crankshaft in both directions to align the bearing journal in the bore. Figure 60-80-52
P-61895
Turn the adjusting pin in as far as possible [Figure 6080-54].

P-61893
Install and tighten the bolt to 21 ft.-lb. (29 Nm) torque [Figure 60-80-52].
NOTE: Align the balancing shaft with the crankcase bore.
60-80-15
Figure 60-80-57
P-61898
Install the idler gear [Figure 60-80-57].

P-61896
NOTE: The bores must align. Figure 60-80-58
Install the thrust washer [Figure 60-80-55]. NOTE: Align the thrust washer with the axis of the shaft. Figure 60-80-56
P-61899
Install the bearing journal [Figure 60-80-58].
P-61897
Tighten the bolt to 21ft.-lb. (29 Nm) torque [Figure 6080-56].
60-80-16
Figure 60-80-61
P-61902
Install a seal in the bore (both sides) [Figure 60-80-61].

P-61900
Figure 60-80-62
Install and tighten the bolt to 21 ft.-lb. (29 Nm) torque [Figure 60-80-59]. Figure 60-80-60
P-61903
Install the governor drive gear in the bearing journal [Figure 60-80-62].
P-61901
Remove both adjusting pins [Figure 60-80-60].
60-80-17
Figure 60-80-65
P-61906
P-61904
Apply thread lock adhesive to the bolt. Install and tighten the bolt to 7-9 ft.-lb. (10-12 Nm) torque [Figure 60-8065]. Figure 60-80-66
Install and tighten the bolt to 15 ft.-lb. (21 Nm) torque [Figure 60-80-63]. Figure 60-80-64
P-61907
P-61905
Put high temperature silicone sealing compound on the rear cover [Figure 60-80-66].
Install the control rod and guide sleeve [Figure 60-8064].
60-80-18
Figure 60-80-69
P-61910
Lightly oil the rotors on the front cover [Figure 60-80-69].

P-61909
Figure 60-80-70
Figure 60-80-68
P-61911
P-61908
Use the grease to install the gasket on the front cover [Figure 60-80-70].
Install the rear cover complete with a new rear seal [Figure 60-80-67] and [Figure 60-80-68]. NOTE: Make sure the rear cover oil pan surface aligns with the engine block surface [Figure 60-80-68]. Install and tighten the bolts to 14-17 ft.-lb. (21-23 Nm) torque.
60-80-19
Figure 60-80-73
P-61913
P-61912
NOTE: Make sure the front cover oil pan surface aligns with the engine block surface [Figure 60-80-73]. Install and tighten the bolts to 14-17 ft.-lb. (19-23 Nm) torque. Figure 60-80-74
Align the rotor on the crankshaft [Figure 60-80-71]. Figure 60-80-72
P-61914
P-61915
Install the front cover [Figure 60-80-72].
Install the connecting rod bearing halves into the connecting rod [Figure 60-80-74].
60-80-20
Figure 60-80-77
P-61917
Install the connecting rod cap on the connecting rod. The ends of rod caps must be aligned [Figure 60-80-77].
CD-15560
Figure 60-80-78 Before installing piston/connecting rod assembly, make sure the piston ring gaps are staggered as shown in [Figure 60-80-75]. Install a piston ring compressor on the piston rings. Figure 60-80-76
P-61918
Tighten the connecting rod bolts as follows [Figure 6080-78]: Initial Torque . . . . . . . . . . . . . . . . . . . . 22 ft.-lb. (30 Nm) 1st Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 NOTE: If the connecting rod bolts are still serviceable, do not reuse the bolts more than five times.
P-61916
Install the piston/connecting rod assembly in the engine block [Figure 60-80-76]. NOTE: The flywheel symbol on the piston must be toward the flywheel.
60-80-21
Figure 60-80-80
P-61939
Install the pulley and bolts [Figure 60-80-80]. Tighten the bolts as follows:
P-61919
Initial torque. . . . . . . . . . . . . . . . 29-37 ft.-lb. (40-50 Nm) Check that the connecting rods can be easily moved back and forth on the crank pin [Figure 60-80-79]. Install the flywheel. (See Removal And Installation on Page 60-70-1.) Install the injection pump. (See Fuel Injection Pump Installation on Page 60-50-15.) First tightening angle: 60 mm long bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 80 mm long bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Second tightening angle: 60 mm long bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 80 mm long bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
60-80-22
Figure 60-80-83
1 1
Piston pin axis
B-14695
Measure at the gauge points (Item 1) [Figure 60-80-83].

P-61940
To determine maximum piston projection measure all the pistons. Figure 60-80-84
Put spacers on sealing surface of the engine block and set dial indicator gauge to 0 [Figure 60-80-81]. See Deutz Engine Tools Identification Chart on page 1. Figure 60-80-82
P-61942
P-61941
Compare the measurements with the specifications to determine the correct cylinder head gasket [Figure 6080-84]. Specifications: Piston Projection Head Gasket Marking of Cylinder
Position the dial gauge on the piston [Figure 60-80-82].
0.017-0.025 inch. (0,43-0,64 mm) . . . . . . . . . . . . . 1 hole 0.025-0.029 inch. (0,64-0,74 mm) . . . . . . . . . . . . 2 holes 0.029-0.033 inch. (0,77-0,85 mm) . . . . . . . . . . . . 3 holes
60-80-23
Figure 60-80-87
P-61945
Install the pushrods [Figure 60-80-87].

P-61943
Figure 60-80-88
Install the cylinder head gasket over the dowel pins [Figure 60-80-85]. The sealing surfaces of the cylinder head gasket must be free of oil. Install the cylinder head. Put a light coat of oil on the short cylinder head bolts. Figure 60-80-86
P-61946
Install the rocker arm bracket [Figure 60-80-88]. NOTE: Align the rocker arm bracket with the pushrods and valves.
P-61944
Install the short cylinder head bolts [Figure 60-80-86]. NOTE: Do not tighten the cylinder head bolts at this time.
60-80-24
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Assembly (Cont'd) Put a light coat of oil on the long head bolts. Figure 60-80-89
Figure 60-80-91
P-61949
Figure 60-80-92
P-61947
Install the long head bolts [Figure 60-80-89]. Figure 60-80-90
MS2062
Tighten the cylinder head bolts in the correct sequence [Figure 60-80-91] and [Figure 60-80-92]. 1st Stage Torque . . . . . . . . . . . . . . . . . 22 ft.lbs. (30 Nm) 2nd Stage Torque . . . . . . . . . . . . . . . . 59 ft.lbs. (80 Nm) 3rd Stage Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
P-61948
Adjust the valve clearance. (See Valve Clearance Adjustment on Page 60-50-23.)
60-80-25
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Assembly (Cont'd) Install the glow plugs. (See Glow Plug Removal And Installation on Page 60-50-4.) Lightly oil and install a new O-ring on the shutoff solenoid. Press and hold the control rod in the stop position. Figure 60-80-93
Figure 60-80-95
P-61952
Install the injectors [Figure 60-80-95]. NOTE: The return line fitting must face the exhaust side. Figure 60-80-96
P-61950
Install the shutoff solenoid [Figure 60-80-93]. Figure 60-80-94
P-61953
Install the clamps and start the bolts. Do not tighten the bolts at this time [Figure 60-80-96].
P-61951
Install and tighten the bolts to 15 ft.-lb. (21 Nm) torque [Figure 60-80-94]. Lightly grease and install a seal on the injectors.
60-80-26
Figure 60-80-99
P-61956
Tighten the cap nuts to 18-21 ft.-lb. (25-28,5 Nm) torque [Figure 60-80-99].
P-61954
Figure 60-80-100 Install a new seal on the injector lines. Install lines and hand tighten [Figure 60-80-97]. NOTE: Do not rebend the injector lines. Do not reuse the injector lines. Figure 60-80-98
P-61957
Install the fuel return lines through the seal and on the injector [Figure 60-80-100]. NOTE: Do not reuse the fuel return lines.
P-61955
Tighten the injector clamp bolts to 12-15 ft.-lb. (16-21 Nm) torque [Figure 60-80-98]. Preload the injector line cap nuts to 4 ft.-lb. (5 Nm) torque.
60-80-27
Figure 60-80-103
P-61960
Install and tighten the bolts on the air intake manifold to 7-9 ft.-lb. (10-12 Nm) torque [Figure 60-80-103].
P-61958
Figure 60-80-104 Install seals on the overflow valve. Install the overflow valve and install the fuel return line [Figure 60-80-101]. Install new gaskets on the air intake manifold. Figure 60-80-102
P-61961
Install a new exhaust manifold gasket. Install the exhaust manifold [Figure 60-80-104].
P-61959
Install the air intake manifold [Figure 60-80-102].
60-80-28
Figure 60-80-107
P-61964
Install the valve cover [Figure 60-80-107].

P-61962
Tighten the bolts to 6-7 ft.-lb. (8-10 Nm) torque. Figure 60-80-108
Apply anti-seize to the studs. Install the nuts on the exhaust manifold studs and tighten to 17-20 ft.-lb. (22,527,5 Nm) torque [Figure 60-80-105]. Figure 60-80-106
P-61965
Install a new gasket on the oil cooler. Install the oil cooler [Figure 60-80-108].
P-61963
Install the valve cover gasket [Figure 60-80-106].
60-80-29
Figure 60-80-111
P-61968
Hand tighten the fuel filter [Figure 60-80-111].

P-61966
Figure 60-80-112
Tighten the bolts to 14-17 ft.-lbs (19-23 Nm) torque [Figure 60-80-109]. Figure 60-80-110
P-61969
Lightly oil the oil filter gasket. Install the oil filter. Hand tighten the oil filter [Figure 60-80-112].
P-61967
Install seals on the fittings [Figure 60-80-110]. Tighten the fittings to 33-41 ft.-lb. (45-55 Nm) torque. Lightly oil the fuel filter gasket. Install the fuel filter.
60-80-30
Figure 60-80-115
P-61972
Lubricate and install new O-rings into the thermostat housing [Figure 60-80-115].
P-61970
Figure 60-80-116 Lightly oil and install the O-rings on the coupler [Figure 60-80-113]. Figure 60-80-114
P-61973
Install a new gasket and coolant pump [Figure 60-80116].

P-61971
Install the coupler in the thermostat housing and coolant pump [Figure 60-80-114].
60-80-31
Figure 60-80-119
P-61976
Install the fuel pump. Install the bolts [Figure 60-80-119].

P-61974
NOTE: Do not tighten the bolts at this time. Figure 60-80-120
Install and tighten the coolant pump bolts to 14-17 ft.-lb. (19-23 Nm) torque [Figure 60-80-117]. Figure 60-80-118
P-61977
P-61975
Install new seals on the fuel lines. Install the fuel lines [Figure 60-80-120].
Install a new seal and insulating hose (if equipped) on the temperature sensor. Install the temperature sensor and tighten to 12-15 ft.-lb. (16-20 Nm) torque [Figure 60-80118].
60-80-32
Figure 60-80-123
P-61980
Trim the gasket [Figure 60-80-123].

P-61978
Figure 60-80-124
Turn the engine 180. Install a new gasket. Install the oil suction pipe and retainer [Figure 60-80-121]. Figure 60-80-122
P-61981
Put sealing compound on the sealing surface of the oil pan [Figure 60-80-124].
P-61979
Tighten the flange bolts first then the retainer bolts to 1417 ft.-lb. (19-23 Nm) torque [Figure 60-80-122].
60-80-33
Sheet Meal Oil Pan Figure 60-80-127
P-61984
P-61982
Install the sheet metal oil pan and tighten the bolts to 1417 ft.-lb. (19-23 Nm) torque [Figure 60-80-127]. Cast Iron Oil Pan Figure 60-80-128
Install a new gasket [Figure 60-80-125]. Figure 60-80-126
P-61983
P-61985
Put sealing compound on the sealing surface of the oil pan gasket [Figure 60-80-126].
Align the cast iron oil pan with the timing cover tighten the bolts to 20-23 ft.-lbs (27-31 Nm) torque [Figure 60-80128].
60-80-34
Figure 60-80-131
P-61988
P-61986
Install the bolts and tighten in the order shown 1-2-3-4-5 to 11-14 ft.-lb. (15.5-18.5 Nm) torque [Figure 60-80131]. Figure 60-80-132
Clean and dry the sealing surface of the governor. Apply a 0.06-0.07 in. (1,5-2,0 mm) bead of sealing compound to the sealing surface of the governor [Figure 60-80129]. Figure 60-80-130
P-61989
Lightly grease and install the O-ring on the cover [Figure 60-80-132].
P-61987
Turn the engine 180. Install the governor [Figure 60-80130].
60-80-35
Figure 60-80-135
P-61992
Connect the wire harness to the governor [Figure 60-80135].

P-61990
Figure 60-80-136 Install the cover and tighten the bolts to 14-17 ft.-lb. (1923 Nm) torque [Figure 60-80-133]. Figure 60-80-134
P-61993
Connect the wire harness to the shutoff solenoid [Figure 60-80-136].

P-61991
Install the plate on the governor and tighten the bolts to 14-17 ft.-lb. (19-23 Nm) torque [Figure 60-80-134].
60-80-36
Figure 60-80-139
P-61996
Install the bolts and tighten as follows [Figure 60-80139]:

P-61994
Connect the glow plug wire connectors [Figure 60-80137]. Turn the engine 180. Figure 60-80-138
M-12 bolt torque . . . . . . . . . . . 66-80 ft.-lb. (89-109 Nm) M-16 bolt torque . . . . . . . . 161-198 ft.-lb. (218-268 Nm) Figure 60-80-140
P-61997
Install the plate [Figure 60-80-140].

P-61995
Install the adapter housing [Figure 60-80-138].
60-80-37
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Assembly (Cont'd) Install the starter. Tighten the bolts to 52 ft.-lb. (70 Nm) torque. Figure 60-80-141
Figure 60-80-143
P-63000
Install new seals on the breather pipe [Figure 60-80143]. Figure 60-80-144
P-61998
TIghten the collar to 30 ft.-lb. (40 Nm) torque (if equipped [Figure 60-80-141]. Figure 60-80-142
P-63001
Install the breather and tighten the bolts to 7-9 ft.-lb. (1012 Nm) torque [Figure 60-80-144].
P-61992
Connect the wire harness and clips [Figure 60-80-142].
60-80-38
Figure 60-80-147
P-63004
Connect the wire harness to the temperature sensor [Figure 60-80-147].

P-63002
Figure 60-80-148 Install the air pipe on the manifold pressure compensator [Figure 60-80-145]. Figure 60-80-146
P-63005
P-63003
Install a seal on the oil pressure switch. Install and tighten the oil pressure switch to 12-15 ft.-lb. (16-20 Nm) torque [Figure 60-80-148].
Install the lift brackets and tighten to 32-38 ft.-lb. (43-51 Nm) torque [Figure 60-80-146].
60-80-39
Figure 60-80-151
P-63008
Lightly grease the bore in the cylinder head. Install the pressure control valve [Figure 60-80-151].
P-63006
Figure 60-80-152 Connect the wire harness to the oil pressure switch [Figure 60-80-149]. Figure 60-80-150
P-63009
P-63007
Install the bolts in the crankcase breather. Tighten the bolts to 6-7 ft.-lbs (7,5-9,5 Nm) torque [Figure 60-80152].
Install the seal, pressure control valve and sleeve on the crankcase breather [Figure 60-80-150].
60-80-40
Figure 60-80-155
P-63012
Install the adapter [Figure 60-80-155].

P-63010
Figure 60-80-156
Apply sealing compound to the coolant pipe. Install the coolant pipe and tighten the bolts to 14-17 ft.-lb. (19-23 Nm) torque [Figure 60-80-153]. Figure 60-80-154
P-63013
Install a new gasket. Install the turbo charger [Figure 6080-156]. NOTE: Prelubricate the turbo charger by spraying a drop of oil into the oil supply line.
P-63011
Apply a light coat of grease on the O-rings. Install the Orings on the adapter [Figure 60-80-154].
60-80-41
Figure 60-80-159
P-63015
Apply a light coat of grease to the O-rings. Install the Orings on the oil return pipe [Figure 60-80-159].
P-63014
Figure 60-80-160 Apply anti-seize to the studs. Install the nuts and tighten to 14-17 ft.-lb. (19-23 Nm) torque [Figure 60-80-157]. Figure 60-80-158
P-63017
Install the oil return pipe [Figure 60-80-160].

P-63016
Install a new seal on the plug. Install the plug and tighten to 28-31 ft.-lb. (38-42 Nm) torque [Figure 60-80-158].
60-80-42
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Assembly (Cont'd) Install the oil pressure pipe. Install seals on the bolts. Figure 60-80-161
Figure 60-80-163
P-63020
Install the elbow [Figure 60-80-163]. NOTE: Do not tighten the hose clamp at this time.
P-63018
Figure 60-80-164
Tighten the bolt (Item 1) to 19-24 ft.-lb. (26-32 Nm) torque. Tighten the bolt (Item 2) [Figure 60-80-161] to 26-32 ft.-lb. (35-43 Nm) torque. Figure 60-80-162
P-63021
Install the breather hose. Tighten the hose clamps [Figure 60-80-164].
P-63019
Install the intake hose [Figure 60-80-162].
60-80-43
Figure 60-80-167
P-63024
Install the alternator bracket. Tighten the bolts to 14-17 ft.-lb. (19-23 Nm) torque [Figure 60-80-167].
P-63022
Figure 60-80-168 Install a new O-ring on the dipstick [Figure 60-80-165]. Figure 60-80-166
P-63025
Install the alternator [Figure 60-80-168].

P-63023
NOTE: Do not tighten the bolt at this time. Install the dipstick [Figure 60-80-166].
60-80-44
Figure 60-80-171
P-63028
P-63026
Adjust the fan/fuel pump belt tension by applying approximately 33 lbs (15 kg) force on the belt. The belt should deflect 0.40 in. (10 mm). Tighten the bolts to 1417 ft.-lb. (19-23 Nm) torque [Figure 60-80-171]. Figure 60-80-172
Install the adjusting bracket with bushings and bolts [Figure 60-80-169]. NOTE: Do not tighten the bolts at this time. Figure 60-80-170
P-63029
Install the alternator belt [Figure 60-80-172].

P-63027
Install the fan/fuel pump belt [Figure 60-80-170].
60-80-45
Figure 60-80-175
P-63032
Install the engine mount bracket [Figure 60-80-175]. Tighten the bolts to 192 ft.-lb. (260 Nm) torque
P-63030
Figure 60-80-176 Adjust the alternator belt tension by applying approximately 33 lbs (15 kg) force to the belt at the mid span of the belt. Tighten the bolts to 22 ft.-lb. (30 Nm) torque [Figure 60-80-173]. Figure 60-80-174
P-63033
Install the engine mount bracket [Figure 60-80-176]. Tighten the bolts to 70 ft.-lb. (95 Nm) torque.
P-63031
Remove the engine from the engine stand.
Install the wire harness on the alternator [Figure 60-80174].
60-80-46
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Cylinder, Checking Clean the engine block and inspect for damage. Figure 60-80-177
Figure 60-80-179
1 2 3
b
B-14697
Check the cylinders with engine block longitudinal (a) and transverse (b) axis and in three planes [Figure 6080-179].
P-63034
Install the main bearing caps [Figure 60-80-177]. Tighten the main bearing cap bolts as follows: Initial Torque . . . . . . . . . . . . . . . . . . . . 22 ft.-lb. (30 Nm) 1st Stage Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 2nd Stage Angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Specifications: Cylinder Bore . . . . . . . . . . . . . . . . . 3.7008 - 3.7016 inch. (94 - 94.02 mm) Wear Limit . . . . . . . . . . . . . . . . . . . . 3.59 inch. (94.1 mm)
Figure 60-80-178
P-63035
Using a dial indicator gauge check the cylinders [Figure 60-80-178].
60-80-47
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Camshaft Bearing, Checking Figure 60-80-180
b a 1 2
B-14698
Check the camshaft bearing bushings at points (1) and (2) in the planes of (a) and (b) [Figure 60-80-180]. Figure 60-80-181
P-63036
Check the camshaft bushings using a gauge [Figure 6080-181]. Inner Diameter . . . . . . . . . . . . . . . . . . 2.362 + 0.002 inch. (60 + 0,054 mm) Wear Limit . . . . . . . . . . . . . . . . . . 2.365 inch. (60,08 mm)
60-80-48
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Camshaft Bearing, Removal And Installation Figure 60-80-182
Figure 60-80-184
P-63039
P-63037
When installing the new camshaft bushings, the oil lube hole must align with the oil hole in the engine block [Figure 60-80-184]. Figure 60-80-185
Remove all the camshaft bearing bushings using a camshaft bushing removal tool as needed [Figure 60-80182]. Figure 60-80-183
P-63040
Install the new camshaft bushings using a camshaft bushing installation tool [Figure 60-80-185].
P-63038
Use the dimensions in [Figure 60-80-183] to install the camshaft bushing at the flywheel end.
60-80-49
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Balancing Shaft Bearing, Checking (If Equipped) Figure 60-80-186
b a
B-14698
Check the balancing bearing bushings at points (1) and (2) in the planes of (a) and (b) [Figure 60-80-186]. Figure 60-80-187
P-63041
Check the balancing shaft bushings using a gauge [Figure 60-80-187]. Inner Diameter . . . . . . . . . . . . . . . . . . 2,128 + 0.002 inch. (54,06 + 0,045 mm) Wear Limit . . . . . . . . . . . . . . . . . 2.131 inch. (54,125 mm)
60-80-50
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Balancing Shaft Bearing, Removal And Installation Figure 60-80-188
Figure 60-80-190
P-63044
P-63042
Install the new balancing shaft bushings using a balancing shaft bushing installation tool [Figure 60-80190].
Remove all the balancing shaft bearing bushings using a balancing shaft bushing removal tool as needed [Figure 60-80-188]. Figure 60-80-189
P-63043
When installing the new balancing shaft bushings, the oil lube hole must align with the oil hole in the engine block [Figure 60-80-189].
60-80-51
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Control Rod Guide Bushing Installation Figure 60-80-191
Figure 60-80-193
P-63047
Install the guide on the arbor assembly with the chamfer pointing toward the crankcase [Figure 60-80-193].
P-63045
Figure 60-80-194 Using the tool, drive the guide bushing out [Figure 6080-191]. Figure 60-80-192
P-63048
Fasten the arbor assembly and bushing on the engine block [Figure 60-80-194].
P-63046
Install the new bushing into the center of the arbor assembly [Figure 60-80-192].
60-80-52
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Control Rod Guide Bushing Installation (Cont'd) Figure 60-80-195
P-63049
Drive the bushing into the engine block as far as it will go [Figure 60-80-195]. Remove the arbor assembly.
60-80-53
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Rear Cover Seal Removal And Installation Figure 60-80-196
Figure 60-80-198
P-63052
Remove speed sensor (if equipped) [Figure 60-80-198].

P-63050
Figure 60-80-199
Remove the rear cover shaft seal [Figure 60-80-196]. Figure 60-80-197
P-63053
Clean the seal seating surface [Figure 60-80-199]. Inspect the cover for damage, replace as needed.
P-63051
Remove cover and spacers [Figure 60-80-197].
60-80-54
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Rear Cover Seal Removal And Installation (Contd) Figure 60-80-200
P-63054
Use the seal driver tool and install to the correct depth [Figure 60-80-200]. See Deutz Engine Tools Identification Chart on page 1. Figure 60-80-201
P-63055
Install the speed sensor (if equipped). Tighten the bolt to 6-7 ft.-lbs (8-10 Nm) torque [Figure 60-80-201].
60-80-55
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Crankshaft, Checking Put the crankshaft on v-blocks. Check the main bearing journals: Specifications: Journal Diameter . . . . . . . . . . . . . . . . 2.912 - 2.913 inch. (73,98 - 74,0 mm) Each Undersize . . . . . . . . . . . . . . . . . . . . . . . 0.010 inch. (0,25 mm) Undersize Limit . . . . . . . . . . . . . . . . . . . . . . . 2.893 inch. (73,48 mm) Figure 60-80-202
Figure 60-80-203
P-56761
Check the connecting rod journals [Figure 60-80-203]. Specifications: Pin Diameter . . . . . . . . . . . . . . . . . . . .2.283 - 2.284 inch. (57,98 - 58,0 mm) Undersize Limit . . . . . . . . . . . . . . . . . . .2.263-2.264 inch. (57,48 - 57,50 mm) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0004 inch. (0,1 mm)
Figure 60-80-204
P-56760
Check the thrust bearing width [Figure 60-80-202]. Specifications: Journal Width. . . . . . . . . . . . . . . . . . 1.417 +0.0016 inch. (36 + 0,04 mm) Limit Oversize . . . . . . . . . . . . . . . . . . . . . . . . 1.395 inch. (36,44 mm) Each Oversize . . . . . . . . . . . . . . . . . . . . . . . 0.016 inch. (0.4 mm)
P-56762
Use a dial indicator and check crankshaft for out of roundness [Figure 60-80-204]. Specifications: Out of Roundness Max.. . . . . . . . . 0.003 inch. (0,07 mm)
60-80-56
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Crankshaft, Checking (Contd) Figure 60-80-205
P-63056
Check the surface of the crankshaft seal area [Figure 60-80-205]. Recondition the crankshaft as needed.
60-80-57
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Connecting Rod, Checking Figure 60-80-206 b
Figure 60-80-208
a
P-63057
Replace small end bushing as needed [Figure 60-80208].

