231 6722178 enUS SM

X 231
Excavator
Service
Manual
Dealer Copy -- Not for Resale

(S/N 508912001 & Above)
Doosan purchased Bobcat Company from Ingersoll-Rand Company in

2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.
6722178 (6-12) Printed in U.S.A. © Melroe Company 1992
1 of 340
2 of 340
CONTENTS
SAFETY
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .i . . . .
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 ...
HYDRAULIC SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 ....
DRIVE SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–1 ....
UPPER WORKS & SWING SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–1 .. PREVENTIVE
MAIN FRAME & TRACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–1 ... MAINTENANCE
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ....
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–1 ....
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–1 ....
HYDRAULIC
SECTION
DRIVE
SECTION
UPPER WORKS
& SWING
SECTION

MAIN FRAME
& TRACKS
ELECTRICAL
SYSTEM
ENGINE
SERVICE
TECHNICAL
DATA
231 (S/N 508912001 & Above) Excavator

3 of 340 –5 Service Manual

FOREWORD
This manual is for the Bobcat hydraulic excavator mechanic. It provides necessary servicing an d
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 servic
e
or repair:
1. Check that the operator canopy 9. Safety treads must in good
is in good condition and is not condition.
modified.
2. Check that ROPS mounting 10. Check for correct function of

hardware is tightened and is indicator lamps.
Melroe approved.
3. The seat belt must be correctly 11. Check hydraulic fluid level,
installed, functional and in engine oil and fuel supply.

good condition.
4. Inspect for loose or broken 12. Inspect for fuel, oil or hydraulic
parts or connections. fluid leaks.
5. Machine signs must be legible 13. Lubricate the hydraulic

and in the correct location. excavator.
6. Steering levers, control levers 14. Check the condition of the

and foot pedals must return to battery and cables.
neutral. Control lock must lock
controls securely.
7. Inspect the air cleaner for 15. Check for any fieldmodifications
damage or leaks. Check the not completed.
condition of the element. FIELD
MODIFICATION
8. Check the electrical charging Recommend to the owner that all

system. necessary corrections be made
before the machine is returned to
service.

Revised
5 of 340 Feb. 94 –3 Service Manual

SAFETY
SAFETY
DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii. . . .
HYDRAULIC EXCAVATOR IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . .iv.
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i. . .
MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v. . .

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii. . .


8 of 340 0 Service Manual
SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manual,
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. Failure
to follow instructions can cause injury or death.
W–2003–0797
The following publications provide information on the safe use and maintenance of the excavator and attachments:
• The Delivery Report is used to assure that complete instructions have been given tothe new owner and that the machine
is in safe operating condition.
• The Operation & Maintenance Manual delivered with the excavator gives operating information as well as routin e
maintenance and service procedures. It is a part of the excavator and must stay with the machine when it is sol d.
Replacement Operation & Maintenance Manuals can be ordered from your Bobcat Excavator dealer.
• The excavator has machine signs (decals) which instruct on the safe operation and care. The signs and their locations
are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat Excavator deale
r.
• The CIMA Safety Manual delivered with the excavator gives information for safe operating and standard signals.

• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.
Warnings on the machine and in the This notice identifies procedures

manuals are for your safety. Failure to which must be followed to avoid
obey warnings can cause injury or damage to the machine.
death. I–2019–0284
W–2044–1285
Safety Alert Symbol: This Safety Symbol is used for important safety messages. When you see thi s
symbol follow the safety message to avoid personal injury or death.

9 of 340 i Service Manual
SAFETY INSTRUCTIONS (Cont’d)
• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing the excavator
. Safety glasses, hear-
ing protection or loader special application kits are required for some work. See your dealer for Melroe Safety equipmen
t.
• Know where fire extinguishers and first aid kits are located and how to use them.
• Do not use the Bobcat excavator where exhaust, arcs, sparks or hot components can contact flammable materia l,
explosive dust or gases.
• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent
a fire hazard and overheating.
• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace an
y
damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to chec
k
for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuelorf
cleaning parts. Use commercial nonflammable solvents.
• Follow any environmental safety regulations when disposing of used fluids such as engine oil, grease or anti–freeze.
• Do not use ether or starting fluids on an engine that has glow plugs. These starting aids can cause an explosion andreinju
you or bystanders.
• Always clean the excavator and disconnect the battery before doing any welding. Cover rubber hoses, battery and a ll

other flammable parts. Keep a fire extinguisher near the excavator when welding. Have good ventilation when grinding
or welding painted parts. Wear a dust mask when grinding painted parts. Toxic dust or gas can be produced.
• Stop the engine and let it cool before adding fuel. No smoking!
• Use the procedure in the Operation & Maintenance or Service Manuals for connecting the battery.

10 of 340 ii Service Manual
SERIAL NUMBER LOCATIONS
A
Always use the serial number of the machine 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 dif ferent procedure in doing a specific service
operation.
HYDRAULIC EXCAVATOR SERIAL NUMBER
The excavator serial number is on the front of the

machine frame, to the left of the boom [A].
N–09233
ENGINE SERIAL NUMBER

B
The engine serial number is located on the engine block,
near the fuel injection pump [B].

N–11917
D
DELIVERY REPORT
All Delivery Report items must be explained to the

owner/operator by the dealer. The dealer is to fill out the
form and the owner/operator signs the form to indicate his
understanding [C].

11 of 340 iii Service Manual
HYDRAULIC EXCAVATOR IDENTIFICATION
BOOM
BUCKET
OPERATOR
CYLINDER
SEAT
BUCKET
LINK BOOM
CYLINDER
CONTROL
LEVERS

BUCKET BLADE CYLINDER
OPERATOR CAB
ARM CYLINDER
ENGINE
COVER
ARM
BLADE
TRACK FRAME
TRACK N–11918
N–11919

12 of 340 iv Service Manual
MACHINE