B-14701
When checking the connecting rod large and small end, measure at the points (1) and (2) and in planes (a) and (b) [Figure 60-80-206]. Figure 60-80-207
Bore for Small End Bushing . . . . . . 1.457 + 0.0008 inch. (37,0 + 0,02 mm) O.D. of Small End Bushing . . . . . . . .1.4539 - 1.461 inch. (39,93 - 37,11 mm) Figure 60-80-209
P-56774 P-56770
Check the small end bushing [Figure 60-80-207]. Specifications: I.D. of Small End Bushing . . . . . . . . . 1.338 - 1.340 inch. (33,975 - 34,035 mm) Wear Limit Bushing Clearance . . . . . . . . . . . 0.003 inch. (0,08 mm)
Press in the small end bushing, make sure the lubrication holes are in alignment [Figure 60-80-209].
60-80-58
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Connecting Rod, Checking (Cont'd) Figure 60-80-210
Figure 60-80-212
P-63060
Tighten the connecting rod cap nuts as follows [Figure 60-80-212].

P-63058
After pressing in the small end bushing, bore the bushing to the following dimensions [Figure 60-80-210]. Specifications: I.D. of Small End Bushing . . . . . . . . . . 1.338-1.340 inch. (33.975 - 34.035 mm) Figure 60-80-211
Initial Torque . . . . . . . . . . . . . . . . . . . . 22 ft.-lb. (30 Nm) 1st Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60 2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
P-63059
Install the correct cap on the correct rod [Figure 60-80211].
60-80-59
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Connecting Rod, Checking (Cont'd) Figure 60-80-213
CD-15454
Measure the big end bore [Figure 60-80-213]. If the measurement is the same as the specific valve, the necessary preload on the bearing halves will be obtained. Specifications: Big End I.D. . . . . . . . . . . . . . . . . . . . 2.425 + 0.0008 inch (61,6 + 0,02 mm) Remove connecting rod cap. Install new bearing halves. Tighten the connecting rod cap nuts and tighten as listed in [Figure 60-80-212 on Page 59]. Measure the bearing halves: Big End Bearing I.D. . . . . . . . . . . . 2.2846 - 2.2862 inch. (58,03 - 58,07 mm) Each Undersize . . . . . . . . . . . . . . . . . . . . . . . 0.010 inch. (0,25 mm) Limit For Undersize . . . . . . . . . . . . 2.2748 - 2.3157 inch. (57,78 - 57,82 mm) Radial Clearance Wear Limit . . . . . . . . . . . . . . . . . 0.005 inch. (0,12 mm) Check the connecting rod, without bearing halves, on a connecting rod tester. Specifications: Parallel Check-Tolerance . . . . . . . 0.002 inch. (0,05 mm) Over a Distance of . . . . . . . . . . . . . . 3.94 inch. (100 mm) Squareness Check-Tolerance . . . . 0.002 inch. (0,05 mm)
60-80-60
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Piston, Checking Figure 60-80-214
Figure 60-80-216
P-63064
Measure the ring gap with a feeler gauge in the cylinder [Figure 60-80-216].
P-56781
Remove the piston rings from the piston [Figure 60-80214]. Remove the piston from the connecting rod. See Connecting Rod, Checking to check connecting rod specifications. (See Connecting Rod, Checking on Page 60-80-58.) Figure 60-80-215
Specifications: Wear Limit 1st Ring Gap . . . . . . . . . . . . . . . . 0.031 inch. (0,8 mm) 2nd Ring Gap . . . . . . . . . . . . . . . . 0.098 inch. (2,5 mm) 3rd Ring Gap . . . . . . . . . . . . . . . 0.045 inch. (1,15 mm)
P-56782
Clean and inspect piston and piston ring grooves [Figure 60-80-215].
60-80-61
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Piston, Checking (Contd) Figure 60-80-217
Piston Pin, Checking Figure 60-80-218
B-8230
P-56784
Check piston pin for wear [Figure 60-80-218]. Specifications: Pin O.D. . . . . . 1.3383-1.3386 inch. (33,994-34,0 mm)
Using new rings, measure the ring grooves using a feeler gauge [Figure 60-80-217]. Specifications: Wear Limit 1st Ring. . . . . . . . . . . . . . . . . . . . . . . Keystone Groove 2nd Ring . . . . . . . . . . . . . . . . . . . 0.007 inch. (0.17 mm) 3rd Ring . . . . . . . . . . . . . . . . . . . 0.004 inch. (0.10 mm)
Measure the keystone groove with the keystone groove gauge [Figure 60-80-217]. If a distance is present between the gauge and piston, the piston is serviceable [Figure 60-80-217]. If the gauge rests against the piston, replace the piston [Figure 60-80-217].
60-80-62
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Piston Rings Installation Figure 60-80-219
P-56789
When installing the piston rings position them as listed below [Figure 60-80-219]. Figure 60-80-220
1 2
3
TS-1928A
lst Ring - Is a trapezoidal ring, (Item 1) [Figure 60-80220]. It is installed on the piston with the facing the combustion chamber. 2nd Ring - Is a tapered compression ring (Item 2) [Figure 60-80-220], which is installed on the piston with the mark TOP facing the combustion chamber. 3rd Ring - Is a bevelled edge slotted oil control ring (Item 3) [Figure 60-80-220]. The gap of each ring must be offset by 180 to the other ring.
60-80-63
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Piston Installation On The Connecting Rod Figure 60-80-221
Figure 60-80-223
P-63062
P-63061
The flywheel symbol on the piston and dowel pins on the connecting rod must be located on the same side [Figure 60-80-223]. Figure 60-80-224
Install the snap ring [Figure 60-80-221]. NOTE The ring gap of the snap rings must face toward the piston crown. Figure 60-80-222
P-63063
Install the snap ring [Figure 60-80-224]. NOTE: The ring gap of the snap rings must face toward the piston crown.
P-63065
Install the piston on the rod. Install the piston pin [Figure 60-80-222].
60-80-64
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Cylinder Head Disassembly NOTE: Do not grind the cylinder head surface, if its damaged, replace the cylinder head. Figure 60-80-225
Figure 60-80-227
P-63067
Remove the valve seals [Figure 60-80-227]. Clean the cylinder head and inspect for damage.
P-63069
Remove the glowplugs [Figure 60-80-225]. Figure 60-80-226
P-63066
Using a valve spring tool, remove the spring locks, valve spring cap, valve spring and valve [Figure 60-80-226]. See Deutz Engine Tools Identification Chart on page 1. Repeat the procedure for all the valves.
60-80-65
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Valves, Checking Figure 60-80-228
Valve seat angle: Specifications: Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Figure 60-80-230
P-56793
P-63070
Measure the valve stem diameter [Figure 60-80-228]. Std. Intake Valve . . . . . . . . . . . . . . . . 0.308-0.0006 inch. (7,98-0,015 mm) Std. Exhaust Valve . . . . . . . . . . . . . . 0.313-0.0006 inch. (7,96-0,015 mm) Figure 60-80-229
Measure the valve seat width [Figure 60-80-230]. Specifications: Width (Intake) . . . . . 0.106 0.016 inch. (1,27 0,4 mm) (Exhaust) . . . . . 0.083 0.016 inch. (2,1 0,4 mm) Figure 60-80-231
Thickness
Angle
P-63068
Diameter
P-56794
Install the valves and measure the valve stem clearance [Figure 60-80-231]. Wear Limit: Intake Valve . . . . . . . . . . . . . . . 0.004 inch (0,10 mm) Exhaust Valve . . . . . . . . . . . . . 0.006 inch (1,13 mm)
Measure the valve edge thickness [Figure 60-80-229]. Specifications: Intake Valve . . . . . . . . . . . . . . . . . 0.071 inch. (1,8 mm) Exhaust Valve . . . . . . . . . . . . . . . 0.043 inch. (1,1 mm) Measure the valve head diameter [Figure 60-80-229]. Specifications: Intake Valve . . . . . 1.618 0.004 inch (41,5 0,1 mm) Exhaust Valve . . 1.430 0.004 inch. (35,9 0,01 mm)
60-80-66
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Valve Clearance Adjustment Figure 60-80-232
P-63071
Measure the valve clearance between the valve head and cylinder head sealing surface [Figure 60-80-232]. Valve penetration into cylinder head: Specifications: Wear Limit . . . . . . . . . . . . . . . . .0.0551 inch. (1,4 mm) Recondition the valve seats and valve guides if worn. Figure 60-80-233 Inclination
Free Length
Square
B-8208
Measure valve spring free length [Figure 60-80-233]. Specifications: Valve Spring Free Length . . . . . . . . . 2.3230.08 inch. (591,9 mm)
60-80-67
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Cylinder Head Assembly Figure 60-80-234
Figure 60-80-236
P-63074
Use the valve spring tool, install the valve spring locks [Figure 60-80-236].
P-63072
Repeat the procedure to install all the valves. Install the valve into the cylinder head and install the valve stem seal [Figure 60-80-234]. Figure 60-80-235 Figure 60-80-237
P-63069
P-63073
Install the glow plugs [Figure 60-80-237]. Tighten the glow plugs to 7-11 ft.-lb. (10-15 Nm) torque.
Install the valve spring and cap [Figure 60-80-235].
60-80-68
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Rocker Arm And Bracket, Checking Figure 60-80-238
Figure 60-80-240
P-63077
Check the oil passages that they are open and clean [Figure 60-80-240].
P-63075
Install the rocker arms on the bracket. Disassemble the rocker arms from the bracket [Figure 60-80-238]. Figure 60-80-239 Figure 60-80-241
P-63078
P-63076
Install the snap ring [Figure 60-80-241].
Check for wear at the following locations and replace as needed [Figure 60-80-239]: Journals Adjusting Bolt Rocker Arm Contact Face Bore
60-80-69
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Front Cover Disassembly Figure 60-80-242
Figure 60-80-244
P-63081
Remove the oil pump and pressure control valve [Figure 60-80-244].
P-63079
Remove the breather vent [Figure 60-80-242]. Figure 60-80-243
P-63080
Inspect the front cover. Replace if necessary [Figure 6080-243]. NOTE: The rotor must turn freely.
60-80-70
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Front Cover Assembly Figure 60-80-245
Figure 60-80-247
P-63084
Install the pressure control valve [Figure 60-80-247].

P-63082
Tighten 27-32 ft.-lb. (36-44 Nm) torque. Figure 60-80-248
Inspect the front cover for damage [Figure 60-80-245]. Replace the front cover if any components are damaged. Figure 60-80-246
P-63085
Install the shaft [Figure 60-80-248].

P-63083
NOTE: Apply a dry lubricant to the shaft seal.
Install the oil pump [Figure 60-80-246]. Tighten the oil pump to 6-7 ft.-lb. (8-9 Nm) torque.
60-80-71
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Turbo Charger Removal and Installation Figure 60-80-249
Figure 60-80-251
P-63019
Remove the air inlet hose (Item 1) [Figure 60-80-251].

P-63021
Figure 60-80-252
Remove the clamp and breather hose [Figure 60-80249]. Figure 60-80-250 1
2
P-63018
Remove the oil pressure pipe (Item 1) [Figure 60-80252]. Installation: Tighten the bolt to 19-24 ft.-lb. (26-32 Nm) torque. Tighten the bolt (Item 2) to 26-32 ft.-lb. (35-43 Nm) torque.
P-63020
Remove the elbow (Item 1) [Figure 60-80-250].
60-80-72
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Turbo Charger Removal and Installation (Contd) Figure 60-80-253
Figure 60-80-255
P-63014
Remove the nuts [Figure 60-80-255].

P-63017
Installation: Apply anti-seize to the studs. Tighten the nuts to 14-17 ft.-lb. (19-23 Nm) torque.
Remove the oil return pipe [Figure 60-80-253]. Figure 60-80-254
P-63016
Remove the plug [Figure 60-80-254].
60-80-73
RECONDITIONING THE ENGINE (S/N 522311001 & ABOVE) (CONTD) Turbo Charger Removal and Installation (Contd) Figure 60-80-256
P-63013
Remove the turbo charger [Figure 60-80-256]. Installation: Prelubricate the turbo charger by spraying a drop of oil into the oil supply line. NOTE: In the event of severe engine oil contamination, drain and flush the engine oil cooler, cab heater and plumbing. Drain the engine oil from the crankcase and replace the engine oil and filter. (See Replacing Oil And Filter on Page 10-90-2.) Start the engine and run at idle until oil pressure is assured. Work the unit until operating temperature of engine is maintained for approximately 15 minutes. Idle and cool the down engine approximately 3 to 4 minutes, and stop the engine. Drain the engine oil from the crankcase again, replace the engine oil and filter. (See Replacing Oil And Filter on Page 10-90-2.) Re-start engine, check for leaks and performance.
60-80-74
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Deutz Engine Tools Identification Chart
B-16718
60-81-1
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly Remove the engine. Mount the engine on a suitable engine stand. Remove the starter. (See Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above) on Page 50-40-1.) Remove the alternator. (See Removal And Installation (S/ N 528911001 & Above And 528611001 & Above) on Page 50-30-3) Drain the oil from the engine oil pan. Remove the turbocharger. See Turbo Charger Removal and Installation on page 70. Remove the fuel injectors. (See Fuel Injector Removal And Installation on Page 60-51-13.) Remove the exhaust manifold. Remove the intake manifold. Remove the oil filter. Remove the valve cover. Figure 60-81-1
Figure 60-81-2
P-56871
Remove the push rods [Figure 60-81-2]. Figure 60-81-3
P-56872
Remove the cylinder head bolts. Remove the cylinder head [Figure 60-81-3].
P-56870
Remove the rocker arms and brackets [Figure 60-81-1].
60-81-2
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly (Cont'd) Figure 60-81-4
Figure 60-81-6
P-56875
Remove the thermostat [Figure 60-81-6].

P-56873
Figure 60-81-7
Remove the fuel injection pumps [Figure 60-81-4]. Figure 60-81-5
P-56876
Remove the oil pressure control valve [Figure 60-81-7].

P-56874
Remove the injection pump roller tappets [Figure 60-815].
60-81-3
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Disassembly (Cont'd)
Figure 60-81-10
1 Figure 60-81-8
P-56884
Remove the timing belt (Item 1) [Figure 60-81-10] and idler.

P-56877
Figure 60-81-11 Remove the plugs and heater oil pressure control valves [Figure 60-81-8]. Figure 60-81-9
P-56885
Remove the camshaft gear [Figure 60-81-11].
Remove the belt pulley (Item 1) [Figure 60-81-9]. Remove the front cover and timing belt. See Front Cover Assembly on page 60.
60-81-4
Figure 60-81-14
P-56889
Using a torque multiplier (Item 1) [Figure 60-81-14]. Remove the crankshaft nut.
P-56886
Figure 60-81-15 Install intermediate plate on the crankshaft [Figure 6081-12]. Figure 60-81-13
P-56890
Remove the oil pump [Figure 60-81-15].

P-56887
Install the crank shaft dolly on the holding plate [Figure 60-81-13].
60-81-5
Figure 60-81-18
P-56893
Remove the connecting rod bolts [Figure 60-81-18].

P-56891
Remove all the piston/connecting rod assemblies from the engine block. To check the piston/connecting rod assembly. See Piston Installation On The Connecting Rod on page 47. Figure 60-81-19
Remove the oil pan [Figure 60-81-16]. Figure 60-81-17
P-56892 P-56894
Remove the oil suction pipe [Figure 60-81-17]. Remove the front cover [Figure 60-81-19]. To disassemble and assemble the front cover. See Front Cover Disassembly on page 54. Remove the flywheel. (See Removal And Installation on Page 60-71-1.)
60-81-6
Figure 60-81-22
P-56901
Remove the camshaft [Figure 60-81-22].

P-56899
Mark the location of each main bearing cap so it will be installed in the original position. Figure 60-81-23
Remove the rear cover [Figure 60-81-20]. To install a new rear seal and inspect the cover. See Rear Cover Seal Removal And Installation on page 38. Figure 60-81-21
P-56902
Remove the main bearing caps bolts [Figure 60-81-23].

P-56900
Remove the main bearing caps. Remove the crankshaft. Check the crankshaft specifications. See Crankshaft, Checking on page 39. Remove the upper half of the main bearings.
Install the timing tool (Item 1) [Figure 60-81-21] for the camshaft. Remove the thrust washer from the camshaft [Figure 6081-21]. Remove the timing tool.
60-81-7
P-56903
Remove the tappets from the engine block [Figure 6081-24].
60-81-8
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Assembly
Figure 60-81-27
1 Figure 60-81-25
2 3
P-56907
Install the heater oil pressure control valves and springs as shown [Figure 60-81-27].
P-56904
Install the thermostat and spring [Figure 60-81-25]. Figure 60-81-26
(Item 1) [Figure 60-81-27] 14.5 PSI (1 bar) spring, marked yellow (Item 2) [Figure 60-81-27] 24.7 PSI (bar) spring, marked red (Item 3) [Figure 60-81-27] 4.4 PSI (bar) spring, marked blue
Figure 60-81-28
1
P-56905
2 Install the plug and tighten to 82 ft.-lb. (111 Nm) torque. [Figure 60-81-26].
P-56908
Install the fittings (Item 1) and plugs (Item 2) [Figure 6081-28]. Tighten the fittings and plugs to 83 ft.-lb. (111 Nm) torque.
60-81-9
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Assembly (Cont'd) Figure 60-81-29
Figure 60-81-31
P-56912
P-56910
Install the oil temperature sending unit. Tighten the sending unit to 17-20 ft.-lb. (22.5-27.5 Nm) torque [Figure 60-81-31]. Figure 60-81-32
Install and tighten the plug to 37 ft.-lb. (50 Nm) torque [Figure 60-81-29]. Figure 60-81-30
P-56913
Install the tappets [Figure 60-81-32].

P-56911
Install the oil pressure switch and tighten to 102-128 in.lb. (11.5-14.5 Nm) torque [Figure 60-81-30].
60-81-10
Figure 60-81-35
P-56900
Install the camshaft timing tool (Item 1) [Figure 60-8135].

P-56914
Install the camshaft [Figure 60-81-33]. Figure 60-81-34
Tighten the camshaft thrust washer bolt to 15 ft.-lb. (21 Nm) torque. Remove the timing tool. Figure 60-81-36
P-56915 P-56917
Install the thrust washer with the lubricating groove toward the crankcase [Figure 60-81-34].
Install the upper main bearing halves [Figure 60-81-36].
60-81-11
Figure 60-81-39
P-56920
Figure 60-81-40
P-56918
Install the other main bearing half into the main bearing caps [Figure 60-81-37]. Figure 60-81-38
P-56921
Measure the bearing journal width at the crankshaft [Figure 60-81-39] & [Figure 60-81-40]. Specifications: Journal Width Std. . . . . . . . . . . . . . . . . .1.378-1.379 inch. (35,0-35,04 mm) Limit for O/S . . . . . . . . . . . . . . . . 1.395 inch. (35,44 mm) Determine the end play for the crankshaft. Specifications: Std. End Play. . . . . . . . . . . . . . . . . . . . .0.004-0.010 inch. (0,1-0,273 mm) Wear Limit . . . . . . . . . . . . . . . . . . . . 0.016 inch. (0,4 mm) Use new thrust washer as needed to get the correct end play.
P-56919
Install the thrust bearings halves on the main bearing cap [Figure 60-81-38]. Measure the width of the thrust washers/main bearing cap [Figure 60-81-38].
60-81-12
Figure 60-81-43
P-56924
Lubricate the thrust washer with grease and install them on the main bearing cap [Figure 60-81-43].
P-56922
Figure 60-81-44 Install the main bearing locating sleeves [Figure 60-8141]. Figure 60-81-42
P-56925
Install the main bearing/thrust washer assembly [Figure 60-81-44].

P-56923
Install the crankshaft into the engine block [Figure 60-8142].
NOTE: The main bearing cap No. 1, at the flywheel end, the chamfer must be towards the flywheel end.
60-81-13
Figure 60-81-47
P-56927
Put sealing compound on the rear cover [Figure 60-8147].

P-56926
Figure 60-81-48 Install the main bearing caps/main bearing assembly [Figure 60-81-45]. Install the caps in the original locations. Figure 60-81-46
P-56928
Install the rear cover complete with a new rear seal [Figure 60-81-48]. NOTE: Make sure the rear cover oil pan surface aligns with the engine block surface. Tighten the bolts to 15 ft.-lb. (21 Nm) torque in the order shown.
CD-15554
Tighten the main bearing cap bolts as follows [Figure 6081-46]: Initial Torque . . . . . . . . . . . . . . . . . . . . 37 ft.-lb. (50 Nm) 1st Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
60-81-14
Figure 60-81-51
P-56930
Install the connecting rod bearing halves into the connecting rod [Figure 60-81-51].
P-56929
Figure 60-81-52 Measure the distance between the top edge of the crank pin (TDC) and cylinder head sealing surface at all cylinders [Figure 60-81-49]. Figure 60-81-50
CD-15560
Before installing piston/connecting rod assembly, make sure the piston ring gaps are staggered as shown in [Figure 60-81-52].
CD-15558
Compare actual dimension with the dimension listed [Figure 60-81-50]: Specifications: Piston Class A . . . . . . . . . . . . . . . . . . . 7.732-7.736 inch. (196,39-196,49 mm) Piston Class B . . . . . . . . . . . . . . . . . . . 7.736-7.744 inch. (196,491-196,69 mm) NOTE: If the crankshaft is undersize, 0.005 inch (0,125 mm) must be added to the dimension listed.
60-81-15
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Assembly (Cont'd) Install a piston ring compressor on the piston rings. Figure 60-81-53
Figure 60-81-55
P-56932
Tighten the connecting rod bolts as follows [Figure 6081-55]: Initial Torque . . . . . . . . . . . . . . . . . . . . 22 ft.-lb. (30 Nm) 1st Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 NOTE: If the connecting rod bolts are still serviceable, do not reuse the bolts more than five times. Figure 60-81-56
P-56931
Install the piston/connecting rod assembly in the engine block [Figure 60-81-53]. NOTE: The flywheel symbol on the piston must be toward the flywheel. Figure 60-81-54
CD-15564
CD-15562
Check that the connecting rods can be easily moved back and forth on the crank pin [Figure 60-81-56].
Install the connecting rod cap on the connecting rod. The numbers must be aligned [Figure 60-81-54].
60-81-16
Figure 60-81-59
CD-15567
Tighten the front cover bolts to 15 ft.-lb. (21 Nm) torque [Figure 60-81-59].
P-56933
Figure 60-81-60 Put sealing compound on the front cover sealing surface [Figure 60-81-57]. NOTE: Make sure the camshaft/centrifugal governor connecting is clean and free of oil. Figure 60-81-58
P-56935
Make sure the mating surfaces are clean and free of oil and install the crankshaft gear on the crankshaft [Figure 60-81-60].
P-56934
Install the front cover with the new shaft seals on the engine block [Figure 60-81-58]. NOTE: Make sure the oil pan sealing surface on the front cover aligns with the sealing surface on the block [Figure 60-81-61 on Page 18].
60-81-17
Figure 60-81-63
P-56939

P-56937
Figure 60-81-64 Install the bolt [Figure 60-81-61]. Figure 60-81-62
P-56886
P-56938
Install the intermediate disc on the crankshaft [Figure 6081-64].
Install the crankshaft timing tool [Figure 60-81-62].
60-81-18
Figure 60-81-67
P-56943
Install the camshaft timing tool [Figure 60-81-67].

P-56940
Figure 60-81-68
Install the crankshaft dolly on the holding plate [Figure 60-81-65]. Figure 60-81-66
P-56944
Install the camshaft gear and bolt [Figure 60-81-68]. NOTE: All mounting surfaces must be clean and free of oil.
P-56942
Using a torque multiplier, tighten the bolt an additional 210 [Figure 60-81-66]. NOTE: Screw the crankshaft timing tool back in as far as it will go. Turn the crankshaft clockwise against the stop. The piston at the front cover is at the TDC position.
60-81-19
Figure 60-81-71
P-56947
Install the oil pump on the engine block [Figure 60-8171].

P-56945
Figure 60-81-72 Tighten the bolt finger tight. The gear must turn freely [Figure 60-81-69]. Figure 60-81-70
CD-15472
Tighten the oil pump bolts to 14-17 ft.-lb. (18,9-23,1 Nm) torque [Figure 60-81-72].
P-56946
Install the gasket on the oil pump [Figure 60-81-70].
Install the engine timing belt. (See Timing Belt Installation on Page 60-51-22.)
60-81-20
Figure 60-81-75
1 1
Piston pin axis
B-14695
Measure at the gauge points (Item 1) [Figure 60-81-75].

P-56968
To determine maximum piston projection measure all the pistons. Figure 60-81-76
Put spacers on sealing surface of the engine block and set dial indicator gauge to 0 [Figure 60-81-73]. See Deutz Engine Tools Identification Chart on page 1. Figure 60-81-74
P-56970
P-56969
Compare the measurements with the specifications to determine the correct cylinder head gasket [Figure 6081-76]. Specifications: Piston Projection Head Gasket Marking of Cylinder
Position the dial gauge on the piston [Figure 60-81-74].
0.023-0.027 inch. (0,59-0,69 mm) . . . . . . . . . . . . 1 Notch 0.027-0.030 inch. (0,69-0,76 mm) . . . . . . . . . . 2 Notches 0.030-0.033 inch. (0,76-0,83 mm) . . . . . . . . . . 3 Notches
60-81-21
Figure 60-81-79
P-56973
Put a light coat of oil on the head bolts [Figure 60-81-79].

P-56971
Install the head bolts. Figure 60-81-80 8 10 6 3 4 1 5 2 9 7
Make sure the dowel pins are installed in the engine block [Figure 60-81-77]. Figure 60-81-78
CD-15479
P-56972
Tighten the cylinder head bolts in the correct sequence [Figure 60-81-80]. Initial Torque . . . . . . . . . . . . . . . . . . . . 22 ft.-lb. (30 Nm) 1st Stage Torque. . . . . . . . . . . . . . . . . 59 ft.-lb. (80 Nm) 2nd Stage Torque . . . . . . . . . . . . . . 118 ft.-lb. (160 Nm) 3rd Stage Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Install the cylinder head gasket [Figure 60-81-78]. The sealing surfaces of the cylinder head gasket is free of oil. Install the cylinder head. Measure the cylinder head bolts. Std. Length. . . . . . . . . . . 5.90 0.03 inch (150 0,8 mm)
60-81-22
Figure 60-81-83
P-56974
Tighten the rocker arm bracket bolts to 15 ft.-lb. (21 Nm) torque [Figure 60-81-83].
P-56871
Install the push rods [Figure 60-81-81]. Figure 60-81-82
Set the valve clearance. Adjustment on page 50. Figure 60-81-84
See
Valve
Clearance
CD-15483 P-56870
Install the rocker arms/bracket assembly [Figure 60-8182].
Install the valve cover gasket [Figure 60-81-84].
60-81-23
Figure 60-81-87
P-56979
Install the intake manifold and tighten the bolts to 15 ft.lb. (21 Nm) torque [Figure 60-81-87].
P-56975
Figure 60-81-88 Install the valve cover [Figure 60-81-85]. Tighten the bolts to 75 in.-lb. (8,5 Nm) torque. Figure 60-81-86
P-56980
Install the exhaust manifold [Figure 60-81-88].

P-56978
Install new intake manifold gasket [Figure 60-81-86].
60-81-24
Figure 60-81-91
P-58013
Turn the camshaft so the fuel lift pump lobe is at B.D.C. (bottom dead center) [Figure 60-81-91].
P-56981
Figure 60-81-92 Install the exhaust manifold and tighten the bolts to 41 ft.lb. (55 Nm) torque [Figure 60-81-89]. Figure 60-81-90
P-58014
Install the fuel lift pump [Figure 60-81-92].

P-58012
Install a new seal on the fuel lift pump [Figure 60-81-90].
60-81-25
Figure 60-81-95
P-58017
Figure 60-81-96
P-58015
Tighten the lift pump bolts to 15 ft.-lb. (21 Nm) torque [Figure 60-81-93]. Install a new oil filter. Install the fuel injectors. (See Fuel Injector Removal And Installation on Page 60-51-13.) Install the fuel injector pumps. (See Fuel Injection Pump Installation on Page 60-51-10.) Figure 60-81-94
P-58018
Install the fuel lines [Figure 60-81-95] & [Figure 60-8196]. Install the oil filter.
P-58016
Install the fuel filter mount [Figure 60-81-94]. Tighten the bolts to 15 ft.-lbs (21 Nm) torque. Install the fuel filter.
60-81-26
Figure 60-81-99
CD-15490
Put sealing compound on the sealing surface of the oil pan [Figure 60-81-99].
CD-15488
Install the oil pan Initially install the corner bolts first and tighten to 5 in.-lb. (0,5 Nm) torque. Figure 60-81-100
Put sealing compound on the sealing surface of the oil suction pipe [Figure 60-81-97]. Figure 60-81-98
B-14696 CD-15489
Install the oil pan bolts and tighten to 15 ft.-lb. (21 Nm) torque as shown in [Figure 60-81-100]. Install the oil suction pipe and tighten the bolts to 15 ft.-lb. (21 Nm) torque [Figure 60-81-98]. Install the oil pan plug and tighten to 40 ft.-lb. (55 Nm) torque. Install the flywheel. (See Removal And Installation on Page 60-71-1.) Install the turbocharger. See Turbo Charger Removal and Installation on page 70. Install the starter. (See Removal And Installation (S/N 528911001 & Above And S/N 528611001 & Above) on Page 50-40-1.) Install the alternator. (See Removal And Installation (S/N 528911001 & Above And 528611001 & Above) on Page 50-30-3.)
60-81-27
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Cylinder, Checking Clean the engine block and inspect for damage. Figure 60-81-101
Figure 60-81-103
1 2 3
b
B-14697
Check the cylinders with engine block longitudinal (a) and transverse (b) axis and in three planes [Figure 6081-103].
P-56722
Install the main bearing caps [Figure 60-81-101]. Tighten the main bearing cap bolts as follows: Initial Torque . . . . . . . . . . . . . . . . . . . . 37 ft.-lb. (50 Nm) 1st Stage Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 2nd Stage Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Specifications: Cylinder Bore. . . . . . . . . . . . . . . . . .3.7008 - 3.7016 inch. (94 - 94.02 mm) Wear Limit . . . . . . . . . . . . . . . . . . . . 3.59 inch. (94.1 mm)
Figure 60-81-102
P-56723
Using a dial indicator gauge check the cylinders [Figure 60-81-102].
60-81-28
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Camshaft Bearing, Checking Figure 60-81-104
b a 1 2
B-14698
Check the camshaft bearing bushings at points (1) and (2) in the planes of (a) and (b) [Figure 60-81-104]. Figure 60-81-105
P-56724
Check the camshaft bushings using a gauge [Figure 6081-105]. Inner Diameter . . . . . . . . . . . . . . . . . . 2.126 + 0.002 inch. (54 + 0,054 mm) Wear Limit . . . . . . . . . . . . . . . . . .2.129 inch. (54,08 mm)
60-81-29
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Camshaft Bearing, Removal And Installation Figure 60-81-106
Figure 60-81-108
CD-15383
P-56725
When installing the new camshaft bushings, the oil lube hole must align with the oil hole in the engine block [Figure 60-81-108]. Figure 60-81-109
Remove all the camshaft bearing bushings using a camshaft bushing removal tool as needed [Figure 60-81106]. Figure 60-81-107
8.980.012 inch (228.10.3 mm)
0.0190.012 inch (0.50.3 mm) 0
4.6810.11 inch (118.90.3 mm)
0.0980.12 inch (25.3mm)
4.610.012 inch (117.10.3 mm)
P-56728
B Install the new camshaft bushings using a camshaft bushing installation tool [Figure 60-81-109].
B-14699
Use the dimensions in [Figure 60-81-107] to install the camshaft bushings.
60-81-30
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Control Rod Guide Bushing Removal Figure 60-81-110
Figure 60-81-112
P-56731
Remove the cover [Figure 60-81-112].

P-56729
Figure 60-81-113
Remove the parallel pin [Figure 60-81-110]. Figure 60-81-111
P-56732
Drill a 7/32 inch (5,5 mm) hole on one side of the pipe [Figure 60-81-113].
P-56730
NOTE: Carefully clean the engine block after drilling. Remove the control rod and spring [Figure 60-81-111].
60-81-31
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Control Rod Guide Bushing Removal (Cont'd) Figure 60-81-114
Figure 60-81-116
P-56735
Press pin in until it does not project beyond the pipe [Figure 60-81-116]. Pull the pipe out completely.
P-56733
Install the puller into the bore until the pin engages [Figure 60-81-114]. Figure 60-81-115
P-56734
Install the spacer tool in position. Pull the pipe from the lower press fit [Figure 60-81-115]. NOTE: Do Not pull pipe completely out. Remove the spacer tool.
60-81-32
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Control Rod Guide Bushing Installation Figure 60-81-117
Figure 60-81-119
P-56738
Install the guide on the arbor assembly with the chamfer pointing toward the crankcase [Figure 60-81-119].
P-56736
Figure 60-81-120 Using the tool, drive the guide bushing out [Figure 6081-117]. Figure 60-81-118
P-56739
Fasten the arbor assembly and bushing on the engine block [Figure 60-81-120].
P-56737
Install the new bushing into the center of the arbor assembly [Figure 60-81-118].
60-81-33
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Control Rod Guide Bushing Installation (Cont'd) Figure 60-81-121
Figure 60-81-123
P-56742
Remove the guide bushing at the flywheel end of the engine block [Figure 60-81-123].
P-56740
Figure 60-81-124 Drive the bushing into the engine block as far as it will go [Figure 60-81-121]. Figure 60-81-122
P-56743
Assemble the arbor without the spacer [Figure 60-81124].

P-56741
Remove the arbor assembly [Figure 60-81-122].
60-81-34
Figure 60-81-127
P-56746
Drive in the guide bushing as far as it will go, at the flywheel end [Figure 60-81-127].
P-56744
Figure 60-81-128 Install the guide bushing on the arbor assembly with the chamfer pointing toward the crankcase [Figure 60-81125]. Figure 60-81-126
P-56747
Remove the arbor assembly [Figure 60-81-128].
P-56745
Fasten the arbor assembly and guide bushing to the engine block [Figure 60-81-126].
60-81-35
Figure 60-81-131
P-56750
Install the new cover flush with the engine block [Figure 60-81-131].
P-56748
Figure 60-81-132 Install the new pipe in the block as far as it will go with the arbor assembly [Figure 60-81-129]. Figure 60-81-130
P-56751
Install the control rod with starter spring into the guide bushings [Figure 60-81-132].
P-56749
NOTE: The control rod must move freely. Put sealing compound on the new plug [Figure 60-81130].
60-81-36
P-56752
Compress the starter spring. Install the parallel pin into the recess for the control rod travel limitation [Figure 6081-133]. Check to make sure it is flush with the surface.
60-81-37
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Rear Cover Seal Removal And Installation Figure 60-81-134
Figure 60-81-136
0.8030.008 inch (20.40.2 mm) B-14700
When installing the new shaft seal, use the dimension shown in [Figure 60-81-136].
P-56755
Figure 60-81-137 Remove the rear cover shaft seal [Figure 60-81-134]. Figure 60-81-135
P-56757
CD-15439
Use the seal driver tool and install to the correct depth [Figure 60-81-137]. See Deutz Engine Tools Identification Chart on page 1.
Clean the seal seating surface [Figure 60-81-135]. Inspect the cover for damage, replace as needed.
60-81-38
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Crankshaft, Checking Put the crankshaft on v-blocks. Check the main bearing journals: Specifications: Journal Diameter . . . . . . . . . . . . . . 2.7538 - 2.7546 inch. (69,97 - 69,99 mm) Each Undersize . . . . . . . . . . . . . . . . . . . . . . . 0.010 inch. (0,25 mm) Undersize Limit . . . . . . . . . . . . . . . . . . . . . . 2.7348 inch. (69.47 mm) Figure 60-81-138
Figure 60-81-139
P-56761
Check the connecting rod journals [Figure 60-81-139]. Specifications: Pin Diameter . . . . . . . . . . . . . . . . . 2.1588 - 2.1596 inch. (54,97 - 54,99 mm) Undersize Limit . . . . . . . . . . . . . . . . . . . . . . 2.1448 inch. (54,47 - 54,49 mm) Wear Limit . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0004 inch. (0,1 mm)
Figure 60-81-140
P-56760
Check the thrust bearing width [Figure 60-81-138]. Specifications: Journal Width . . . . . . . . . . . . . . . . . . 1.378 +0.0016 inch. (35 + 0,04 mm) Limit Oversize . . . . . . . . . . . . . . . . . . . . . . . . 1.395 inch. (35,44 mm) Each Oversize . . . . . . . . . . . . . . . . . . . . . . . . 0.016 inch. (0.4 mm)
P-56762
Use a dial indicator and check crankshaft for out of roundness [Figure 60-81-140]. Specifications: Out of Roundness Max.. . . . . . . . . 0.002 inch. (0,05 mm)
60-81-39
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Crankshaft, Checking (Contd) Figure 60-81-141
P-56763
Check the surface of the crankshaft seal area [Figure 60-81-141]. Recondition the crankshaft as needed.
60-81-40
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Connecting Rod, Checking Figure 60-81-142 b
Figure 60-81-144
a
P-56773
Replace small end busing as needed [Figure 60-81144].

B-14701
When checking the connecting rod large and small end, measure at the points (1) and (2) and in planes (a) and (b) [Figure 60-81-142]. Figure 60-81-143
Bore for Small End Bushing . . . . . . 1.299 + 0.0008 inch. (33 + 0,02 mm) O.D. of Small End Bushing . . . . . . . 1.3017 - 1.303 inch. (33,07 - 33,11 mm) Figure 60-81-145
P-56774 P-56770
Check the small end bushing [Figure 60-81-143]. Specifications: I.D. of Small End Bushing . . . . . . . . . . 1.18 - 1.182 inch. (30.025 - 30.035 mm) Wear Limit Bushing Clearance . . . . . . . . . . . 0.003 inch. (0,08 mm)
Press in the small end bushing, make sure the lubrication holes are in alignment [Figure 60-81-145].
60-81-41
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Connecting Rod, Checking (Cont'd) Figure 60-81-146
Figure 60-81-148
P-56768
Tighten the connecting rod cap nuts as follows [Figure 60-81-148].

CD-15450
After pressing in the small end bushing, bore the bushing to the following dimensions [Figure 60-81-146]. Specifications: I.D. of Small End Bushing . . . . . . . . . . 1.181-1.182 inch. (30.025 - 30.035 mm) Figure 60-81-147
Initial Torque . . . . . . . . . . . . . . . . . . . . 22 ft.-lb. (30 Nm) 1st Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 2nd Step Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2908
2908
CD-15451
Install the correct cap on the correct rod [Figure 60-81147].
60-81-42
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Connecting Rod, Checking (Cont'd) Figure 60-81-149
CD-15454
Measure the big end bore [Figure 60-81-149]. If the measurement is the same as the specific valve, the necessary preload on the bearing halves will be obtained. Specifications: Big End I.D. . . . . . . . . . . . . . . . . . . . 2.303 + 0.0008 inch (58,5 + 0,02 mm) Remove connecting rod cap. Install new bearing halves. Tighten the connecting rod cap nuts and tighten as listed above. Measure the bearing halves: Big End Bearing I.D. . . . . . . . . . . . 2.1662 - 2.1675 inch. (55.024 - 55.055 mm) Each Undersize . . . . . . . . . . . . . . . . . . . . . . . 0.010 inch. (0,25 mm) Limit For Undersize . . . . . . . . . . . . 2.1466 - 2.1478 inch. (54.524 - 54.555 mm) Radial Clearance Wear Limit . . . . . . . . . . . . . . . . .0.005 inch. (0,12 mm) Check the connecting rod, without bearing halves, on a connecting rod tester. Specifications: Parallel Check-Tolerance. . . . . . . .0.118 inch. (0.03 mm) Over a Distance of . . . . . . . . . . . . . . 3.94 inch. (100 mm) Squareness Check-Tolerance . . . .0.002 inch. (0,05 mm)
60-81-43
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Piston, Checking Figure 60-81-150
Figure 60-81-152
P-56783
Measure the ring gap with a feeler gauge in the cylinder [Figure 60-81-152].
P-56781
Remove the piston rings from the piston [Figure 60-81150]. Remove the piston from the connecting rod. See Connecting Rod, Checking to check connecting rod specifications. (See Connecting Rod, Checking on Page 60-81-41.) Figure 60-81-151
Specifications: Wear Limit 1st Ring Gap . . . . . . . . . . . . . . . . . . 0.031 in. (0.8 mm) 2nd Ring Gap . . . . . . . . . . . . . . . . . 0.098 in (2.5 mm) 3rd Ring Gap . . . . . . . . . . . . . . . . . . 0.043 in (1,1 mm)
P-56782
Clean and inspect piston and piston ring grooves [Figure 60-81-151].
60-81-44
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Piston, Checking (Contd) Figure 60-81-153
Piston Pin, Checking Figure 60-81-154
B-8230
P-56784
Check piston pin for wear [Figure 60-81-154]. Specifications: Pin O.D. . . . . . . .1.180-1.181 inch. (29.995-30.0 mm)
Using new rings, measure the ring grooves using a feeler gauge [Figure 60-81-153]. Specifications: Wear Limit 1st Ring. . . . . . . . . . . . . . . . . . . . . . . . Trapezoidal Slot 2nd Ring . . . . . . . . . . . . . . . . . . . . 0.0078 in (0.20 mm) 3rd Ring . . . . . . . . . . . . . . . . . . . . 0.0059 in (0.15 mm) Measure the trapezoidal slot with the trapezoidal slot gauge [Figure 60-81-153]. If a distance is present between the gauge and piston, the piston is serviceable [Figure 60-81-153]. If the gauge rests against the piston, replace the piston [Figure 60-81-153].
60-81-45
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Piston Rings Installation Figure 60-81-155
P-56789
When installing the piston rings position them as listed below [Figure 60-81-155]. Figure 60-81-156
1 2
3
TS-1928A
lst Ring - Is a trapezoidal ring, (Item 1) [Figure 60-81156]. It is installed on the piston with the mark BLF/M 2011 facing the combustion chamber. 2nd Ring - Is a tapered compression ring (Item 2) [Figure 60-81-156], which is installed on the piston with the mark TOP facing the combustion chamber. 3rd Ring - Is a bevelled edge slotted oil control ring (Item 3) [Figure 60-81-156]. The gap of each ring must be offset by 180 to the other ring.
60-81-46
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Piston Installation On The Connecting Rod Figure 60-81-157
Figure 60-81-159
2908
2908
CD-15451
Figure 60-81-160
P-56780
Install the piston [Figure 60-81-157]. Install the snap ring [Figure 60-81-157]. Figure 60-81-158
2 3
P13908
The flywheel symbol (Item 1) [Figure 60-81-158] & [Figure 60-81-160] on the piston must point toward the flywheel (Item 3) [Figure 60-81-160], when properly installed on the connecting rod. The numbers on the connecting rod and cap (Item 1) [Figure 60-81-159] & (Item 2) [Figure 60-81-160] point toward the camshaft side of the engine when being install in the engine block.
N-19068
60-81-47
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Cylinder Head Disassembly NOTE: Do not grind the cylinder head surface, if its damaged, replace the cylinder head. Figure 60-81-161
P-56791
Using a valve spring tool, remove the spring locks, valve spring cap, valve spring and valve [Figure 60-81-161]. See Deutz Engine Tools Identification Chart on page 1. Repeat the procedure for all the valves. Figure 60-81-162
P-56792
Remove the valve seals [Figure 60-81-162]. Clean the cylinder head and inspect for damage.
60-81-48
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Valves, Checking Figure 60-81-163
Valve seat angle: Specifications: Intake Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Exhaust Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Figure 60-81-165
P-56793
P-56795
Measure the valve stem diameter [Figure 60-81-163]. Std. Intake Valve . . . . . . . . . . . . . . . . . . .0.3134-0.314 in (7,97-7,98 mm) Std. Exhaust Valve. . . . . . . . . . . . . . . . . .0.3124-0.313 in (7,95-7.96 mm) Figure 60-81-164
Measure the valve seat width [Figure 60-81-165]. Specifications: Width (Intake) . . . . . 0.062 0.016 inch. (1,58 0,4 mm) (Exhaust) . . . . . 0.067 0.016 inch. (1,7 0,4 mm) Figure 60-81-166
Thickness
Angle
P-56796
Diameter
P-56794
Install the valves and measure the valve stem clearance [Figure 60-81-166]. Wear Limit: Intake Valve . . . . . . . . . . . . . . . 0.0197 inch (0.5 mm) Exhaust Valve. . . . . . . . . . . . . . 0.0511 inch (1.3 mm)
Measure the valve edge thickness [Figure 60-81-164]. Specifications: Intake Valve . . . . . . . . . . . . . . . . .0.055 inch. (1,4 mm) Exhaust Valve . . . . . . . . . . . . . . . . .0.05 inch. (1,2 mm) Measure the valve head diameter [Figure 60-81-164]. Specifications: Intake Valve . . . . . 1.594 0.004 inch (40,5 0,1 mm) Exhaust Valve . .1.374 0.004 inch. (34,9 0,01 mm)
60-81-49
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Valve Clearance Adjustment Figure 60-81-167
P-56797
Measure the valve clearance between the valve head and cylinder head sealing surface [Figure 60-81-167]. Valve penetration into cylinder head: Specifications: Wear Limit . . . . . . . . . . . . . . . . . 0.0512 inch. (1,3 mm) Recondition the valve seats and valve guides if worn. Figure 60-81-168 Inclination
Free Length
Square
B-8208
Measure valve spring free length [Figure 60-81-168]. Specifications: Valve Spring Diameter . . . . . . . . 0.132 inch. (3,35 mm) Free Length . . . . . . . . . . . . . . . . . 1.53 inch. (38.9 mm) Valve Spring Diameter . . . . . . . . 0.134 inch. (3,40 mm) Free Length . . . . . . . . . . . . . . . . 1.547 inch. (39,3 mm) Inclination . . . . . . . . . . . . . . . . . . . 0.126 inch. (3,2 mm)
60-81-50
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Cylinder Head Assembly Figure 60-81-169
Figure 60-81-171
P-56805
P-56803
Use the tool and press the valve stem as far as it will go [Figure 60-81-171]. See Deutz Engine Tools Identification Chart on page 1. Figure 60-81-172
Install the valve into the cylinder head and install the protective sleeve or masking tape on the valve stem grooves [Figure 60-81-169]. Figure 60-81-170
P-56806
Install the valve spring and cap [Figure 60-81-172].

P-56804
Install the valve seal on the protective sleeve and push the seal down [Figure 60-81-170]. Remove the protective sleeve.
60-81-51
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Cylinder Head Assembly (Cont'd) Figure 60-81-173
P-56791
Use the valve spring tool, install the valve spring tool [Figure 60-81-173]. Repeat the procedure to install all the valves.
60-81-52
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Rocker Arm And Bracket, Checking Figure 60-81-174
Figure 60-81-176
P-56810
Check the oil passages that they are open and clean [Figure 60-81-176].
P-56808
Install the rocker arms on the bracket. Disassembly the rocker arms from the bracket [Figure 60-81-174]. Figure 60-81-175 Figure 60-81-177
P-56811
P-56809
Install the snap ring [Figure 60-81-177].
Check for wear at the following locations and replace as needed [Figure 60-81-175]: Journals Adjusting Bolt Rocker Arm Contact Face Bore
60-81-53
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Front Cover Disassembly NOTE: Dynamometer testing is recommended if the governor assembly is re-built. Figure 60-81-178
Figure 60-81-180
P-56813
Remove the governor spring (Item 1) [Figure 60-81180]. Figure 60-81-181

CD-15343
Remove the engine shut-down solenoid [Figure 60-81178]. Figure 60-81-179
P-56814
Mark the governor lever shaft (Item 1) [Figure 60-81181] for proper installation. Remove the governor lever shaft.
CD-15344
Disconnect the governor spring [Figure 60-81-179].
60-81-54
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Front Cover Disassembly (Contd) Figure 60-81-182
Figure 60-81-184
P-56817
Remove the camshaft seal [Figure 60-81-184].

P-56815
Figure 60-81-185
Remove the shims below the governor lever shaft [Figure 60-81-182]. Figure 60-81-183
P-56818
Remove the crankshaft seal [Figure 60-81-185].
P-56816
Remove the centrifugal governor [Figure 60-81-183].
60-81-55
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Front Cover Disassembly (Contd) Figure 60-81-186
Figure 60-81-188
P-56821
Remove the shut-down lever with spacer bushings [Figure 60-81-188].

P-56819
Figure 60-81-189 Disconnect the spring [Figure 60-81-186]. Figure 60-81-187
P-56822
P-56820
Remove the shaft, spacer bushing and spring [Figure 60-81-189].
Remove the dowel pin [Figure 60-81-187].
60-81-56
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Front Cover Disassembly (Cont'd) Figure 60-81-190
Figure 60-81-192
P-56825
Remove the dowel pin [Figure 60-81-192].

P-56823
Figure 60-81-193
Remove the O-ring [Figure 60-81-190]. Figure 60-81-191
P-56826
Remove the pin from the lever [Figure 60-81-193].

P-56824
Do not damage the cover sealing surface.
Remove the cover [Figure 60-81-191].
60-81-57
Figure 60-81-196
P-56829
P-56827
Before removing the torque control assembly, measure the height from the cover [Figure 60-81-196] and make a record of this for assembly. Figure 60-81-197
Remove the speed control lever and spacer bushing [Figure 60-81-194]. Figure 60-81-195
P-56830
Remove the nut and clamp [Figure 60-81-197].

P-56828
Remove the torque control assembly. Remove the O-ring [Figure 60-81-195].
60-81-58
P-56831
Remove the breather vent [Figure 60-81-198]. NOTE: On later model Deutz engines the breather is located in the valve cover. The breather vent shown in photo [Figure 60-81-198] is used in both engines.
60-81-59
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Front Cover Assembly Figure 60-81-199
If the torque control was disassembled, do the following procedure to assemble: Figure 60-81-201
4 5
P-56839 P-56832
Inspect the front cover for damage [Figure 60-81-199]. Replace the front cover as needed. Figure 60-81-200
Turn (Item 1) into (Item 2) until lightly bottomed, back (Item 1) [Figure 60-81-201] out 1-1/2 turns. Tighten the lock nut (Item 3) [Figure 60-81-201] to 12 ft.lb. (16 Nm) torque. Turn (Item 4) as far as it will go into (Item 5) [Figure 6081-201]. Turn back one full turn. Tighten the lock nut (Item 6) [Figure 60-81-201] to 53 in.lb. (6 Nm) torque. Figure 60-81-202
P-56838
Inspect the individual parts of the torque control assembly [Figure 60-81-200]. Replace the parts as needed.
P-56840
Install the torque control into the front cover [Figure 6081-202].
60-81-60
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Front Cover Assembly (Cont'd) Figure 60-81-203
Figure 60-81-205
P-56843
Tighten the clamp nut to 88 in.-lb. (10 Nm) torque [Figure 60-81-205].
P-56841
Figure 60-81-206 Install the torque control assembly to the dimensions taken [Figure 60-81-203] or use the procedure below: See Front Cover Disassembly on page 54. Measure the thread reach [Figure 60-81-203]. Specifications: Thread Reach . . . . . . . . . . . . . . . . . . 0.252 0.019 inch. (6,4 0,5 mm) NOTE: Dynamometer testing may be necessary depending on engine performance. Figure 60-81-204
P-56844
Press the camshaft seal into the front cover [Figure 6081-206]. See Deutz Engine Tools Identification Chart on page 1. NOTE: Do not put oil on the camshaft seal before installation.
CD-15374
Install the clamp and nut [Figure 60-81-204].
60-81-61
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Front Cover Assembly (Cont'd) Do Not put oil on the crankshaft seal. Figure 60-81-207
Figure 60-81-209 0.910.039 inch (231 mm)
P-56847-
Adjust the minimum speed screw to 0.91 + 0.039 inch (23
1.0 mm) [Figure 60-81-209].

Tighten the lock nut to 40 in.-lb. (4.5 Nm) torque.
P-56845
Figure 60-81-210 Press the crankshaft seal into the front cover [Figure 6081-207]. Figure 60-81-208
P-56848
Install the spacer bushing and spring on the shut down shaft [Figure 60-81-210].
P-56846
Install the stop bolt and nut. The nut must be flush with the end of the bolt [Figure 60-81-208]. Tighten the nut to 40 in.-lb. (4,5 Nm) torque.
60-81-62
Figure 60-81-213
P-56851
Install the spacer bushing [Figure 60-81-213].

P-56849
Figure 60-81-214
Install the shut down shaft [Figure 60-81-211]. Figure 60-81-212
P-56852
Install the shut down lever and dowel pin [Figure 60-81214].
P-56850
Put grease on the O-ring and install on the shaft [Figure 60-81-212].
60-81-63
Figure 60-81-217
P-56855
When installing the speed control lever, make sure it is installed in the correct direction [Figure 60-81-217].
P-56853
Figure 60-81-218 Put grease on the O-ring and install in the front cover [Figure 60-81-215]. Figure 60-81-216
P-56856
Install the dowel pin into the speed control lever [Figure 60-81-218].
P-56854
Install the spacer bushing on the speed control lever [Figure 60-81-216]. Install the speed control lever into the front cover [Figure 60-81-216].
60-81-64
Figure 60-81-221
CD-15392
Inspect the governor plate for wear [Figure 60-81-221].

P-56857
Replace as needed. Figure 60-81-222
Drive the pin into the lever [Figure 60-81-219]. The groove in the speed control shaft must be in line with the dowel pin bore. Figure 60-81-220
P-56858
Assemble the governor plate with the centrifugal governor [Figure 60-81-222].
CD-15391
Inspect the centrifugal governor for wear [Figure 60-81220]. Replace as needed.
60-81-65
Figure 60-81-225
1 2
CD-15396
Install shims of at least 0.011 inch (0,3 mm) thickness at points (Items 1 & 2) [Figure 60-81-225].
CD-15394
Figure 60-81-226 Install centrifugal governor assembly into the front cover [Figure 60-81-223]. Be careful not to damage the shaft seal. Figure 60-81-224
CD-15397
Install the governor lever shaft without the idling lever [Figure 60-81-226]. Tighten the bolts to 81 in.-lb. (9,2 Nm) torque.
CD-15395
Inspect roller lever, shaft and idling lever wear [Figure 60-81-224]. Replace the parts as needed.
60-81-66
Figure 60-81-229
P-56860
Assemble the roller lever with the idling lever and shaft [Figure 60-81-229].
CD-15398
Measure the ball bearing by lightly pressing the roller lever [Figure 60-81-227]. Set the dial gauge to zero. Figure 60-81-228
Install the complete governor lever shaft assembly into the front cover. Figure 60-81-230
P-56861A
CD-15399
Tighten the bolts to 81 in.-lb. (9,2 Nm) torque [Figure 60-81-230]. NOTE: The longer space (Item 1) [Figure 60-81-230] on the governor lever shaft goes down toward the cover when installed.
Place dial indicator on ball bearing [Figure 60-81-228]. Make record of the two readings. The required tolerance is 0.0019 inch (0,05 mm). It is possible to install extra shims (max 0.0019 inch [0.05mm]) at (Items 1 & 2) [Figure 60-81-225 on Page 66] to get the required measurement.
60-81-67
Figure 60-81-233
P-56864
Install a greased O-ring on the shut down solenoid [Figure 60-81-233].

P-56862
Figure 60-81-234 Connect the governor spring [Figure 60-81-231]. Figure 60-81-232
P-56865
P-56863
Install the shut down solenoid into the front cover [Figure 60-81-234]. Tighten the bolts to 10-12 ft.-lb. (13,5-16,3 Nm) torque.
Install the cover with new gasket. Tighten the bolts to 40 in.-lb. (4,5 Nm) torque [Figure 60-81-232].
60-81-68
Figure 60-81-237
P-56868
Install the idle speed casting (If equipped) [Figure 60-81237].

P-56866
Tighten the bolt to 41 4 in.-lb. (4.6 0.4 Nm) torque. Install new O-ring on the breather vent [Figure 60-81235]. Figure 60-81-236
P-56867
Install the breather vent into the front cover. Tighten the bolts to 75 in.-lb. (8,5 Nm) torque [Figure 60-81-236].
60-81-69
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Turbo Charger Removal and Installation Figure 60-81-238
Figure 60-81-240
P-56984
Remove the air inlet hose (Item 1) [Figure 60-81-240].

P-56986
Figure 60-81-241
Remove the lube oil line [Figure 60-81-238]. Installation: Tighten the bolt to 21 ft.-lb. (29 Nm) torque. Figure 60-81-239
1 1
P-56983
Remove the bolts (Item 2) [Figure 60-81-241]. Installation: Tighten the bolts to 15 ft.-lb. (21 Nm) torque.
P-56985
Remove the vent pipe (Item 1) [Figure 60-81-239]. Installation: Initially tighten the bolt to 6 ft.-lb. (8.5 Nm) torque. Final tighten the bolts to 9 ft.-lb. (12.5 Nm) torque.
60-81-70
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Turbo Charger Removal and Installation (Contd) Figure 60-81-242
P-56982
Remove the hose (Item 1) [Figure 60-81-242] and turbo charger. NOTE: In the event of severe engine oil contamination, drain and flush the engine oil cooler, cab heater and plumbing. Drain the engine oil from the crankcase and replace the engine oil and filter. (See Replacing Oil And Filter on Page 10-90-2) Start the engine and run at idle until oil pressure is assured. Work the unit until operating temperature of engine is maintained for approximately 15 minutes. Idle and cool the down engine approximately 3 to 4 minutes, and stop the engine. Drain the engine oil from the crankcase again, replace the engine oil and filter. (See Replacing Oil And Filter on Page 10-90-2.) Re-start engine, check for leaks and performance.
60-81-71
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Crankshaft Gear Mounting Bolt Torque Procedure The tool listed will be needed to do the following procedure:
Figure 60-81-245
1 MEL1522 - Torque Multiplier Support Device MEL1526 - Torque Multiplier Figure 60-81-243
P13135
Mark the crankshaft gear mounting bolt (Item 1) [Figure 60-81-245]. Figure 60-81-246
P5292
If the V-belt pulley is installed, remove the four bolts and remove the pulley (Item 1) [Figure 60-81-243]. Figure 60-81-244
1
P13136
NOTE: If the torque multiplier tool (Item 1) [Figure 6081-246] has a degree wheel, the crankshaft bolt does not have to be marked. Install the torque multiplier tool (Item 1) [Figure 60-81246], with the socket, into the tool.
P13135A
Install the tool (Item 1) [Figure 60-81-244] on the crankshaft hub using the V-belt pulley bolts. Install the crankshaft gear mounting bolt (Item 2) [Figure 60-81-244] and tighten to 96 ft.-lb. (130 Nm) torque.
60-81-72
RECONDITIONING THE ENGINE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Crankshaft Gear Mounting Bolt Torque Procedure (Contd) Figure 60-81-247
P13137
Figure 60-81-248
P13135
Tighten the gear bolt 210 (+ or - 10) [Figure 60-81247] & [Figure 60-81-248].
60-81-73
60-81-74
HEATING, VENTILATION, AIR CONDITIONING AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . 70-120-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1 AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 70-40-2 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-3 Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-2 BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1 Checking The Electrical System . . . . . . . . . . . . . . . . . . . . 70-80-5 Cleaning The A/C Evaporator Coil & Heater Coil (S/N 522311001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-2 Cleaning The A/C Evaporator Coil And Heater Coil (S/N 528911001 & Above And 528611001 & Above). . . . . . . . . 70-80-3 Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 70-80-2 Engine Coolant By-Passing The Heater Valve . . . . . . . . 70-80-15 Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1 COMPONENTS (S/N 522311001 & ABOVE) . . . . . . . . . . . . . 70-50-1 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1 COMPONENTS (S/N 528911001 & ABOVE AND 52864001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-1 Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-51-1 COMPRESSOR (S/N 522311001 & ABOVE) . . . . . . . . . . . . 70-140-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-140-1 COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-141-1 Compressor Clutch Disassembly And Assembly. . . . . . . 70-141-3 Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-141-2 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-141-1 CONDENSER (S/N 522311001 & ABOVE) . . . . . . . . . . . . . 70-150-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-150-1 CONDENSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-151-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-151-1 EVAPORATOR/HEATER UNIT (S/N 522311001 & ABOVE) . 70-10-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1 SAFETY & MAINTENANCE
DRIVE SYSTEM
ELECTRICAL SYSTEM & ANALYSIS
HVAC
SPECIFICATIONS
70-01
442 Excavtor Service Manual
HEATING, VENTILATION, AIR CONDITIONING (CONTD) EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-11-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 70-11-5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-11-1 EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-200-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-200-1 GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . Component Replacement And Refrigeration Leaks. . . . . . Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1 70-90-3 70-90-1 70-90-1
HEATER/AC FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1 Resistor Removal And Installation . . . . . . . . . . . . . . . . . . . 70-20-3 HEATER COIL/EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . 70-180-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-180-1 HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1 PRESSURE SWITCH (S/N 522311001 & ABOVE). . . . . . . . 70-170-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-170-1 PRESSURE SWITCH (S/N 528911001 & ABOVE AND 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-171-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-171-1 RECEIVER/DRYER (S/N 522311001 & ABOVE) . . . . . . . . . 70-160-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-160-1 RECEIVER/DRYER (S/N 528911001 & ABOVE AND 528611001 & ABOVE)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-161-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-161-1 REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . Air Conditioning Compressor Belt . . . . . . . . . . . . . . . . . . . Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . Heater Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1 70-70-1 70-70-2 70-70-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1 Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

70-02
HEATING, VENTILATION, AIR CONDITIONING (CONTD) SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . 70-130-1 Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1 SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . 70-100-1 Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . 70-100-1 Gauge Pressure Related Troubleshooting. . . . . . . . . . . . 70-100-2 TEMPERATURE/PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . 70-110-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-190-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-190-1 UPGRADED AIR CONDITIONING SYSTEM . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . Evaporator Removal And Installation. . . . . . . . . . . . . . . . Evaporator Unit Removal And Installation . . . . . . . . . . . . Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . Switch Removal And Installation . . . . . . . . . . . . . . . . . . . Thermostat Removal And Installation . . . . . . . . . . . . . . . 70-210-1 70-210-4 70-210-7 70-210-1 70-210-8 70-210-8 70-210-7
70-03
442 Excavtor Service Manual
70-04
EVAPORATOR/HEATER UNIT (S/N 522311001 & ABOVE) Removal And Installation Drain the radiator. (See COOLING SYSTEM on Page 1070-1.) Discharge the air conditioning system. (See SYSTEM CHARGING AND RECLAMATION on Page 70-130-1).
Figure 70-10-3
1 Remove the seat and seat mount. (See SEAT AND SEAT MOUNT on Page 40-30-1.) Figure 70-10-1
P-36826
Remove the four bolts (Item 1) [Figure 70-10-3] and washers. Figure 70-10-4
1 1
P-36828
Remove the air conditioner hoses (Item 1) [Figure 7010-1]. Figure 70-10-2 1
P-36825
Raise the air conditioning/heating unit to gain access to the heater hoses (Item 1) [Figure 70-10-4] Remove the heater hoses. Remove the evaporator/heater unit from the excavator.
P-36827
70-10-1
70-10-2
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) Removal And Installation Figure 70-11-1 2
Figure 70-11-3
2 1
1
P-63541
1 Loosen the clamp (Item 1). Remove the hose (Item 2) [Figure 70-11-3].
P-61833
Figure 70-11-4 Remove the six screws (Item 1) and cover (Item 2) [Figure 70-11-1]. Figure 70-11-2
P-63593
Remove the adapter (Item 1) from the louver (Item 2) [Figure 70-11-4].
P-61832
Remove the louver. Remove the foam (Item 1) [Figure 70-11-2]. Remove the seat and seat mount. (See SEAT AND SEAT MOUNT on Page 40-30-1)
70-11-1
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) (CONTD) Removal And Installation (Contd)
Figure 70-11-7
1 Figure 70-11-5 2
1
P-63538
2 Loosen the clamp (Item 1). Remove the hose (Item 2) [Figure 70-11-7].
P-63592
Figure 70-11-8 Loosen the clamp (Item 1). Remove the hose (Item 2) [Figure 70-11-5]. Tilt the cab. (See Tilting The Cab on Page 10-160-2) Figure 70-11-6 1
P-63589
Remove the 2 hoses (Item 1) [Figure 70-11-8].
P-63601
Loosen the clamps (Item 1). Remove the 2 heater hoses (Item 2) [Figure 70-11-6].
70-11-2
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 70-11-9 2 1
Figure 70-11-11
1 1
P-63579
Remove the tiestraps (Item 1) [Figure 70-11-11].

P-63581
Figure 70-11-12 1
Remove the 2 bolts (Item 1) from the retainer (Item 2) [Figure 70-11-9]. Remove the retainer. Figure 70-11-10
1
P-63578
Disconnect the 2 wire connectors (Item 1) [Figure 70-1112].
P-63580
Remove the control cable (Item 1) [Figure 70-11-10].
70-11-3
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 70-11-13
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 70-11-15
1 2
1
P-63577
1
P-63575
Remove the 4 bolts (Item 1) [Figure 70-11-13] and washers. Lower the cab. Figure 70-11-14
The heater unit is shown removed in [Figure 70-11-15] and [Figure 70-11-16] for photo clarity. Figure 70-11-16
1
P-63576
1
P-63584
Loosen the clamps. Remove the 3 hoses (Item 1) [Figure 70-11-14].
Loosen the clamps (Item 1). Remove the hoses (Item 2) [Figure 70-11-15] from the 2 vents (Item 1) [Figure 7011-16].
70-11-4
Figure 70-11-17
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) (CONTD) Disassembly And Assembly NOTE: The evaporator and thermostat are not used in this application. (See UPGRADED AIR CONDITIONING SYSTEM on Page 70-210-1) Figure 70-11-19
P-63587
NOTE: The clamps and hoses can be accessed from the top and right of the housing [Figure 70-1117]. Figure 70-11-18
P-63566
Remove the seal (Item 1) [Figure 70-11-19] from the bottom of the evaporator/heater box. Figure 70-11-20
P-63599
Remove the evaporator/heater unit [Figure 70-11-18].
P-63567
70-11-5
Figure 70-11-21
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) (CONTD) 1 Disassembly And Assembly (Contd) Figure 70-11-23 2
P-63559
Remove the 4 screws (Item 1) from the cover (Item 2) [Figure 70-11-21].
P-63562
Figure 70-11-22 Remove the tiestrap (Item 1) [Figure 70-11-23]. Figure 70-11-24 1
P-63560
Remove the filter (Item 1) [Figure 70-11-22].

P-63563
Disconnect the electrical connectors (Item 1) [Figure 7011-24].
70-11-6
Figure 70-11-25
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) (CONTD) Disassembly And Assembly (Contd) 1 Figure 70-11-27
2
P-63564
2 Remove the screw (Item 1) from the blower (Item 2) [Figure 70-11-25].
P-63570
Remove the blower. Figure 70-11-26 1 1 Raise the evaporator (Item 1). Remove the thermostat wire (Item 2) [Figure 70-11-27]. Figure 70-11-28 1
P-63568
Remove the seals (Item 1) [Figure 70-11-26].
P-63571
Remove the evaporator (Item 1) [Figure 70-11-28].
70-11-7
Figure 70-11-29
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) (CONTD) Disassembly And Assembly (Contd) Figure 70-11-31
1 1
P-63572
Remove the nut (Item 1) [Figure 70-11-29]. Figure 70-11-30

P-63574
Remove the heater coil (Item 1) [Figure 70-11-31]. Figure 70-11-32
P-63573
1 Remove the thermostat (Item 1) [Figure 70-11-30].

P-63552
Remove the 2 screws (Item 1) [Figure 70-11-32] from the housing. (Both ends)
70-11-8
Figure 70-11-33 1
EVAPORATOR/HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) (CONTD) Disassembly And Assembly (Contd) Figure 70-11-35
1
P-63553
Remove the 6 screws (Item 1) [Figure 70-11-33]. Figure 70-11-34

P-63555
Remove the fan/motor assembly (Item 1) [Figure 70-1135]. Figure 70-11-36
1 1
P-63554
Separate the 2 housing sections (Item 1) [Figure 70-1134].

P-63556
Remove the cushion (Item 1) [Figure 70-11-36].
70-11-9
Figure 70-11-37
P-63557
Remove the clamp (Item 1) [Figure 70-11-37]. (Both sides) Figure 70-11-38
P-63558
Remove the fans (Item 1) from the motor (Item 2) [Figure 70-11-38].
70-11-10
HEATER/AC FAN Removal And Installation Remove the evaporator/heater unit. (See EVAPORATOR/HEATER UNIT (S/N 522311001 & ABOVE) on Page 70-10-1 or See EVAPORATOR/ HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) on Page 70-11-1.) Remove the thermostat. (See THERMOSTAT on Page 70-190-1.) Mark around the edges of both mount brackets. Figure 70-20-1
Figure 70-20-3
1 1
P-40356
Remove the two screws (Item 1) [Figure 70-20-3] from both ends. Figure 70-20-4
P-40350
Remove the bolt (Item 1) [Figure 70-20-1], washer and mount (Item 2) [Figure 70-20-1] from both sides. Figure 70-20-2
P-40357
Cut and remove the cable ties (Item 1) [Figure 70-20-4] Remove the nut (Item 2) [Figure 70-20-4] washers, ground wires and thermostat mount.
P-40355
Remove the four screws (Item 1) [Figure 70-20-2] from both sides.
70-20-1
HEATER/AC FAN (CONTD) Removal And Installation (Contd) Figure 70-20-5
Figure 70-20-7
P-40363
1
P-40361
Remove the top cover (Item 1) [Figure 70-20-7] and heater coil/evaporator. Figure 70-20-8
Remove the four screws (Item 1) and bracket (Item 2) [Figure 70-20-5]. Figure 70-20-6 1
1
P-40364
Remove the fan (Item 1) [Figure 70-20-8].

P-40362
Remove the four screws (Item 1) [Figure 70-20-6], washers and nuts.
70-20-2
HEATER/AC FAN (CONTD) Resistor Removal And Installation NOTE: The resistor removal and installation is shown out of the excavator. The procedure can be done with the evaporator/heater unit installed in the excavator. Remove the seat and seat mount. (See SEAT AND SEAT MOUNT on Page 40-30-1.) Figure 70-20-9
P-40368
Disconnect the wire harness (Item 1) [Figure 70-20-9] Figure 70-20-10
2
P-40369
Remove the screws (Item 1) [Figure 70-20-10]. Remove the resistor (Item 2) [Figure 70-20-10].
70-20-3
70-20-4
HEATER VALVE Removal And Installation Drain the radiator. (See COOLING SYSTEM on Page 1070-1.) Tilt the cab. (See Tilting The Cab on Page 10-160-2.) Figure 70-30-1 1 1
Figure 70-30-3
1
P-40343
2 Loosen the hose clamps (Item 1) [Figure 70-30-3]. Figure 70-30-4
P-40346
Remove the four nuts (Item 1) [Figure 70-30-1] and washers. Remove the filter (Item 2) [Figure 70-30-1]. Figure 70-30-2 1
P-40344
Mark and remove the hoses (Item 1) [Figure 70-30-4] 1 1 Lower the valve out of the cab.
P-40347
Cut and remove the cable ties (Item 1) [Figure 70-30-2].
70-30-1
HEATER VALVE (CONTD) Removal and Installation (Contd) Figure 70-30-5
P-40345
Mark the cable length and remove the clamp (Item 1) [Figure 70-30-5]. Remove the cable (Item 2) [Figure 70-30-5] from the valve. Remove the heater valve.
70-30-2
70-40-1
AIR CONDITIONING SYSTEM FLOW Principles In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit. At these five points in the system the refrigerant goes through pressure and temperature changes. The compressor (Item 1) takes in heated, low pressure refrigerant gas through the suction valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge valve (high pressure side) on the condenser (Item 2) [Figure 70-401 on Page 3]. Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the refrigerant from a gas to a liquid. The liquid refrigerant moves on to the receiver/dryer (Item 3) where impurities such as moisture and dirt are filtered out. The receiver/dryer also serves as the storage tank for the liquid refrigerant. The liquid refrigerant (still under high pressure) flows to the expansion valve (Item 4) [Figure 70-40-1 on Page 3].
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5). As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the evaporator. The hot humid air of the machines cab is drawn through or blown into the evaporator by the evaporator fan (Item 6) [Figure 70-40-1 on Page 3]. Since the refrigerant is colder than the air, it absorbs the heat from the air and produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and drips into the drain pan, which directs the water out of the cab. The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor
70-40-2
AIR CONDITIONING SYSTEM FLOW (CONTD) Chart Figure 70-40-1
Thermostat
Cold Air Evaporator
5 4 Expansion Valve Evaporator
Blower
Compressor
Condenser
Pressure
Switch Sight Glass
Fan Desiccant 3 Receiver Drier
STATUS OF R134A High Pressure Gas High Pressure Liquid Low Pressure Liquid Low Pressure Gas b-16691
70-40-3
70-40-4
COMPONENTS (S/N 522311001 & ABOVE) Identification Figure 70-50-1
Figure 70-50-3
1 2
P-36870
1
P-40348
Compressor: The compressor (Item 1) [Figure 70-50-1] is the pump that circulates the refrigerant throughout the system. It raises the pressure of the refrigerant for heat transfer through the condenser and evaporator. NOTE: The A/C system (compressor) is recommended to be turned on for at least five minutes weekly throughout the year to lubricate the internal components. Figure 70-50-2
Receiver/Drier: The receiver/drier (Item 1) [Figure 70-503] is the unit that receives the liquid refrigerant from the condenser and removes moisture and foreign matter from the system. It also serves as a storage tank for the extra liquid refrigerant until it is needed by the evaporator. Pressure Switch: The pressure switch (Item 2) [Figure 70-50-3] will disengage the compressor clutch at high pressure readings on the high side, or at low pressure on the high side, which indicates loss of refrigerant. Figure 70-50-4
1 1
P-40349
P-36869
Condenser: The condenser (Item 1) [Figure 70-50-2] is the unit that receives the high pressure, high temperature refrigerant vapor from the compressor and condenses it into a high temperature liquid.
Heater/Evaporator Unit: The heater/evaporator unit (Item 1) [Figure 70-50-4] is located under the operator seat in the excavator cab. The unit delivers the cold air for the A/ C and warm air for heat into the cab. The unit contains the blower, heat & A/C coils, thermostat and expansion valve.
70-50-1
COMPONENTS (S/N 522311001 & ABOVE) (CONTD) Identification (Contd) Figure 70-50-5
Figure 70-50-6
2 1 2 3 3 5 6 1
P-32714
P-36826
Fan Switch: This is a four position rotary switch (Item 1) [Figure 70-50-6]. When the fan switch is in the off position the A/C will not engage. A/C Switch: The rocker switch (Item 2) [Figure 70-50-6] will be illuminated when the A/C is engaged. Temperature Control Lever: Push the lever (Item 3) [Figure 70-50-6] forward to increase the cab temperature; backward to decrease temperature
Expansion Valve: The expansion valve (Item 1) [Figure 70-50-5] controls the amount of refrigerant entering the evaporator coil. Thermostat: The thermostat (Item 2) [Figure 70-50-5] controls the temperature of the evaporator coil. Heater Coil: The heater coil (Item 3) [Figure 70-50-5] supplies the warm air into the cab by passing air through the coil. Evaporator Coil: The evaporator coil (Item 4) [Figure 7050-5] cools and dehumidifies the air before it enters the cab. Heater/Evaporator Blower: The blower (Item 5) [Figure 70-50-5] is used to push air through the heater and evaporator coils and into the cab. Heater Valve: The heater valve (Item 6) [Figure 70-50-5] is used to control the amount of engine coolant that flows to the heater coil.
70-50-2
COMPONENTS (S/N 528911001 & ABOVE AND 52864001 & ABOVE) Identification Figure 70-51-1
Figure 70-51-3
1 2
P-63305
1 Receiver/Drier: The receiver/drier (Item 1) [Figure 70-513] is the unit that receives the liquid refrigerant from the condenser and removes moisture and foreign matter from the system. It also serves as a storage tank for the extra liquid refrigerant until it is needed by the evaporator. Pressure Switch: The pressure switch (Item 2) [Figure 70-51-3] will disengage the compressor clutch at high pressure readings on the high side, or at low pressure on the high side, which indicates loss of refrigerant. Figure 70-51-4
P-63303
Compressor: The compressor (Item 1) [Figure 70-51-1] is the pump that circulates the refrigerant throughout the system. It raises the pressure of the refrigerant for heat transfer through the condenser and evaporator. NOTE: The A/C system (compressor) is recommended to be turned on for at least five minutes weekly throughout the year to lubricate the internal components. Figure 70-51-2
1 1
P-63306
P-63304
Condenser: The condenser (Item 1) [Figure 70-51-2] is the unit that receives the high pressure, high temperature refrigerant vapor from the compressor and condenses it into a high temperature liquid.
Heater Unit: The heater unit (Item 1) [Figure 70-51-4] is located under the operator seat in the excavator cab. The unit delivers warm air for heat into the cab. The unit contains the blower, heater coil and thermostat.
70-51-1
COMPONENTS (S/N 528911001 & ABOVE AND 52864001 & ABOVE) Identification (Contd) Figure 70-51-5 2 3 4
Heater Valve: The heater valve (Item 1) [Figure 70-51-6] is used to control the amount of engine coolant that flows to the heater coil. Figure 70-51-7
2 1 1
P-32714 P-63561
NOTE: The evaporator coil and thermostat are not used in this application. See Upgraded A/C system [Figure 70-51-8]. Thermostat: The thermostat (Item 1) [Figure 70-51-5] is not used in this application. Heater Coil: The heater coil (Item 2) [Figure 70-51-5] supplies the warm air into the cab by passing air through the coil. Evaporator Coil: The evaporator coil (Item 3) [Figure 7051-5] is not used in this application. Heater/Evaporator Blower: The blower (Item 4) [Figure 70-51-5] is used to push air through the heater and evaporator coils and into the cab. Figure 70-51-6
Fan Switch: This is a four position rotary switch (Item 1) [Figure 70-51-7]. When the fan switch is in the off position the A/C will not engage. A/C Switch: The rocker switch (Item 2) [Figure 70-51-7] will be illuminated when the A/C is engaged. Temperature Control Lever: Push the lever (Item 3) [Figure 70-51-7] forward to increase the cab temperature; backward to decrease temperature
P-63536
70-51-2
COMPONENTS (S/N 528911001 & ABOVE AND 52864001 & ABOVE) Identification (Contd) Upgraded A/C System Figure 70-51-8
1 2
P-61549
Expansion Valve: The expansion valve (Item 1) [Figure 70-51-8] controls the amount of refrigerant entering the evaporator coil. Thermostat: The thermostat (Item 2) [Figure 70-51-8] controls the temperature of the evaporator coil. Evaporator Coil: The evaporator coil (Item 3) [Figure 7051-8] cools and dehumidifies the air before it enters the cab. Evaporator Blower: The blower (Item 4) [Figure 70-51-8] is used to push air through the evaporator coil and into the cab.
70-51-3
70-51-4
SAFETY Safety Equipment In servicing A/C and heater systems you will be exposed to high pressures, temperatures and several chemical hazards. Moving belts and pulleys are normal shop hazards. Figure 70-60-1
Figure 70-60-2
P16399
P16398
R-134a inside a canister or in an A/C system is a liquid under pressure. When it escapes or releases into the air, ITS TEMPERATURE DROPS TO 21.6 f DEGREES INSTANTLY. If it spills on your skin or in your eyes you should flood the area with cool water and SEEK MEDICAL ATTENTION FAST! It is a good idea to wear gloves [Figure 70-60-2] to prevent frost bite if you should get refrigerant on your hands.
In addition to exercising caution in your work, DO WEAR SAFETY GLASSES OR A FACE SHIELD [Figure 7060-1] when you are using R-134a or a leak detector, adjusting service valves or the manifold gauge set connectors. Safety glasses or a transparent face shield are practical safety items and one or the other is absolutely required.
WARNING
HFC 134A refrigerant can be dangerous if not properly handled. Liquid 134A may cause blindness if it contacts the eyes and may cause serious frostbite if it contacts the skin. Gaseous 134A becomes lethal (phosgene) gas when it contacts open flame or very hot substances. NEVER SMOKE when there is the possibility of even small amounts of 134A in the air. Any servicing work that involves release or addition of 134A to the system must be done by a competent refrigeration dealer who has the proper equipment, knowledge, and experience to service refrigeration equipment.
W-2373-0500
WARNING
In the event of a leakage, wear safety goggles. Escaping refrigerant can cause severe injuries to eyes. In contact with a flame, R134a refrigerant gives a toxic gas.
W-2371-0500
70-60-1
70-60-2
REGULAR MAINTENANCE Heater Air Filter Remove the Heat/AC filter. (See FRESH AIR FILTER (S/ N 522311001 & ABOVE) on Page 10-61-1 or See FRESH AIR FILTER (S/N 528911001 & ABOVE AND S/ N 528611001 & ABOVE) on Page 10-62-1.) Clean the filter by shaking or using low air pressure. Replace the filter two to four times per year under normal operating conditions, up to weekly under extremely dusty operating conditions.
Air Conditioning Compressor Belt Open the tailgate. Figure 70-70-3 S/N 522311001 & Above
P-56413
P-40348
Check the condition of the belt (Item 1) [Figure 70-70-3] [Figure 70-70-4] and adjust as needed every 100 hours of operation. (See AIR CONDITIONING COMPRESSOR BELT (S/N 522311001 & ABOVE) on Page 10-150-1 or See AIR CONDITIONING COMPRESSOR BELT (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 10-151-1.)
70-70-1
REGULAR MAINTENANCE (CONTD) Cleaning The Condenser Open the right side cover. Figure 70-70-5
P-63304
Check the condenser (Item 1) [Figure 70-70-5] for mud or dirt. If the condensor needs to be cleaned, use low air pressure or water pressure to clean the condensor.
70-70-2
BASIC TROUBLESHOOTING Poor A/C Performance Start the excavator. Engage the A/C system with the blower fan on high. Run the excavator at full RPM for approximately 15 minutes, with the cab door closed. Figure 70-80-6 EARLY MODELS 1
Figure 70-80-8
N-22411
Check the temperature at the louvers (Item 1) [Figure 70-80-6] and [Figure 70-80-7] with a thermometer [Figure 70-80-8]. The louver temperature should be between 36-53 F. (2,2 -11,6 C) depending on the amount of humidity in the air. If louver temperature is too high see the System Troubleshooting Chart. ((See SYSTEM TROUBLESHOOTING CHART on Page 70-100-1.).) 1 Check the fan for proper operation or noise, and replace if necessary. ((See HEATER/AC FAN on Page 70-20-1.).) Check the air conditioning compressor belt tension. ((See AIR CONDITIONING COMPRESSOR BELT (S/N 522311001 & ABOVE) on Page 10-150-1.) or (See AIR CONDITIONING COMPRESSOR BELT (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 10151-1.).) Check the A/C evaporator coil for dirt or mud, and clean if necessary. ((See Cleaning The A/C Evaporator Coil & Heater Coil (S/N 522311001 & Above) on Page 70-80-2.) or (See Cleaning The A/C Evaporator Coil And Heater Coil (S/N 528911001 & Above And 528611001 & Above) on Page 70-80-3.).) Inspect the sight glass located on the receiver/drier for air bubbles. ((See COMPONENTS (S/N 522311001 & ABOVE) on Page 70-50-1.) or (See COMPONENTS (S/N 528911001 & ABOVE AND 52864001 & ABOVE) on Page 70-51-1.).) Check the engine coolant to see if it is bypassing the heater valve. ((See Engine Coolant By-Passing The Heater Valve on Page 70-80-15.).)
P-32675
Figure 70-80-7 LATER MODELS 1
P-58141
70-80-1
BASIC TROUBLESHOOTING (CONTD) Compressor Drive Belt Inspection Figure 70-80-9
Cleaning The A/C Evaporator Coil & Heater Coil (S/N 522311001 & Above) Remove the seat and seat mount. ((See SEAT AND SEAT MOUNT on Page 40-30-1.).) Figure 70-80-10
1 1
P-63303
3 Inspect and adjust the compressor drive belt (Item 1) [Figure 70-80-9] every 100 hours of operation. ((See AIR CONDITIONING COMPRESSOR BELT (S/N 522311001 & ABOVE) on Page 10-150-1.) or (See AIR CONDITIONING COMPRESSOR BELT (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 10151-1.).)
P-36826
Remove the bolts (Item 1) [Figure 70-80-10]. Remove the cover (Item 2) [Figure 70-80-10]. Clean the evaporator coil and heater coil (Item 3) [Figure 70-80-10] with low pressure air or water.
70-80-2
BASIC TROUBLESHOOTING (CONTD) Cleaning The A/C Evaporator Coil And Heater Coil (S/N 528911001 & Above And 528611001 & Above) Early Models Remove the Evaporator/Heater Unit (S/N 528911001 & Above and 528611001 & Above). ((See EVAPORATOR/ HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) on Page 70-11-1.).) Later Models Remove the Upgraded Air Conditioning System. ((See UPGRADED AIR CONDITIONING SYSTEM on Page 70-210-1.).) Evaporator/Heater Unit Figure 70-80-11
Figure 70-80-12 3 2
P-63561
Remove the filter (Item 1) clean the evaporator coil (Item 2) and heater coil (Item 3) [Figure 70-80-12] with low pressure air or water. Upgraded Air Conditioning System
1 Figure 70-80-13 1 2 1 1 1 1
1 2
P-63559
Remove the 4 screws (Item 1) from the cover (Item 2) [Figure 70-80-11]. Remove the cover.
P-61548
Remove the 5 screws (Item 1) from the bottom plate (Item 2) [Figure 70-80-13]. Remove the bottom plate.
70-80-3
BASIC TROUBLESHOOTING (CONTD) Cleaning The A/C Evaporator Coil And Heater Coil (S/ N 528911001 & Above And 528611001 & Above) (Contd) Figure 70-80-14
1
P-61549
Clean the evaporator coil (Item 1) [Figure 70-80-14] with low pressure air or water.
70-80-4
BASIC TROUBLESHOOTING (CONTD) Checking The Electrical System If the excavator A/C system, shows no blower motor function, no A/C switch light and no A/C compressor function. Do the following checks at the A/C relay. Figure 70-80-15
Figure 70-80-16 S/N 522311001 & Above
1 1
B-16658
1 Figure 70-80-17 2 S/N 528911001 & Above And 528611001 & Above
P-32706
The A/C relay is located in the right console. Remove the 3 screws (Item 1) and cover (Item 2) [Figure 70-80-15]. 1
B-23196
Remove the K3 relay (Item 1) [Figure 70-80-16] or [Figure 70-80-17].
70-80-5
BASIC TROUBLESHOOTING (CONTD) Checking The Electrical System (Contd) Figure 70-80-18
Figure 70-80-19
2 3 1
P-63619
P-63617
If the above voltages and continuity checks are OK, but the problem still persists, replace the A/C relay (Item 1) [Figure 70-80-19]. Check to see if the compressor clutch is engaging. With a person in the operator seat and the cab door open, turn the key switch to RUN, without starting the excavator.
With a multimeter, check the voltage at the excavator A/C relay connector terminals [Figure 70-80-18]. The voltage at Pin 30 (Item 1) [Figure 70-80-18] (Yellow Wire) should be 12 volts at all times. If there is no voltage check the fuse #F8, at the fuse box. (See [Figure 70-80-16 on Page 5] or [Figure 70-80-17 on Page 5]. If the fuse is OK, refer to the electrical diagram to trace the yellow wire to its source. The voltage at pin 85 (Item 2) [Figure 70-80-18] (Brown Wire) should be 12 volts when the ignition key is in the ON position. If there is no voltage check the fuse #FA at the fuse box. (See [Figure 70-80-24 on Page 8]) If the fuse is OK, refer to the electrical diagram to trace the brown wire to its source. Pin 86 (Item 3) [Figure 70-80-18] (Green Wire) is the ground wire. Check for continuity at Pin 86 to ground. If there is no continuity trace the green wire to its source using the electrical diagram.
70-80-6
BASIC TROUBLESHOOTING (CONTD) Checking The Electrical System (Contd) Figure 70-80-20 2 Early Models
Figure 70-80-22
P-32705
Figure 70-80-23
P-56399
Figure 70-80-21 Later Models 1
P-32702
P-58140
If the compressor clutch does not engage, check the main fuse (Item 1) [Figure 70-80-22] located under the battery compartment cover (Item 1) [Figure 70-80-23]. Replace the fuse if burned out.
Push the A/C switch (Item 1) [Figure 70-80-20] or [Figure 70-80-21] to the ON position. Turn the blower fan switch (Item 2) [Figure 70-80-20] or [Figure 70-80-21] to the first ON position. The compressor clutch should make a click sound, which indicates the clutch is engaging.
70-80-7
BASIC TROUBLESHOOTING (CONTD) Checking The Electrical System (Contd) Figure 70-80-24 S/N 522311001 & Above
Figure 70-80-26
1
P-63620
P-40476
With a multimeter, check the resistance to the compressor clutch (Item 1) [Figure 70-80-26]. If there is no resistance value, replace the compressor clutch. ((See COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 70-141-1.).) Figure 70-80-27
Figure 70-80-25 S/N 528911001 & Above And S/N 528611001 & Above
1 1
P-61567
If the fuses are good, disconnect the wire harness (Item 1) [Figure 70-80-24] or [Figure 70-80-25] from the compressor clutch wire.
P-63621
With a multimeter, check the voltage to the compressor clutch at the wire harness (Item 1) [Figure 70-80-27]. If the voltage reading is approximately 12 volts, the system is operating correctly. If there is no power at the clutch, reconnect the wiring harness to the compressor clutch.
70-80-8
Figure 70-80-30
1 2
P-63622
P-63624
If there is voltage at the harness, check the resistance at the pressure switch (Item 1) [Figure 70-80-30]. If there is no resistance value, check for low or high refrigerant levels in the system. (See Gauge Pressure Related Troubleshooting on Page 70-100-2.) If a resistance value is observed, the pressure switch is good. If there is no voltage at the wiring harness check the harness for broken wires. If there are no broken wires, reconnect the wire harness to the pressure switch. Early Models Tilt the cab. ((See Tilting The Cab on Page 10-160-2.).)
Disconnect the wire harness (Item 1) from the pressure switch (Item 2) [Figure 70-80-28]. Figure 70-80-29
Figure 70-80-31
P-63623
Using a multimeter check the wiring harness (Item 1) [Figure 70-80-29] for voltage. 1 The voltage should be approximately 12 volts.
P-63616
Remove the hose (Item 1) [Figure 70-80-31].
70-80-9
BASIC TROUBLESHOOTING (CONTD) Checking The Electrical System (Contd) Figure 70-80-32 1
Figure 70-80-34
P-63625
P-63578
Disconnect the thermostat/blower fan wire harness (Item 1) [Figure 70-80-32]. Figure 70-80-33
The resistance value of the thermostat should be 10 Ohms at 68 F (20 C), between Pin 8 & Pin 9 on the electrical connector (Item 1) [Figure 70-80-34]. (Between the yellow wire and green wire) If there is no resistance value, replace the thermostat. ((See THERMOSTAT on Page 70-190-1.).) If there is no voltage at the wiring harness check the harness for broken wires.
If there are no broken wires use the following procedure to check the blower fan and switch. Figure 70-80-35
P-63625
1 Check the wire harness (Item 1) [Figure 70-80-33] for voltage. The voltage should be approximately 12 volts, from Pin A4 (yellow wire) to ground. If there is no voltage at the wiring harness, check the harness for broken wires. If there is voltage at the wiring harness, check the thermostat for resistance.
P-63578
70-80-10
Figure 70-80-37
P-63626
P-63627
If there is voltage at the wiring harness, check the resistance to the blower fan at the thermostat/blower fan wiring connector (Item 1) [Figure 70-80-37]. Check the resistance between Pin 2 (brown wire) and Pin 10 (blue wire). Check the resistance between Pin 2 (brown wire) and Pin 9 (black wire). Check the resistance between Pin 2 (brown wire) and Pin 8 (red wire). If there is no resistance value at any of these pins, replace the blower fan. ((See HEATER/AC FAN on Page 70-20-1.).) If there is resistance value at any of the pins, check the climate controls at the control panel inside the excavator cab.
Check the wire harness (Item 1) [Figure 70-80-36] 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 7080-36], Pin 10. (Green/blue wire). The voltage should be 12 volts. In the cab, place the blower switch in position 2. Check for voltage at the harness connector (Item 1) [Figure 7080-36], Pin 9. (green/gray wire). The voltage should be 12 volts. In the cab, place the blower switch in position 3. Check for voltage at the harness connector (Item 1) [Figure 7080-36], Pin 8. (Green/black wire). The voltage should be 12 volts. If there is no voltage at the wiring harness, check the harness for broken wires.
70-80-11
Figure 70-80-40
1
P-63630
1
P-63628
Check the harness (Item 1) [Figure 70-80-40] for voltage. The voltage should be approximately 12 volts. If there is no voltage at the wiring harness, check the harness for broken wires.
Remove the switch panel (Item 1) [Figure 70-80-38]. Figure 70-80-39
1
P-63629
Remove the wiring harness (Item 1) [Figure 70-80-39].
70-80-12
Figure 70-80-42 1
P-63628
A1 A2 A3
A4
P-63631
Remove the switch panel (Item 1) [Figure 70-80-42]. Figure 70-80-43
If there is voltage at the wiring harness, check the blower switch [Figure 70-80-41] 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 A4 terminal and the A3 terminal [Figure 70-80-41]. With the switch in the 2 position, there should be resistance between A4 terminal and the A2 terminal [Figure 70-80-41]. With the switch in the 3 position, there should be resistance between A4 terminal and the A1 terminal [Figure 70-80-41]. If any of the above resistance tests fail, replace the blower switch. If the above resistance tests are good, check the A/C switch.
P-63634
At the excavator cab, disconnect the wire harness (Item 1) [Figure 70-80-43] from the A/C switch. Check the harness for voltage. The voltage should be approximately 12 volts. If there is no voltage at the wiring harness, check the harness for broken wires.
70-80-13
P-63635
Remove the switch (Item 1) [Figure 70-80-44]. Figure 70-80-45
1 2
4
P-63636
If there is voltage at the wiring harness, check the A/C switch [Figure 70-80-45] for resistance. With the switch in the OFF position there should be no resistance between any of the 4 terminals (Item 1, 2, 3, 4) [Figure 70-80-45] on the A/C switch. With the switch in the ON position there should be resistance between terminal (Item 1) and terminal (Item 2) [Figure 70-80-45]. If no resistance value is found, replace the A/C switch. Check the resistance between the wire terminal C and wire terminal B frame [Figure 70-80-45] should be approximately 39K Ohms.
70-80-14
BASIC TROUBLESHOOTING (CONTD) Engine Coolant By-Passing The Heater Valve Figure 70-80-46
Figure 70-80-47 S/N 522311001 & Above 1
1 2
P-36826
Figure 70-80-48
P-32714
S/N 528911001 & Above And S/N 528611001 & Above
Push the A/C switch (Item 1) to the OFF position. Turn the fan switch (Item 2) to the High Speed position., Turn the temperature control (Item 3) [Figure 70-80-46] to the High A/C position, with the key switch OFF. Start the excavator and run at high idle, for ten minutes.
P-63536
Check the temperature of the heater hoses (Item 1) [Figure 70-80-47] or [Figure 70-80-48]. If the hoses are hot, the heater valve is leaking internally, and needs to be replaced.
70-80-15
70-80-16
GENERAL AIR CONDITIONING SERVICE GUIDELINES Compressor Oil Figure 70-90-49
Compressor Oil Check The compressor oil should be checked as follows when oil is being added to an in service excavator. There is a close affinity between oil and refrigerant. During normal operation, part of the oil circulates with the refrigerant in the system. Therefore, when checking the amount of oil in the system or replacing any system component, the compressor must be run in advance to insure return of oil to the compressor. If the amount of refrigerant in the system has decreased, charge the system. (See SYSTEM CHARGING AND RECLAMATION on Page 70-130-1.) Open the cab door and windows. Run the blower at maximum speed.
P-63469
Run the compressor for at least 20 minutes at 800-1200 RPM. Remove the compressor. (See COMPRESSOR (S/N 522311001 & ABOVE) on Page 70-140-1 or See COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) on Page 70-141-1.)
The compressor (Item 1) [Figure 70-90-49] is factory filled with 150-170 cc's of PAG oil (Poly Alkelene Glycol). Unlike engine oil, it is not necessary to frequently check or change the compressor oil. It is necessary to check, replenish or replace the compressor oil in the following cases: 1. When the evaporator, condenser or receiver-drier is replaced. 2. When refrigerant has leaked from the system. 3. When refrigerant is suddenly released from the cooling cycle. 4. When any oil related problems occur in the cooling cycle. When one of the components (the evaporator, condenser or receiver-drier) is replaced, one ounce (30 cc) of PAG oil should be added for each component replaced. If the A/C compressor is changed, no oil should be added to the system, because the compressor comes factory filled with oil. NOTE: Only PAG oil should be used. Never mix R-12 and R-134a Oils.
70-90-1
GENERAL AIR CONDITIONING SERVICE GUIDELINES (CONT'D) Compressor Oil Check (Cont'd) Figure 70-90-50
Figure 70-90-52
1
P-63472
1
P-63470
Add new compressor oil through the suction side connector (Item 1) [Figure 70-90-52]. Installation: Add 150 -170 cc's of PAG oil.
Remove the oil drain plug (Item 1) [Figure 70-90-50] and drain the oil through the connectors and the oil drain hole. Figure 70-90-51
NOTE: The suction port on the compressor is marked with an L and is the larger port on the compressor.
P-63471
NOTE: After draining the oil through the drain hole and the connectors, extract the remaining oil through the discharge-side connector by rotating the drive pulley (Item 1) [Figure 70-9051] several times by hand. Measure the drained oil in a measuring cylinder. Check the oil for contamination, dirt, metal shavings, or varnish color, discard the oil if contaminated. NOTE: If metal shavings are found in the compressor oil, replace the complete compressor assembly.
70-90-2
GENERAL AIR CONDITIONING SERVICE GUIDELINES (CONT'D) Component Replacement And Refrigeration Leaks Figure 70-90-53
P-63305
Whenever the A/C system is opened to the atmosphere or there has been a leak in the system, the receiver/drier (Item 1) [Figure 70-90-53] must be changed. Never leave hose fittings, compressor fittings or components uncapped while working on the A/C system.
70-90-3
70-90-4
SYSTEM TROUBLESHOOTING CHART Blower Motor Does Not Operate POSSIBLE CAUSE 1. 2. INSPECTION SOLUTION Replace fuse/repair wiring. Repair the wiring or connector. Replace Motor. Replace Resistor. Replace Fan Switch.
Blown Fuse. Inspect Broken wiring or Check the fan motor ground and connectors. bad connection. 3. Fan motor Check the lead wires from the motor with a circuit malfunction. tester. 4. Resistor Check resistor using a circuit tester. malfunction. 5. Fan motor switch Check power into and out of the fan switch. malfunction. Blower motor operators normally, but air flow is insufficient POSSIBLE CAUSE INSPECTION 1. Evaporator inlet Check evaporator for plugging. obstruction 2. Air leak. Check to make sure air hoses are properly hooked to louvers and air ducts. 3. Defective thermo. Check thermostat using a circuit tester. switch (frozen evaporator). Insufficient cooling although air flow and compressor operation are normal POSSIBLE CAUSE INSPECTION 1. System low on The high side pressure will be low and bubbles refrigerant. may be present in sight glass on receiver drier. 2. Excessive refrigerant. The high pressure side pressure will be high.
SOLUTION Remove obstruction and clean evaporator fins with air or water. Repair or adjust. Replace thermostat.
SOLUTION Repair any leaks and recharge the refrigerant to the correct level. Use refrigerant recovery equipment to capture excess refrigerant charge to the correct refrigerant level. SOLUTION Adjust tension. Replace compressor.
The compressor does not operate at all, or operates improperly POSSIBLE CAUSE INSPECTION 1. Loose drive belt. The belt is vibrating or oscillating. 2. Internal The compressor is locked up and the belt slips. compressor malfunction. Magnetic clutch related 3. Low battery Clutch slips. voltage. 4. Faulty coil. Clutch slips. 5. Oil on the clutch Clutch slips. surface. 6. Open oil. Clutch does not engage and there is not reading when a circuit tester is connected between the coil and terminals. 7. Broken wiring or Clutch will not engage. Inspect the ground and poor ground. connections. 8. Wiring harness Test the conductance of the pressure switch, components. thermostat, relay, etc.
Recharge the battery. Replace the magnetic clutch. Replace or clean the clutch surface. Replace clutch.
Repair. Check operation.
70-100-1
SYSTEM TROUBLESHOOTING CHART (CONTD) Gauge Pressure Related Troubleshooting Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F (30-38 degrees C) and compressor speed of approximately 2000 RPM are: High pressure side pressure: 210-265 PSI Low pressure side pressure: 15-33 PSI As a rule of thumb the high side pressure will be around eight times greater than the low side pressure. POSSIBLE CAUSE Low pressure side too high. INSPECTION The low pressure side pressure normally becomes too high when the high pressure side pressure is too high. As this is explained below, the following inspection is only used when the low pressure side is too high. Frost is present on the suction hose. The high and low pressure side gauge pressures equalize when the magnetic clutch is disengaged. SOLUTION
Expansion valve opens too far. 2. Defective compressor Low pressure side too low. 1. Low refrigerant charge 2. Clogged or closed expansion valve. 3. Restriction between drier and expansion valve. 4. Thermostat malfunction High pressure side too high. 1. Poor condenser performance 2. Excessive refrigerant.
1.
Replace expansion valve. Replace compressor.
The high side pressure will be low and bubbles may be present in sight glass on receiver drier. The expansion valves inlet side is frosted. Moisture or other contaminants can be the cause. Frost on the line between drier and expansion valve. A negative low pressure reading may be shown. The evaporator is frozen.
Repair any leaks and recharge the refrigerant to the correct level. Clean or replace the expansion valve. Flush system or replace hose. Replace thermostat.
Dirty of clogged condenser fins. Condenser fans not operating. The high pressure side pressure will be high.
3.
Excessive oil charge.
The high pressure side will be high.
4. 5.
Air in system. Restriction in drier condenser or high pressure line.
Pressure side will be high. High pressure side will be high, and low pressure side will be low.
Clean fins, and/or repair the fan. Use refrigerant recovery equipment to capture excess refrigerant. Charge to the correct refrigerant level. Evacuate system. Remove oil from condenser and compressor. Measure oil from compressor and add correct oil charge back into compressor. Flush system with nitrogen. Replace drier. Evacuate and recharge with refrigerant. Evacuate and flush system replacing defective parts.
70-100-2
SYSTEM TROUBLESHOOTING CHART (CONTD) Gauge Pressure Related Troubleshooting (Contd) POSSIBLE CAUSE High pressure side too low. 1. Low refrigerant charge. The high side pressure will be low and bubbles may be present in sight glass on receiver drier. Repair any leaks and recharge the refrigerant to the correct level. INSPECTION SOLUTION
System pressures equal 1. 2. Clutch not operating. See magnetic clutch related topics above. Compressor not pumping. Equal high and low pressures. Replace compressor.
70-100-3
70-100-4
TEMPERATURE/PRESSURE Chart NORMAL EVAPORATOR RANGE TEMP F. 16 18 20 22 24 26 28 30 32 34 26 38 40 42 44 46 48 50 55 60 70 75 80 85 90 91 92 Evaporator Pressures represent gas temperatures inside the coil. Not the coil surface. For an estimate of the temperature air coming off the coil add 8-10 degrees F. to the temperature on the chart. Condenser Temperatures are not ambient temperatures but condensing temperatures. add 40 degrees F. to the ambient temperature to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature. PSIG 15.69 17.04 18.43 19.87 21.35 22.88 24.47 26.10 27.79 29.52 31.32 33.17 35.07 37.03 39.05 40.09 45.48 51.27 57.47 64.10 71.19 78.75 86.80 95.40 104.40 106-30 108.20 NORMAL CONDENSER RANGE TEMP F. 93 94 95 100 102 104 106 108 110 112 114 116 118 120 122 124 126 128 130 135 140 145 150 155 160 165 PSIG 110.20 112.10 114.10 124.30 128.50 132.90 137.30 141.90 146.50 151.30 156.10 161.10 166.10 171.30 176.60 182.00 187.50 193.10 198.90 213.70 229.40 245.80 263.00 281.10 300.10 320.20
170 340.80 Example: Ambient Temperature = 90 degrees F. 90 degrees F. + 40 degrees F. 130 degrees F. condenser temperature = 200 psig Conditions and pressures will vary from system to system.
70-110-1
70-110-2
AIR CONDITIONING SERVICE Chart Service Company/Phone Number: Date: Machine Model: Machine Serial Number: Machine Hours: Pre Service Conditions Ambient Temperature: Louver Temperature Cab Temperature at Head Position: Temperature into Condenser: High Side Pressure Low Side Pressure Ambient Humidity Observations:
Machine Dealer: Customer: 15 Minutes 30 Minutes Notes
Explain services required:
Post Service Conditions Ambient Temperature: Louver Temperature: Cab Temperature at Head Position: Temperature into Condenser: High Side Pressure Low Side Pressure Ambient Humidity Observations:
15 Minutes
30 Minutes
Notes
70-120-1
70-120-2
SYSTEM CHARGING AND RECLAMATION Reclamation Procedure
Figure 70-130-55 1
Figure 70-130-54
2 1
P-23024A
P-63450
Open the right side cover and locate the low pressure port (Item 1) and high pressure port (Item 2) [Figure 70130-54].
WARNING
W-2371-0500
NOTE: Before reclaiming a refrigeration system, it is recommended to identify the type of refrigerant that is in the A/C system and if it is pure enough to use. The tool MEL 1592, Refrigerant Identifier (Item 1) [Figure 70-13055] will determine, the kind of refrigerant and any possible harmful or dangerous substances that may be present in the system. Thus preventing mixing of dangerous material with your reclaimed R-134a in your reclaimer, and further contamination to other A/C systems that are reclaimed and charged from your MEL 1581 Recovery/Recycling/ Recharging Machine.
NOTE: This test is run with the excavator engine OFF, and the A/C switch in the OFF position.
70-130-1
SYSTEM CHARGING AND RECLAMATION (CONT'D) Reclamation Procedure (Cont'd) Remove the protective cap and connect the Refrigerant Identifier to the low pressure hose. Connect the Refrigerant Identifier to its power source. Follow the steps displayed on the refrigerant identifier screen. Allow two minutes for the refrigerant identifier to display the type of refrigerant and air content. An alarm will sound if potentially flammable hydrocarbons are present and will also indicate on the visual display. Disconnect the refrigerant identifier from the excavator A/ C. If the refrigerant is dangerous or flammable, it must be evacuated from the A/C system into a separate container and properly and safely disposed of. If R134a is found, evacuate the system. IMPORTANT: Only A/C trained technicians should perform the reclaiming and recharging procedure.
WARNING
W-2373-0500
Figure 70-130-56
N-22291
Use an approved recovery/charging unit [Figure 70-13056] to evacuate the system. Connect the reclaimer to the excavator A/C charge ports.
70-130-2
SYSTEM CHARGING AND RECLAMATION (CONT'D) Reclamation Procedure (Cont'd) Figure 70-130-57
Figure 70-130-59
2 1
N-22381
P-63451
Connect the Red hose (Item 1) [Figure 70-130-57] to the high pressure port and open the valve. Connect the Blue hose (Item 2) [Figure 70-130-57] to the low pressure port and open the valve. Figure 70-130-58
NOTE: The reclaimer unit, has a complete step by step set of instructions [Figure 70-130-59] to follow for reclamation and recharging of the A/C system. A trained technician should follow these instructions as they may very slightly depending on the model and brand of reclaimer used. The AC system holds 2.64 lbs (1.20 Kg) of refrigerant. Add 1 oz of Pag oil to the system when a A/C component has been replaced. The compressor comes from the factory pre-filled with oil.
N-22292
Turn the reclaimer unit [Figure 70-130-58] to the ON position and follow the on screen instructions.
70-130-3
70-130-4
COMPRESSOR (S/N 522311001 & ABOVE) Removal And Installation Discharge the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 70-130-1.) Figure 70-140-1
Figure 70-140-3
P-40478
Remove the bolt (Item 1) and nut. Remove the belt (Item 2) [Figure 70-140-3] from the pulley and remove the compressor.
P-40476
Remove the A/C hoses (Item 1) [Figure 70-140-1]. Figure 70-140-2
2 1
P-40477
Remove the bolt (Item 1), washer, spacers and nut. Remove the ground wire (Item 2) [Figure 70-140-2].
70-140-1
70-140-2
COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Removal And Installation Discharge the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 70-130-1) Figure 70-141-1 1
Figure 70-141-3
P-61569
Remove the two bolts (Item 1) [Figure 70-141-3], washers and nuts Figure 70-141-4
P-61567
Remove the A/C hoses (Item 1) [Figure 70-141-1]. Figure 70-141-2 1 2
P-61570
3 4 1
P-61568
Remove the two bolts (Item 1), washers and nuts. Remove the belt (Item 2) [Figure 70-141-4]. Remove the compressor.
Remove the tiestrap (Item 1), bolt (Item 2), washer, and nut. Remove the ground wire (Item 3) and disconnect the wire harness (Item 4) [Figure 70-141-2].
70-141-1
COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Parts Identification
Not Available At Time Of Print
70-141-2
COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Compressor Clutch Disassembly And Assembly Figure 70-141-5
Figure 70-141-7
P-61574
Remove the shims (Item 1) [Figure 70-141-7] from either the armature shaft or armature plate.
P-61571
Figure 70-141-8 Remove the bolt (Item 1) [Figure 70-141-5]. Installation: Tighten the bolt to 8-10 ft.-lbs. (12-14 Nm) torque. Figure 70-141-6
P-61582
Installation: Install the needed shims until the correct clearance between the armature plate and compressor clutch is obtained [Figure 70-141-8].
P-61572
Pull straight up on the armature plate (Item 1) [Figure 70-141-6] and remove the armature plate from the compressor clutch.
The specified clearance for the clutch is 0.01-0.02 in. (0.3-0.6 mm). Adjusting shims are available in the following thicknesses: 0.0118 in (0.3 mm) 0.0197 in (0.5 mm)
70-141-3
COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Compressor Clutch Disassembly And Assembly (Contd) Figure 70-141-9
Figure 70-141-11
P-61576
Install a puller (Item 1) [Figure 70-141-11] on the pulley and remove the pulley/bearing assembly.
P-61573
Figure 70-141-12
Remove the snap ring (Item 1) [Figure 70-141-9]. Figure 70-141-10 1
P-61577
The bearing (Item 1) [Figure 70-141-12] is staked in to the pulley and is not serviceable separately.
P-61575
Temporarily install the bolt (Item 1) [Figure 70-141-10].
70-141-4
COMPRESSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Compressor Clutch Disassembly And Assembly (Contd) Figure 70-141-13
Figure 70-141-15
1 1
1 1
P-61580
Remove the three screws (Item 1) [Figure 70-141-15] from the compressor.
P-61578
Installation: Tighten the screws to 2.9-4.3 ft.-lbs. (4-6 Nm) torque. Remove the coil from the compressor. The compressor is not serviceable and must be replaced as a complete unit.
Remove the bolt (Item 1) [Figure 70-141-13] from the shaft. Figure 70-141-14
P-61579
Slide the grommet and wire harness (Item 1) [Figure 70141-14] from the wire holder.
70-141-5
70-141-6
CONDENSER (S/N 522311001 & ABOVE) Removal And Installation Open the right side cover. Remove the refrigerant from the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 70130-1.) Mark the A/C hoses for correct installation. Figure 70-150-1
Figure 70-150-2
P-36867
1 Remove the bolt (Item 1) [Figure 70-150-2] and washer. Remove the mount (Item 2) [Figure 70-150-2]. Figure 70-150-3
P-36866
1 Remove the top hose (Item 1) [Figure 70-150-1]. Plug the hose with a proper A/C plug.
WARNING
P-36868
W-2371-0500
Remove the bottom hose (Item 1) [Figure 70-150-3]. Plug the hose with a proper A/C plug.
70-150-1
CONDENSER (S/N 522311001 & ABOVE) Removal And Installation (Contd) Figure 70-150-4
P-36869
Slide the condenser (Item 1) [Figure 70-150-4] towards the operator cab. Remove the condenser.
70-150-2
CONDENSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Removal And Installation Open the right side cover. Remove the refrigerant from the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 70130-1) Mark the A/C hoses for correct installation. Figure 70-151-1
Figure 70-151-2
1
P-63454
1 Remove the bottom hose (Item 1) [Figure 70-151-2]. Plug the hose with a proper A/C plug. Figure 70-151-3
P-63455
Remove the top hose (Item 1) [Figure 70-151-1]. Plug the hose with a proper A/C plug.
WARNING
W-2371-0500
1
P-63457
Remove the bolt (Item 1) [Figure 70-151-3] and nut.
70-151-1
CONDENSOR (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Removal And Installation (Contd) Figure 70-151-4
1 1
P-63456
Remove the bolts (Item 1) [Figure 70-151-4]. Remove the condenser.
70-151-2
RECEIVER/DRYER (S/N 522311001 & ABOVE) Removal And Installation Open the right side cover. Remove the refrigerant from the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 70130-1.) Figure 70-160-1
Figure 70-160-2
1 1 2 Remove the drier. Loosen the clamp (Item 1) [Figure 70-160-2].
P-36871
NOTE: When replacing a receiver/dryer, one fluid ounce (30 cc) of PAG oil must be added to the system when recharging. 1
P-36870
Mark the A/C hoses (Item 1) [Figure 70-160-1] for correct installation. Remove the hoses. Plug the hoses with proper A/C plugs. NOTE: Both fittings on the drier are the same size. The hoses can be installed incorrectly.
WARNING
W-2371-0500
70-160-1
70-160-2
RECEIVER/DRYER (S/N 528911001 & ABOVE AND 528611001 & ABOVE)) Removal And Installation Open the right side cover. Remove the refrigerant from the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 70130-1) Figure 70-161-1
Figure 70-161-2
P-63460
Loosen the clamp (Item 1) [Figure 70-161-2]. Remove the drier.
2 1
P-63458
NOTE: When replacing a receiver/dryer, one fluid ounce (30 cc) of PAG oil must be added to the system when recharging.
Mark the A/C hoses (Item 1) [Figure 70-161-1] for correct installation. Remove the hoses. Plug the hoses with proper A/C plugs. NOTE: Both fittings on the drier are the same size. The hoses can be installed incorrectly.
WARNING
W-2371-0500
70-161-1
70-161-2
PRESSURE SWITCH (S/N 522311001 & ABOVE) Removal And Installation Open the right side cover. NOTE: The pressure switch can be removed without discharging the A/C system. Figure 70-170-1
Figure 70-170-2
1 2
P-40464
The valve (Item 1) [Figure 70-170-2] is located in the receiver/drier and is located under the pressure switch. Remove the refrigerant from the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 70130-1.)
P-36867
Remove the pressure switch. Disconnect the wire harness (Item 1) [Figure 70-170-1] Remove the switch (Item 2) [Figure 70-170-1] from the receiver/drier. With a tire valve core removal tool, remove the valve core. Replace with a new core.
WARNING
W-2371-0500
70-170-1
70-170-2
PRESSURE SWITCH (S/N 528911001 & ABOVE AND 528611001 & ABOVE) Removal And Installation Open the right side cover. NOTE: The pressure switch can be removed without discharging the A/C system. Figure 70-171-1
Figure 70-171-2
P-40464
1 The valve (Item 1) [Figure 70-171-2] is located in the receiver/drier and is located under the pressure switch. 2 Remove the refrigerant from the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 70130-1.)
P-63305
Remove the pressure switch. With a tire valve core removal tool, remove the valve core. Replace with a new core.
Disconnect the wire harness (Item 1) [Figure 70-171-1]. Remove the switch (Item 2) [Figure 70-171-1] from the receiver/drier.
WARNING
W-2371-0500
70-171-1
70-171-2
HEATER COIL/EVAPORATOR Removal And Installation Remove the evaporator/heater unit. (See EVAPORATOR/HEATER UNIT (S/N 522311001 & ABOVE) on Page 70-10-1 or See EVAPORATOR/ HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) on Page 70-11-1.) Remove the thermostat. (See THERMOSTAT on Page 70-190-1.) NOTE: The heater coil and evaporator are a combined unit and are not serviceable separately.
Figure 70-180-3
1 1
P-40356
Mark around the edges of both mount brackets. Figure 70-180-1 Remove the two screws (Item 1) [Figure 70-180-3] from both ends. Figure 70-180-4
2 1
P-40350
Remove the bolt (Item 1), washer and mount (Item 2) [Figure 70-180-1] from both sides. Figure 70-180-2
P-40357
Cut and remove the cable ties (Item 1) [Figure 70-180-4] Remove the nut (Item 2) [Figure 70-180-4], washers, ground wires and thermostat mount. 1 1
P-40355
Remove the four screws (Item 1) [Figure 70-180-2] from both sides.
70-180-1
HEATER COIL/EVAPORATOR (CONTD) Removal And Installation (Contd) Figure 70-180-5
Figure 70-180-7
P-40363
1 2
1
P-40361
Remove the top cover (Item 1) [Figure 70-180-7] and heater coil/evaporator. Figure 70-180-8
Remove the four screws (Item 1) and bracket (Item 2) [Figure 70-180-5]. Figure 70-180-6
1
P-40366
P-40362
Remove the heater coil/evaporator (Item 1) [Figure 70180-8] from the top cover
Remove the four screws (Item 1) [Figure 70-180-6], washers and nuts.
70-180-2
THERMOSTAT Removal And Installation NOTE: The thermostat can be changed without evacuating the A/C system, or removing the evaporator/heater unit from the excavator. Remove the seat and seat mount. (See SEAT AND SEAT MOUNT on Page 40-30-1.) Figure 70-190-1
Figure 70-190-3
2
P-40351
Mark and remove the wires (Item 1) [Figure 70-190-3]. 1 Remove the nut (Item 2) [Figure 70-190-3]. Figure 70-190-4
P-40352
1 Remove the thermostat probe (Item 1) [Figure 70-190-1] from the evaporator. Figure 70-190-2
P-40354
Straighten the thermostat probe and pull the thermostat (Item 1) [Figure 70-190-4] out of the housing.
P-40353
Cut and remove the cable tie (Item 1) [Figure 70-190-2].
70-190-1
THERMOSTAT (CONTD) Removal And Installation (Contd) Figure 70-190-5
P-40367
Installation: The control shaft (Item 1) [Figure 70-190-5] must be rotated to the ON position, as shown
70-190-2
EXPANSION VALVE Removal And Installation Evacuate the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 70-130-1.) Remove the evaporator/heater unit. (See EVAPORATOR/HEATER UNIT (S/N 522311001 & ABOVE) on Page 70-10-1 or See EVAPORATOR/ HEATER UNIT (S/N 528911001 & ABOVE AND 528611001 & ABOVE) on Page 70-11-1.)
Figure 70-200-2
WARNING
W-2371-0500
P-40371
Remove the clamp (Item 1) [Figure 70-200-2]. Loosen the nut (Item 2) and remove the expansion valve (Item 3) [Figure 70-200-2].
Figure 70-200-1
1
P-40370
Remove the A/C tape (Item 1) [Figure 70-200-1]
70-200-1
70-200-2
UPGRADED AIR CONDITIONING SYSTEM Evaporator Unit Removal And Installation Discharge the A/C system. (See SYSTEM CHARGING AND RECLAMATION on Page 70-130-1.)
Figure 70-210-4
WARNING
W-2371-0500
1
P-32701
W-2373-0500
Remove the floormat (Item 1) [Figure 70-210-4]. Figure 70-210-5
1 2 1
P-33790
Figure 70-210-3
Remove the five screws (Item 1) and right console front cover (Item 2) [Figure 70-210-5].
P-32712
Turn the battery switch (Item 1) [Figure 70-210-3] to the off position.
70-210-1
UPGRADED AIR CONDITIONING SYSTEM (CONTD) Evaporator Unit Removal And Installation (Contd) Figure 70-210-6
Figure 70-210-8
1 1 2
P-49638
P-33791
Disconnect the wire harness connector (Item 1) [Figure 70-210-8]. Figure 70-210-9
Remove the screws (Item 1) and the cover (Item 2) [Figure 70-210-6]. Figure 70-210-7 3 1 1
P-48719
P-32707
Remove the yellow wire (Item 1), green wire (Item 2) and red wire (Item 3) [Figure 70-210-9] from the wire harness connector.
Remove the nut and wires (Item 1) [Figure 70-210-7].
70-210-2
UPGRADED AIR CONDITIONING SYSTEM (CONTD) Evaporator Unit Removal And Installation (Contd) Figure 70-210-10
Figure 70-210-12
1 1
P-49613
P-49614
Remove the two hoses (Item 1) [Figure 70-210-12] from the evaporator unit. Figure 70-210-13
Remove the wire harnesses (Item 1) [Figure 70-210-10] from the right console. Figure 70-210-11
1 1 2
P-49592
Remove the drain hose (Item 1) [Figure 70-210-13].

P-33029
Loosen the nut (Item 2) [Figure 70-210-13]. Remove the two bolts (Item 1) [Figure 70-210-11] and washers from the right arm rest. Remove the arm rest. Remove the seat and seat mount. (See SEAT AND SEAT MOUNT on Page 40-30-1.) Lift and remove the evaporator unit (Item 3) [Figure 70210-13].
70-210-3
UPGRADED AIR CONDITIONING SYSTEM (CONTD) Disassembly And Assembly Remove the evaporator unit. (See Evaporator Unit Removal And Installation on Page 70-210-1.)
Figure 70-210-16
1 Figure 70-210-14
P-61542
Remove the two nuts (Item 1) and plate (Item 2) [Figure 70-210-16]. Figure 70-210-17
P-61540
Remove the two control knobs (Item 1) [Figure 70-21014]. Figure 70-210-15
1 1
P-61543
Remove the screw (Item 1) [Figure 70-210-17].
P-61541
Remove the two washers (Item 1) [Figure 70-210-15].
70-210-4
UPGRADED AIR CONDITIONING SYSTEM (CONTD) Disassembly And Assembly (Contd) Figure 70-210-18 1
Figure 70-210-20
1 1
P-61546
1 1 1
P-61544
Remove the cover (Item 1) [Figure 70-210-20]. Figure 70-210-21
Remove the five screws (Item 1) [Figure 70-210-18]. Figure 70-210-19
1 2
1
P-61547
1
P-61545
Remove the vents (Item 1) [Figure 70-210-21] from the cover.
Remove the six screws (Item 1) and seals (Item 2) [Figure 70-210-19].
70-210-5
UPGRADED AIR CONDITIONING SYSTEM (CONTD) Disassembly And Assembly (Contd) Figure 70-210-22 1 1 1
P-61548
Remove the five screws (Item 1) and bottom plate (Item 2) [Figure 70-210-22].
70-210-6
UPGRADED AIR CONDITIONING SYSTEM (CONTD) Thermostat Removal And Installation Disassemble the evaporator unit. (See Disassembly And Assembly on Page 70-210-4.) Figure 70-210-23
Evaporator Removal And Installation Figure 70-210-24
1 1 2
P-61550
Remove the evaporator (Item 1) [Figure 70-210-24].

P-61549
Figure 70-210-25
Remove the thermostat (Item 1) from the evaporator (Item 2) [Figure 70-210-23].
P-61551
Remove the plate (Item 1) [Figure 70-210-25] from the evaporator.
70-210-7
UPGRADED AIR CONDITIONING SYSTEM (CONTD) Fan Removal And Installation Figure 70-210-26
Figure 70-210-28
1 1
P-61554
P-61552
Remove the fan assembly (Item 1) [Figure 70-210-28] from the bracket. NOTE: The fan/motor assembly must be replaced as a complete unit. Switch Removal And Installation
Remove the six screws (Item 1) [Figure 70-210-26]. Figure 70-210-27
Figure 70-210-29
2
P-61553
1 Mark and remove the wires (Item 1) [Figure 70-210-27]. Remove the tiestraps (Item 2) [Figure 70-210-27].
P-61555
Remove the switches (Item 1) [Figure 70-210-29].
70-210-8
SPECIFICATIONS CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-80-1 Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . . . . . . . . . . . SPEC-80-1 U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-80-2 ENGINE BOLT TORQUE (S/N 522311001 & ABOVE) . . . . . . . . . . . . . SPEC-30-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1 ENGINE BOLT TORQUE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-31-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-31-1 ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE) . . . . . . . . . . . SPEC-20-1 Camshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6 Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4 Crankshaft And Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-5 Cylinder Head and Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-4 Engine Balancing Shaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-6 Piston And Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-3 Valve, Valve Guide and Seat Insert . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-2 DRIVE SYSTEM
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 Camshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-6 Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4 Crankshaft And Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-5 SPECIFICATIONS Cylinder Head and Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-4 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-1 Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-6 Piston And Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-3 Valve, Valve Guide and Seat Insert . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-21-2 EXCAVATOR BOLT TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1 FUEL, COOLANT AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1 Chart (S/N 522311001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1 Chart (S/N 528911001 & Above And S/N 528611001 & Above) . . . SPEC-70-3 Continued On Next Page
SPEC-01
SPECIFICATIONS (CONTD) HYDRAULIC EXCAVATOR SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5 Capacities (S/N 522311001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6 Capacities (S/N 528911001 & Above And S/N 528611001 & Above) . . . . . SPEC-10-6 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2 Digging Force. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-6 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3 Engine (S/N 522311001 & Above) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2 Engine (S/N 528911001 & Above And S/N 528611001 & Above) . . . . . . . . SPEC-10-3 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4 Hydraulic Cycle Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4 Hydraulic System (S/N 522311001 & Above) . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3 Hydraulic System (S/N 528911001 & Above And S/N 528611001 & Above) SPEC-10-4 Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2 Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5 Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4 Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-5 HYDRAULIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1 TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1 Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1 Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
SPEC-02
HYDRAULIC EXCAVATOR SPECIFICATIONS Machine Dimensions All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses. Where applicable, specifications conform to SAE or ISO standards. Specifications are subject to change without notice.
243 (6170) 1710 (9340) 205 (5195) 107 (272)
104 (2639) 167 (4250)
286 (7260)
B-16806
SPEC-10-1
HYDRAULIC EXCAVATOR SPECIFICATIONS (CONTD) Performance Operating Weight w/Cab 24 Bucket, rubber tracks) Travel Speed Low High Controls Vehicle Excavator Functions Two Hand or Foot Levers control speed & direction. RH console switch controls 2 speed travel. Right and left joysticks control boom, arm, bucket, arm and swing. RH thumb switch controls auxiliary hyd. LH foot pedal controls boom swing Separate hand lever controls blade. 1.7 MPH (2,7 km/hr.) 3.2 MPH (5,2 km/hr.) 16534 lbs (7500 Kg)
Engine (S/N 522311001 & Above) Make Model Fuel Horsepower (SAE NET) Maximum Governed RPM (Full Load) Maximum Torque High Idle RPM Low Idle RPM No. of Cylinders Displacement Bore x Stroke Lubrication Filter Air Cleaner Deutz BF4M 1012E Diesel/Liquid (Antifreeze mixture) 71 HP (53 kW) @ 2000 RPM NA NA 2300 RPM 650 RPM Four 210 cu.in. (3450 cm) 3.7 inch (94 mm) x 4.5 inch (115 mm) Forced Cartridge Type - Full Flow Dry replaceable paper cartridge, dual element
SPEC-10-2
HYDRAULIC EXCAVATOR SPECIFICATIONS (CONTD) Engine (S/N 528911001 & Above And S/N 528611001 & Above) Make Model Fuel Horsepower Maximum Governed RPM (Full Load) Maximum Torque High Idle RPM Low Idle RPM No. of Cylinders Displacement Bore x Stroke Lubrication Filter Air Cleaner Electrical Starter Alternator Battery Hydraulic System (S/N 522311001 & Above) Variable Displacement Piston Pump Gear Pumps (2 combined) System Relief Settings -Gear Pump -Piston Pump Swing Blade And Boom Swing Circuits Bucket, Arm, Boom and Travel Circuits Auxiliary Flow Control Valves Drive Motors Swing Motor 37.5 GPM (142 L/min) 17.4 GPM (66 L/min) 3335 PSI (230 bar) 4060 PSI (280 bar) 3335 PSI (230 bar) 4060 PSI (280 bar) 26.42 GPM (100 LPM) Three Spool Open Center Valve, Six Spool Closed Center 2 Axial Piston Piston Motor 12 Volt (2,0 kW) Reduction Drive 14 Volt, 55 Amps, open, negative ground 12 Volt, 450 Cold Crank Amps. @ 0F (-18C) Deutz BF4M 2011 Diesel/Liquid (Oil cooled) 73 HP (54 kW) @ 2200 RPM NA NA 2200 900 Four 190 cu.in. (3108 cm) 3.7 (94 mm) X 4.4 (112 mm) Pressure System W/Filter Cartridge type - Full Flow Dry replaceable paper cartridge, dual element
SPEC-10-3
HYDRAULIC EXCAVATOR SPECIFICATIONS (CONTD) Hydraulic System (S/N 528911001 & Above And S/N 528611001 & Above) Variable Displacement Piston Pump Gear Pumps (2 combined) System Relief Settings -Gear Pump -Piston Pump Swing Blade And Boom Swing Circuits Bucket, Arm, Boom and Travel Circuits Auxiliary Flow Control Valves Drive Motors Swing Motor Hydraulic Cycle Times Bucket Arm Boom Boom Offset Blade Swing System Swing Drive Swing Circle Swing Speed Hydraulic Cylinders Cylinder Boom Arm Bucket Boom Swing Blade Bore Dia. in. (mm) 4.7 (120 mm) 4.5 (115 mm) 3.5 (90 mm) 4.1 (105 mm) 3.9 (100 mm) Rod Dia. in. (mm) 2.4 (60 mm) 2.8 (70 mm) 2.4 (60 mm) 2.4 (60 mm) 2.0 (50 mm) Stroke in. (mm) 33.5 (850 mm) 26.4 (670 mm) 28.3 (720 mm) 24.6 (625 mm) 7.9 (200 mm) Radial Piston Motor W/Brake Single Row Shear Type Ball Bearings With Internal Gear 10 RPM Curl 2.2 sec. Retract 3.5 sec. Raise 6.5 sec. Left 9.7 sec. Raise 2.2 sec. Dump 2.7 sec. Extend 4.2 sec. Lower 5.9 sec. Right 9.7 sec. Lower 2.2 sec. 41.2 GPM (156 L/min) 17.9 GPM (68 L/min) 3335 PSI (230 bar) 4060 PSI (280 bar) 3335 PSI (230 bar) 4060 PSI (280 bar) 26.4 GPM (100 LPM) Three Spool Open Center Valve, Six Spool Closed Center 2 Axial Piston Piston Motor
SPEC-10-4
HYDRAULIC EXCAVATOR SPECIFICATIONS (CONTD) Drive System Final Drive Type of Reduction Max. Drawbar Pull Gradability Brakes Travel Service & Parking Swing Service Parking Undercarriage Type Track Type Width No. of Shoes No. of Track Rollers Ground Pressure Rubber (Standard) 18 inch (457 mm) NA 7 4.1 PSI (0.28 bar) Steel (Optional) NA 42 7 4.23 PSI (0.29 bar) Each Track is Driven by an Axial Piston Motor Two Stage Planetary Gear Reduction 13613 lbs. (60.5 KN)) 60%
NA NA NA Spring loaded multi disc brake applied when control lever is in neutral NA
Crawler-Tractor Design, Sealed Track Rollers W/Box-Section Track Roller Frame. Grease Type Track Adjusters W/Shock Absorbing Recoil Springs.
SPEC-10-5
HYDRAULIC EXCAVATOR SPECIFICATIONS (CONTD) Capacities (S/N 522311001 & Above) Fuel Tank Cooling System Engine & Oil Filter Hydraulic Reservoir Travel Motor (Each) Capacities (S/N 528911001 & Above And S/N 528611001 & Above) Fuel Tank Cooling System Engine & Oil Filter Hydraulic Reservoir Travel Motor (Each) Digging Force Arm Bucket NA NA 34 Gals. (130 L) 10 Qts. (9.4 L) 14.8 Qts. (14 L) 29 Gals. (110 L) 1.9 Qts. (1,8 L) 34 Gals. (130 L) 3 Gals. (12 L) 10.5 Qts. (10 L) 29 Gals. (110 L) 1.9 Qts. (1,8 L)
SPEC-10-6
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE)

All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
General Displacement Bore Stroke Crankshaft Rotation (Facing Flywheel) Ignition Combustion System Compression Ratio Compression Firing Order Weight Fuel System Fuel Injection Pump Pressure (5 Revolutions) Injection Pump Testing Tightness (10 Seconds) Injection Nozzle Opening Pressure NA 3335-3451 PSI (230-238 bar) 3625-3741 PSI (250-258 bar) 195 cu. in. (3192 cu.cm.) 3.70 (94) 4.53 (115) Counterclockwise 4 Stroke Diesel-Compression Direct Injection 17.5-1 406-479 PSI (28-33 Bar) 1-3-4-2 728 lbs. (330 Kg)
SPEC-20-1
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE) (CONTD) Valve, Valve Guide and Seat Insert Valve Clearance (Intake) Oil temp. Below 176F (80C) Valve Clearance (Exhaust) Oil temp. Below 176F (80C) Valve Guide I.D. Valve Rim Thickness (Intake) Valve Rim Thickness (Exhaust) Valve Seat Insert O.D. (Intake) Valve Seat Insert O.D. (Exhaust) Valve Seat Insert Bore (Intake) Valve Seat Insert Bore (Exhaust) Valve Stem Diameter (Intake) Valve Stem Diameter (Exhaust) Valve Stem Clearance (Intake) Wear Limit Valve Stem Clearance (Exhaust) Wear Limit Valve Head O.D. (Intake) Valve Head O.D. (Exhaust) Valve Seat Width (Intake) Valve Seat Width (Exhaust) Seat Angle (Intake) Seat Angle (Exhaust) Valve Recess Valve Spring Free Length Valve Spring Inclination 0.012 (0,3) 0.020 (0,5) NA 0.071 (1,8) 0.043 (1,1) 0.106 (2,7) 0.083 (2,1) NA NA 0.308-0.314 (7,83-7,98) 0.307-0.313 (7,81-7,96) 0.0118 (0,3) 0.004 (0,10) 0.020 (0,5) 0.005 (0,13) 1.637-1.646 (41,6-41,8) 1.409-1.417 (35,8-36,0) 0.106 (2,7) 0.083 (2,1) 30 45 0.055 (1,4) 2.248-2.398 (57,1-60,9) NA
SPEC-20-2
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE) (CONTD)

Piston And Rings Piston Diameter I.D. for Piston Pin Piston Pin Diameter Piston Ring Groove-1st Piston Ring Groove-2nd Piston Ring Groove-3rd Piston Ring Clearance-1st Wear Limit Piston Ring Clearance-2nd Wear Limit Piston Ring Clearance-3rd Wear Limit Piston Ring Gap-1st Wear Limit-1st Piston Ring Gap-2nd Wear Limit-2nd Piston Ring Gap-3rd Wear Limit-3rd Bore for Piston Pin Bushing Piston Pin Bushing O.D. Piston Pin Bushing I.D. (pressed in) Wear Limit NA NA 1.338-1.339 (33,994-34,0) NA NA NA NA Keystone Groove NA 0.007 (0,17) NA 0.004 (0,10) 0.031 (0,8) Maximum NA 0.098 (2,5) Maximum NA 0.045 (1,15) Maximum NA NA NA NA NA
SPEC-20-3
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE) (CONTD) Connecting Rod Small End Bushing I.D. (Pressed In) Wear Limit Bore for Small End Bushing O.D. for Small End Bushing Parallel Check Alignment Connecting Rod Width Connecting Rod End Play Wear Limit Center Distance From Small to Large Bore Bore for Large End Bearing Large End Bearing Shells I.D. Limit for Undersize Large End Bearing Radial Clearance Wear Limit Large End Bearing Width Cylinder Head and Block Cylinder Head Studs-Length Cylinder Bore Wear Limit Cylinder Sleeves I.D. (Seated in Block) N/A 3.700-3.702 (94,0-94,02) 3.705 (94,1) 0.351-.366 (8,92-8,95) 1.338-1.340 (33,975-34,035) 0.003 (0,08) 1.457-1.458 (37,0-37,02) 1.454-1.461 (36,93-37,11) Permissible 0.0019 over a distance of 3.937 (0,05 Over 100,0) 0.002 (0.05) NA NA NA NA 2.425-2.426 (61,6-61,62) 2.285-2.286 (58,03-58,07) 2.275-2.276 (57,78-57,82) NA 0.005 (0.12) NA
SPEC-20-4
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE) (CONTD) Crankshaft And Main Bearings Crankshaft Pin Width Crankshaft Pin Diameter Crankshaft Pin Undersize Limit Oval Wear Limit Crankshaft Journal Width Crankshaft Journal Diameter Oval Wear Limit Eccentricity Max. Permitted Thrust Bearing Journal Width Wear Limit Main Bearing Shell I.D. Radial Clearance Wear Limit Bearing Bore in Crankcase Thrust Bearing Stop Rings O.D. Oversize Limit for Oversize Crankshaft End Play Wear Limit NA 2.283-2.284 (57,98-58,0) 2.263-2.264 (57,48-57,50) 0.003 (0.07) 1.417-1.419 (36,0-36,04) 2.912-2,913 (73,98-74,0) 0.0004 (0,01) 0.0028 (0,07) 1.417-1.419 (36,00-36,04) 1.435 (36,44) 2.9126-2.9134 (73,98-74,0) NA NA NA NA NA NA 0.0039-0.0118 (0,10-0,30) NA
SPEC-20-5
ENGINE SPECIFICATIONS (S/N 522311001 & ABOVE) (CONTD) Camshaft And Bearings Camshaft End Play Wear Limit Camshaft Bearing I.D. Wear Limit Radial Clearance Cam Lift (Intake) Cam Lift (Exhaust) Camshaft Bushing Seated in Block (Flywheel End) Oil Pump Oil Pump Pressure Setting Min. Eng. Oil Pressure, Oil Temp. 250F (120C) at 650 RPM 1800 RPM 2800 RPM Thermostat Rating Governor Control Rod Travel (Minimum) Engine Balancing Shaft And Bearings Bearing Bushing I.D. Wear Limit 2.128-2.130 (54,06-54,105) 2.131 (54,125) 0.661 (16,8) NA NA 11.6 PSI (.8 bar) NA NA NA NA NA 2.362-2.364 (60-60,054) 2.365 (60,080) NA NA NA 2.362+0.002 (60+0.054)
SPEC-20-6
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE)
General Make/Model Displacement Bore Stroke Crankshaft Rotation (Facing Flywheel) Ignition Combustion System Compression Ratio Compression Firing Order Weight Fuel System Fuel Injection Pump Pressure (5 Revolutions) Injection Pump Testing Tightness Injection Nozzle Opening Pressure NA 2755-2871 PSI (190-198 bar) for 10 sec. 3045-3161 PSI (210-218 bar) BF4 M 2011 190 cu. in. (3108 cu.cm.) 3.70 (94) 4.41 (112) Counterclockwise 4 Stroke Diesel-Compression Direct Injection 17.5-1 319-392 (22-27 bar) 1-3-4-2 551 lbs. (250 Kg)
SPEC-21-1
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Valve, Valve Guide and Seat Insert Valve Clearance (Intake) Oil temp. Below 176F (80C) Valve Clearance (Exhaust) Oil temp. Below 176F (80C) Valve Guide I.D. Valve Rim Thickness (Intake) Valve Rim Thickness (Exhaust) Valve Seat Insert O.D. (Intake) Valve Seat Insert O.D. (Exhaust) Valve Seat Insert Bore (Intake) Valve Seat Insert Bore (Exhaust) Valve Stem Diameter (Intake) Valve Stem Diameter (Exhaust) Valve Stem Clearance (Intake) Wear Limit Valve Stem Clearance (Exhaust) Wear Limit Valve Head O.D. (Intake) Valve Head O.D. (Exhaust) Valve Seat Width (Intake) Valve Seat Width (Exhaust) Seat Angle (Intake) Seat Angle (Exhaust) Valve Recess Valve Spring Free Length 0.132 (3.35) Dia. Springs Valve Spring Free Length 0.034 (3,4) Dia. Springs Valve Spring Inclination 0.012 (0,3) 0.020 (0,5) N/A 0.055 (1,4) 0.005 (1,2) N/A 0.083 (2,1) N/A N/A 0.3134-0.314 (7,97-7,98) 0.3124-0.313 (7,95-7,96) 0.0118 (0,3) 0.0197 (0,5) 0.0197 (0,5) 0.0511 (1,3) 1.590-1.598 (40,4-40,6) 1.370-1.378 (34,89-34,91) 0.0464-0.0827 (1,18-1,98) 0.0511-0.0827 (1,3-2,1) 30 45 0.0512 (1,3) 1.53 (38,9) 1.547 (39,3) 0.126 (3,2)
SPEC-21-2
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD)
Piston And Rings Piston Diameter I.D. for Piston Pin Piston Pin Diameter Piston Ring Groove-1st Piston Ring Groove-2nd Piston Ring Groove-3rd Piston Ring Clearance-1st Wear Limit Piston Ring Clearance-2nd Wear Limit Piston Ring Clearance-3rd Wear Limit Piston Ring Gap-1st Wear Limit-1st Piston Ring Gap-2nd Wear Limit-2nd Piston Ring Gap-3rd Wear Limit-3rd Bore for Piston Pin Bushing Piston Pin Bushing O.D. Piston Pin Bushing I.D. (pressed in) Wear Limit N/A N/A 1.1809-1.1811 (29,995-30,0) N/A N/A N/A Keystone Groove N/A 0.0078 (0,20) N/A 0.0059 (0,15) N/A 0.031 (0,8) Maximum N/A 0.098 (2,5) Maximum N/A 0.043 (1,1) Maximum 0.004 (0,10) N/A N/A N/A N/A
SPEC-21-3
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Connecting Rod Small End Bushing I.D. (Pressed In) Wear Limit Bore for Small End Bushing O.D. for Small End Bushing Parallel Check Alignment Connecting Rod Width Connecting Rod End Play Wear LImit Center Distance From Small to Large Bore Bore for Large End Bearing Large End Bearing Shells I.D. Limit for Undersize Large End Bearing Radial Clearance Wear Limit Large End Bearing Width Cylinder Head and Block Cylinder Head Bolts Length Cylinder Bore Wear Limit Cylinder Sleeves I.D. (Seated in Block) 5.6-6.2 (142-158) 3.7008-3.7016 (94,0-94,02) 3.59 (94,1) N/A 1.181-1.182 (30,025-30,035) 0.003 (0,08) 1.299-1.2998 (33-33,02) 1.3017-1.303 (33,07-33,11) Permissible 0.118 over a distance of 3.94 (0,03 Over 100,0) N/A N/A N/A N/A N/A 2.303-2.3038 (58,5-58,52) 2.1662-2.1675 (55,024-55,055) 2.1466-2.1478 (54,524-54,555) 0.005 (0,12) N/A N/A
SPEC-21-4
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Crankshaft And Main Bearings Crankshaft Pin Width Crankshaft Pin Diameter Crankshaft Pin Undersize Limit Oval Wear Limit Eccentricity Max Permitted Crankshaft Journal Width Oversize Crankshaft Main Bearing Journal Diameter Wear Limit Oval Wear Limit Eccentricity Max. Permitted Thrust Bearing Journal Width Wear Limit Main Bearing Shell I.D. Radial Clearance Wear Limit Bearing Bore in Crankcase Thrust Bearing Journal Width Limit for Oversize Crankshaft End Play Wear Limit N/A 2.1588-2.1596 (54,97-54,99) 2.1445 (54,47) 0.0004 (0,01) 0.0019 (0,05) 1.378-1.379 (35,0-35,04) 1.395 (35,44) 2.7538-2.7546 (69,97-69,99) 2.7348 (69,47) 0.0003 (0,008) 0.002 (0,05) 1.378-1.379 (35,0-35,04) 1.395 (35,44) 2.797-2.798 (70,02-70,055) .001-.003 (0,03-0,085) N/A 2.952-2,953 (75-75,019) 1.378-1.3796 (35-35,04) 1.395 (35,44) 0.004-0.010 (0,1-0,273) 0.016 (0,4)
SPEC-21-5
ENGINE SPECIFICATIONS (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Camshaft And Bearings Camshaft End Play Wear Limit Camshaft Bearing I.D. Wear Limit Radial Clearance Cam Lift (Intake) Cam Lift (Exhaust) Camshaft Bushing Seated in Block Wear Limit Oil Pump Oil Pump Pressure Setting Min. Eng. Oil Pressure, Oil Temp. 250F (120C) at 650 RPM 1800 RPM 2800 RPM Thermostat Rating N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 2.126-2.128 54-54,054) 2.129 (54,08)
SPEC-21-6
ENGINE BOLT TORQUE (S/N 522311001 & ABOVE) Specifications Ft.-lb. (Nm) Adaptor Housing Mount Bolts Air Intake Manifold Bolts Alternator Bracket Mount Bolts Alternator Mount Bolts Breather Bolts Camshaft Bolt Camshaft Thrust Washer Bolts Compressor Drive Gear Mount Nut Connecting Rod Cap Bolts Coolant Pipe Mount Bolts Coolant Pump Mount Bolts Crankcase Breather Mount Bolts Crankcase Screw Plugs Crankshaft Gear Mount Bolt Crankshaft Bearing Cap Bolt Cylinder Head Bolts Step 1 Step 2 Step 3 Engine Lift Bracket Mount Bolts Engine Mount Bolt Exhaust Manifold Nuts Exhaust Turbocharger Nuts Flywheel Bolts Step 1 30-45 mm Long 50-85 mm long Step 2 Step 3 30 mm long 35-85 mm long Flywheel Pulley Mount Bolts Step 1 Step 2 - 60 mm long - 80 mm long Step 3 - 60 mm long - 80 mm long Front Cover Bolts Fuel Filter Bracket Bolts Fuel Filter Line Fittings 29-37 (40-50) 60 degrees 60 degrees 30 degrees 60 degrees 14-17 (19-23) NA 33-41 (45-55) (M-12) (M-16) 66-80 (89-109) 161-198 (218-268) 7-9 (10-12) 14-17 (19-23) 22 (30) 7-9 (10-12) NA NA 147-184 (200-250) 22 (30) Plus 60 degrees, 30 degrees = 90 degrees 14-17 (19-23) 14-17 (19-23) 6-7 (7,5-9,5) NA NA 22 (30) Plus 60 degrees, 30 degrees = 90 degrees 22 (30) 59 (80) Plus 90 degrees 32-38 (43-51) 48-55 (65-75) 17-20 (22,5-27,5) NA 15-22 (20-30) 22-30 (30-40) 60 degrees 30 degrees 60 degrees
SPEC-30-1
ENGINE BOLT TORQUE (S/N 522311001 & ABOVE) (CONTD) Specifications (Contd) Ft.-lb. (Nm) Fuel Clamping Plate Pump Bolts Fuel Shut Off Solenoid Bolts Glow Plugs Governor Control Rod Bolts Governor Drive Gear Mount Bolt Governor Mount Bolts Governor Mount Bolt Retaining Plate Bolts Idler Pulley Mount Nut Injector Clamping Pad Bolts Injector Line Cap Nut Injector Pump Mount Bolts Step 1 Step 2 Step 3 Main Bearing Cap Bolts Oil Cooler Collar Screws Oil Cooler Mount Bolts Oil Cooler Plugs Oil Pan Mount Bolts Oil Pan Drain Plug Oil Pump Mount Bolts Oil Pressure Control Valve Oil Pressure Pipe Oil Pressure Switch Oil Return Line Cap Nut Oil Return Pipe Oil Suction Pipe Oil Temperature Switch Overflow Valve Rocker Arm Cylinder Head Bolts Rocker Arm Bolts Rocker Arm Set Screw Locknut Starter Collar Nut Starter Mount Bolts (Top) (Bottom) (Steel) (Cast) (Initial) (Final) 5 (7) 7 (10) 22 (30) 22 (30) Plus 60 degrees, 60 degrees = 120 degrees 59 (80) 118 (160) 14-17 (19-23) 59 (80) 14-17 (19-23) 20-23 (27-31) 6-7 (8-9) 6-7 (8-9) 27-32 (36-44) 19-24 (26-32) 26-32 (35-43) 12-15 (16-20) NA 28-31 (38-42) 14-17 (19-23) N.A 22 (30) 15 (21) NA 13-16 (18-22) 30 (40) 52 (70) 15-18 (20-24) 15 (21) 13-16 (18-22) 7-9 (10-12) 16 (21) 11-14 (15,5-18,5) 14-17 (19-23) 14-17 (19-23) 12-15 (16-21) 18-21 (25-28,5)
SPEC-30-2
ENGINE BOLT TORQUE (S/N 522311001 & ABOVE) (CONTD) Specifications (Contd)
Ft.-lb. (Nm) Speed Sensor Timing Belt Tensioner Pulley Nut Timing Cover Mount Bolts Turbocharger Mount Bolts Turbocharger Cover Mount Bolts Turbocharger Rotor And Pulley Mount Nut Valve Adjustment Locknut Valve Cover Bolts V-Belt Pulley Bolts Vibration Damper Pulley Mount Bolts Step 1 Step 2 - 60 mm long 80 mm long Step 3 - 60 mm long 80 mm long Water Pump Mount Bolts Water Temperature Sensor 6-7 (8-10) NA 14-17 (19-23) 14-17 (19-23) 7 (9) 89 (120) 13-16 (18-22) 6-7 (8-10) 16 (21) NA 30-37 (40-50) 60 degrees 60 degrees 30 degrees 60 degrees 14-17 (19-23) 12-15 (16-20)
SPEC-30-3
SPEC-30-4
ENGINE BOLT TORQUE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) Specifications Ft.-lb. (Nm) Air Intake Manifold Bolts Alternator Bracket Mount Bolts Alternator Mount Bolts Breather Pipe Bolts Camshaft Bolt Step 1 Step 2 Camshaft Gear Mount Bolt Camshaft Thrust Washer Bolts Connecting Rod Cap Bolts Crankshaft Gear Mount Bolt Crankshaft Bearing Cap Bolt Cylinder Head Bolts Step 1 Step 2 Step 3 Step 4 Engine Mount Bolts Exhaust Manifold Bolts Exhaust Turbocharger Nuts Flywheel Bolts Step 1 Step 2 Step 3 Flywheel Pulley Mount Bolts Step 1 Step 2 Step 3 Front Cover Bolts Front Cover Stop Nut Fuel Filter Bracket Bolts Fuel Line Bolts 22 (30) 60 degrees 30 degrees 15 (21) 3 (4,5) 15 (21) 20-23 (27-31) 22 (30) 60 degrees 30 degrees 22 (30) 59 (80) 118 (160) Plus 90 degrees 48-55 (65-75) 41 (55) N/A 22 (30) Plus 210 Degrees 22 (30) Plus 210 Degrees 15 (21) 22 (30) Plus 60 degrees, 60 degrees = 120 degrees 96 (130) plus 210 degrees 37 (50) Plus 60 degrees, 45 degrees = 105 degrees 15 (21) N/A N/A 6 (8,5)
SPEC-31-1
ENGINE BOLT TORQUE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Specifications (Contd) Ft.-lb. (Nm) Fuel Lift Pump Bolts Fuel Shut Off Solenoid Bolts Governor Lever Shaft Bolts Governor Cover Bolts Governor Mount Bolts Idle Speed Bolts Idler Pulley Mount Bolts Injector Clamping Pad Bolts Injector Line Cap Nut Injector Line Clamping Pad Bolts Injector Nozzle Cap Nut Injector Pump Mount Bolts Main Bearing Cap Bolts Minimum Speed Screw Lock Nut Oil Pan Mount Bolts (Steel) (Cast) 30 mm long) (Cast 55 mm long) Oil Pan Drain Plug Oil Pump Mount Bolts Oil Pressure Pipe Oil Pressure Switch Oil Return Clamping Pad Oil Return Pipe Oil Suction Pipe Oil Temperature Sensor Oil Temperature Switch Rear Cover Bolts Rocker Arm Bracket Bolts Starter Mount Bolts 15 (21) 10-12 (13,5-16,3) 7 (9,2) 3 (4,5) 7 (9,2) 3-4 (4,2-5) 33 (45) 16 (21) 10-12 (13,5-16,5) 16 (21) 29-37 (40-50) 15 (21) 37 (50) Plus 60 degrees, 45 degrees = 105 degrees 3 (4,5) 15 (21) 16 (21) 16 (21) 40 (55) 14-17 (18,9-23,1) 82 (111) 8-11 (11,5-14,5) 6 (8,5) 30 (40) 15 (21) 17-20 (22,5-27,5) 17-21 (22,5-27,5) 15 (21) 15 (21) 32 (43,5)
SPEC-31-2
ENGINE BOLT TORQUE (S/N 528911001 & ABOVE AND S/N 528611001 & ABOVE) (CONTD) Specifications (Contd)
Ft.-lb. (Nm) Thermostat Timing Belt Tensioner Pulley Nut Torque Control Clamp Nut Torque Control Locknut Turbocharger Carrier Mount Bolts Turbocharger Vent Pipe Bolts Step 1 Step 2 Turbocharger Oil Line Bolt V-Belt Pulley Bolts Valve Adjustment Lock Nut Valve Cover Bolts 6 (8,5) 9 (12,5) 21 (29) 28-34 (38-46) 13-16 (18-22) 6 (8,5) 55 (75) 14-17 (19-23) 7 (10) 12 (16) 15 (21))
SPEC-31-3
SPEC-31-4
EXCAVATOR BOLT TORQUE Specifications S/N 522311001 & Above Ft.-lb. (Nm) Air Cleaner Mount Bolts Backup Relief Valve Control Valve Mount Bolts (6 spool) (3 spool) Drive Sprockets Engine Mount Bolts Exhaust Pipe To Exhaust Manifold Mount Bolts Filter Housing Mount Bolts Front Panel Bolts Hydraulic Pump Drive Coupler Mount Bolts Hydraulic Pump Mount Bolts (Piston Pump) (Gear Pump) Hydraulic Reservoir Mount Bolts Main Relief Valve Load Sense Relief Valve Operator Cab Mount Bolts/ Nuts (Front And Rear) (Side Bolts) Pivot Pin Seat Belt Mount Bolts Seat Mount Bolts 18-19 (24-26) 52 (70) 48-55 (65-75) 32-35 (43-47) 177-203 (240-275) 48-55 (65-75) NA NA NA 36 (49) 125-140 (170-190) 22-26 (30-35) NA 46-57 (63-77) 18 (25) 81-92 (110-125) 48-55 (65-75) NA NA NA S/N 528911001 & Above S/N 528611001 & Above Ft.-lb. (Nm) 18-19 (24-26) 52 (70) 48-55 (65-75) 32-35 (43-47) 177-203 (240-275) 48-55 (65-75) NA NA NA 15-18 (20-25) 125-140 (170-190) 48-55 (65-75) NA 46-57 (63-77) 18 (25) 81-92 (110-125) 48-55 (65-75) NA NA NA
SPEC-40-1
SPEC-40-2
TORQUE SPECIFICATIONS FOR BOLTS Torque For General SAE Bolts The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from Melroe that have zinc phosphate coating are specified by the letter H following the part number. THREAD SIZE .250 INCH LBS. (Nm) .3125 .375 .4375 .500 .5625 .625 FOOT LBS. (Nm) .750 .875 1.000 1.125 1.250 1.375 1.500 1.625 1.750 1.875 2.000 Torque For General Metric Bolts Grade Nominal Diameter M6 M8 M10 M12 Standard Screw and Bolt 4 Unit Special Screw and Bolt 7 ft lbs 7.23 to 8.32 17.4 to 20.3 35.4 to 41.2 57.1 to 66.5 SAE GRADE 5 80-90 (9,0-10,2) 180-200 (20,3-22,6) 25-28 (34-38) 40-45 (54-61) 65-70 (88-95) 90-100 (122-136) 125-140 (170-190) 220-245 (300-330) 330-360 (450-490) 475-525 (645-710) 650-720 (880-975) 900-1000 (1200-1360) 1200-1350 (1630-1830) 1500-1650 (2040-2240) 2000-2800 (2720-2980) 2500-2750 (3390-3730) 3150-3500 (4270-4750) 3800-4200 (5150-5700) SAE GRADE 8 110-120 (12,4-13,6) 215-240 (24,2-27,1) 35-40 (47-54) 60-65 (81-88) 90-100 (122-136) 125-140 (170-190) 175-190 (240-260) 300-330 (410-450) 475-525 (645-710) 725-800 (985-1085) 1050-1175 (1425-1600) 1475-1625 (2000-2200) 2000-2200 (2720-2980) 2600-2850 (3530-3870) 3450-3800 (4680-5150) 4300-4800 (5830-6500) 5500-6100 (5830-6500) 6500-7200 (8800-9800)
Nm kfg m ft lbs Nm kgf m 7.9 to 9.3 0.80 to 0.95 5.8 to 6.9 9.8 to 11.3 1.00 to 1.15 17.7 to 20.6 1.8 to 2.1 13.0 to 15.2 23.5 to 27.5 2.4 to 2.8 39.2 to 45.1 4.0 to 4.6 28.9 to 33.3 48.1 to 55.9 4.9 to 5.7 62.8 to 72.6 6.4 to 7.4 46.3 to 53.5 77.5 to 90.2 7.9 to 9.2
SPEC-50-1
SPEC-50-2
HYDRAULIC FLUID SPECIFICATIONS Specifications Use Bobcat hydraulic fluid (P/N 6903117 - 2, 2 1/2 Gal.), (P/N 6903118 - 5 Gal.), (P/N 6903119 - 55 Gal.).
When temperatures below zero degree F (-18C) are common, the excavator must be kept in a warm building. Extra warm-up time must be used each time the excavator is started during cold temperature conditions. Cold fluid will not flow easily and it makes action of the hydraulic function slower. Loss of fluid flow to the hydraulic system can cause damage in less than 60 seconds.
WARNING
During cold weather 32F (0C) and below, do not operate machine until the engine has run for at least five (5) minutes at less than half throttle. This warmup period is necessary for foot pedal operation and safe stopping. Do not operate controls during warmup period. When temperatures are below -20F (30C), the hydrostatic oil must be heated or kept warm. The hydrostatic system will not get enough oil at low temperatures. Park the machine in an area where the temperature will be above 0F (-18C), if possible.
W-2027-1285
DO NOT use automatic transmission fluids in the excavator or permanent damage to the hydraulic system will result.
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 or 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-2072-0496
SPEC-60-1
SPEC-60-2
FUEL, COOLANT AND LUBRICANTS Chart (S/N 522311001 & Above) Use this chart for correct selection of Fuel, Coolant and Lubricants. RESERVOIR Engine oil KIND OF FLUID *Use SAE Viscosity Number as Listed With API Classification CD or Better RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE) CAPACITY REFILL 10.5 qts. (10 L)
Fuel
**Diesel Fuel
Temp. F +15 (9) Down to -20 (-29) Below -20 (-29)
No. 2 100% 50% 0%
No.1 0% 50% 100%
34 gal. (130 L)
Cooling System Hydraulic Tank
***Coolant Mixture Bobcat Fluid
3 gal. (12,0 L) Tank Cap. 29 gal. (110 L)
Drive Motors (each side)
Gear Lube
SAE - 80 W-90 LS
1.9 qts. (1,8 L)
SPEC-70-1
**ENGINE OIL SPECIFICATIONS When fuel sulphur content is less than 0.5% change the engine oil and filter as shown in the Service Schedule (See SERVICE SCHEDULE on Page 10-50-1.) Change engine oil and filter according to the following chart if fuel sulphur content is above 0.5%. FUEL SULPHUR CONTENT 0.5 - 1.0% Above 1.0% CHANGE INTERVAL OF ENGINE & OIL FILTER 1/2 of Regular Interval 1/4 of Regular Interval
*** COOLANT MIXTURE Ethylene Glycol (Factory Installed) Add premixed coolant; 50% water and 50% ethylene glycol to the surge tank if the coolant level is low. Use a refractometer to check the condition of ethylene glycol in the cooling system.
SPEC-70-2
FUEL, COOLANT AND LUBRICANTS (CONTD) Chart (S/N 528911001 & Above And S/N 528611001 & Above) Use this chart for correct selection of Fuel, Coolant and Lubricants. RESERVOIR Engine oil/ Engine coolant KIND OF FLUID *Use SAE Viscosity Number as Listed With API Classification CD or Better RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE) CAPACITY REFILL 14.8 qts. (14 L) System Capacity 10 qts (9.4 L) w/ filter oil change
Fuel
**Diesel Fuel
Temp. F +15 (9) Down to -20 (-29) Below -20 (-29)
No. 2 100% 50% 0%
No.1 0% 50% 100%
34 gal. (130 L)
Hydraulic Tank
Bobcat Fluid
Tank Cap. 29 gal. (110 L)
Drive Motors (each side)
Gear Lube
SAE - 80 W-90 LS
1.9 qts. (1,8 L)
SPEC-70-3
**ENGINE OIL SPECIFICATIONS When fuel sulphur content is less than 0.5% change the engine oil and filter as shown in the Service Schedule (See SERVICE SCHEDULE on Page 10-50-1.) Change engine oil and filter according to the following chart if fuel sulphur content is above 0.5%. FUEL SULPHUR CONTENT 0.5 - 1.0% Above 1.0% CHANGE INTERVAL OF ENGINE & OIL FILTER 1/2 of Regular Interval 1/4 of Regular Interval
SPEC-70-4
CONVERSIONS Decimal And Millimeter Equivalents
SPEC-80-1
CONVERSIONS (CONTD) U.S. To Metric Conversion
SPEC-80-2
ROUTE TO ATTENTION
SERVICE MANUAL REVISION

NOTICE
Revision No: Date: Product: Model: Manual No:
PARTS MANAGER SERVICE MANAGER X SALES MANAGER
Insert This Sheet With The Below Listed Manual For Future Reference.
442-1 November 7, 2002 Bobcat Excavator 442 6901801 (9-02)
The following pages are a revision to the above Service Manual. Take out existing pages and put in the new pages as listed below:
TAKE OUT 10-01, 10-02 10-130-1, 10-130-2 10-140-1, 10-140-2 10-01, 10-02
PUT IN Alphabetical Index 10-130-1, 10-130-2 10-140-1, 10-140-2 10-160-1 through 10-160-6 Added Text change Text change Text change Text change Added section Text change Text change Text change Text change Text change
CHANGE DECRIPTION
10-150-1 through 10-150-6 10-150-1, 10-150-2 20-01 through 20-06 20-34-1 through 20-34-8 20-80-1, 20-80-2 20-100-1, 20-100-2 30-01, 30-02 30-30-1, 30-30-2 40-01, 40-02 40-10-1, 40-10-2 40-20-1 through 40-20-8 40-30-1, 40-30-2 40-80-1, 40-80-2 40-01, 40-02 40-10-1 through 40-10-8 40-20-1 through 40-20-8 40-30-1, 40-30-2 40-80-1 through 40-80-4 40-110-1, 40-110-2 40-170-1 through 40-170-4 40-170-1 through 40-170-4 40-180-1, 40-180-2 40-190-1, 40-190-2 40-200-1, 40-200-2 50-01, 50-02 50-50-1, 50-50-2 50-01, 50-02 50-50-1through 50-50-4 20-01 through 20-06 20-34-1 through 20-34-6 20-80-1 through 20-80-6 20-100-1through 20-100-4 30-01, 30-02
Procedure moved to Section 40 Text change Text change Text change Text change Text change Section added Text change Remove duplicated section Remove duplicated section Remove duplicated section Text change Text change
Printed in U.S.A.
TAKE OUT 60-01, 60-02 60-20-1, 60-20-2 70-01, 70-02 70-20-1, 70-20-2 70-30-1, 70-30-2 70-40-1 through 70-40-4 70-50-1, 70-50-2 70-170-1, 70-170-2 70-180-1, 70-180-2 70-190-1, 70-190-2 70-200-1, 70-200-2 70-210-1, 70-210-2 70-220-1, 70-220-2 60-01, 60-02
PUT IN Text change Text change Text change Text change Text change Text change Text change Text change Text change Text change Text change 60-20-1 through 60-20-4 70-01, 70-02 70-20-1 through 70-20-4 70-30-1, 70-30-2 70-40-1 through 70-40-4 70-50-1, 70-50-2 70-170-1, 70-170-2 70-180-1, 70-180-2 70-190-1, 70-190-2 70-200-1, 70-200-2
CHANGE DECRIPTION
Procedure moved to 70-200-1 Procedure combined with 70-180-1
Machine Name Operation & Maintenance Manual
ROUTE TO ATTENTION

NOTICE
442-2 January 15, 2003 Bobcat Excavator 442 6901801 (9-02)
The following pages are a revision to the above Service Manual. Take out existing pages and put in the new pages as listed below:
TAKE OUT Alphabetical Index Hyd/Hyd Schematic 442 Excavator (S/N 522311001 & Above) (Printed September 2002) 20-120-1, 20-120-2 20-130-1, 20-130-2 30-01, 30-02 30-20-1 through 30-20-6
PUT IN Alphabetical Index Hyd/Hyd Schematic 442 Excavator (S/N 522311001 & Above) (Printed January 2003) 20-120-1, 20-120-2 20-130-1 through 20-130-6 30-01, 30-02 30-20-1 through 30-20-8 30-30-1 through 30-30-4 30-40-1 through 30-40-10 30-50-1 through 30-50-8 30-60-1 through 30-60-10 30-70-1 through 30-70-4 30-80-1 through 30-80-10 Text change Text change Text change Text change Section added Section added Section added Section added Section added Section added Text change Text change Text change Text change Text change Text change Text change Section added Section added Text change
CHANGE DESCRIPTION Minor corrections to legend and schematic
40-01, 40-02 40-20-1 through 40-20-8 40-50-1, 40-50-2 40-90-1, 40-90-2 40-160-1, 40-160-2 50-01, 50-02 50-40-1, 50-40-2
40-01, 40-02 40-20-1 through 40-20-20 40-50-1, 40-50-2 40-90-1, 40-90-2 40-160-1 through 40-160-4 50-01, 50-02 50-40-1, 50-40-2 50-90-1, 50-90-2 50-100-1, 50-100-2
Printed in U.S.A.
TAKE OUT 70-01, 70-02 70-130-1, 70-130-2 70-200-1, 70-200-2 70-01, 70-02
PUT IN Text change Text change Text change 70-130-1 through 70-130-4 70-200-1, 70-200-2
CHANGE DESCRIPTION
ROUTE TO ATTENTION

NOTICE
442-3 15 November 2004 Bobcat Excavator 442 6901801 (9-02)
The following sections are a revision to the above Service Manual. Take out existing sections and put in the new sections as listed below:
TAKE OUT Cover 10-01 10-20 10-40 10-50 10-60 Cover 10-01 10-20 10-40 10-41 10-50 10-60 10-61 10-62 10-70 10-80 10-90 10-100 10-140 10-150 10-70 10-80 10-90 10-100 10-140 10-150 10-151 Hyd/Hyd Schematic Printed January 2003 MS1433
PUT IN S/N Added Text Change Text Change Text Change
REVISION DESCRIPTION
Added Section Text Change Text Change Added Section Added Section Text Change Text Change Text Change Text Change Text Change Text Change Added Section Revised Schematic
Hyd/Hyd Schematic Printed November 2004 MS1433 Hyd/Hyd Schematic Printed November 2004 V-0621
Added Schematic
Printed in U.S.A.
TAKE OUT 20-01 20-40 20-50 20-51 20-01 20-40 20-50 20-51 20-52 20-53 20-60 20-101 20-160 20-170 20-60 20-61 20-101 20-102 20-160 20-170 20-171 30-01 30-20 50-01 50-10 30-01 30-20 50-01 50-10
PUT IN Text Change Text Change Text Change Text Change Added Section Added Section Text Change Added Section Text Change Added Section Text Change Text Change Added Section Text Change Text Change 50-01 50-10
CHANGE DESCRIPTION
Electrical Schematic Printed November 2004 V-0616, V-0617, V-0618, V-0619, V-0620 60-01 60-10 60-20 60-40 60-60 60-70 60-01 60-10 60-20 60-21 60-40 60-41 60-60 60-61 60-70 60-71 60-81
Added Schematics
Text Change Text Change Text Change Added Text Text Change Added Section Text Change Added Section Text Change Added Section Added Section
ROUTE TO ATTENTION

NOTICE
442-4 15 April 2005 Bobcat Excavator 442 6901801 (4-05)
Please discard your old 442 Bobcat Excavator Service Manual (P/N 6901801) Dated 9-02 and replace it with the revised 442 Bobcat Excavator Service Manual (P/N 6901801) Dated 4-05.
Printed in U.S.A.
ROUTE TO ATTENTION

NOTICE
442-5 24 March 2006 Bobcat Excavator 442 6901801 (4-05)
442 Service Manual (P/N 6901801) Dated (2-06) contains updated service information which replaces the previous 442 Service Manual (P/N 6901801) Dated (4-05)
.
Printed in U.S.A.
ROUTE TO ATTENTION

NOTICE
442-6 12 July 2006 Bobcat Excavator 442 6901801 (2-06)
The following Sections are a revision to the above Service Manual.
Cover 20-50 20-52 20-70 20-80 Spec-10
Printed in U.S.A.
ROUTE TO ATTENTION

NOTICE
442-7 15 November 2007 Bobcat Excavator 442 6901801 (11-07)
The following Sections are a revision to the above Service Manual

. COVER ALPHABETICAL INDEX FOREWORD HYDRAULIC / HYDROSTATIC SCHEMATICS ELECTRICAL SCHEMATICS Section 60-01 Section 60-51
Printed in U.S.A.

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442

Bobcat Company 2007

Never service the Hydraulic Excavator instructions.

Cleaning and maintenance are required daily.

SAFETY & MAINTENANCE

442 Excavator Service Manual

442 Excavator Service Manual

9. Safety treads must be in good condition.

2. Check that ROPS mounting hardware is tightened and is Bobcat approved.

4. Inspect for loose or broken parts or connections.

12. Inspect for fuel, hydraulic fluid leaks.

5. Machine signs must be legible and in the correct location.

13. Lubricate the excavator.

14. Check the condition of the battery and cables.

8. Check the electrical charging system.

442 Excavator Service Manual

Safety Alert Symbol

Call Before You Dig

Engine Serial Number Figure 2

S/N 522311001 & Above

S/N 528911001 & Above S/N 528611001 & Above

442 Excavator Service Manual

DELIVERY REPORT Figure 4

442 Excavator Service Manual

RETURN TO TANK COUPLER AUXILIARY COUPLERS BUCKET

RIGHT SIDE COVER REAR COVER

442 Excavator Service Manual

442 Excavator Service Manual

SAFETY & MAINTENANCE

ELECTRICAL SYSTEM & ANALYSIS ENGINE SERVICE

Continued On Next Page

442 Excavator Service Manual

Continued On Next Page

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

LIFTING THE EXCAVATOR Procedure

442 Excavator Service Manual

442 Excavator Service Manual

1 Entering And Exiting The Excavator Figure 10-20-1

442 Excavator Service Manual

1 Exit through the window [Figure 10-20-5].

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

REAR COVER Opening And Closing The Rear Cover

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

442 Excavator Service Manual

Position the excavator as shown [Figure 10-61-1]. Figure 10-61-2

442 Excavator Service Manual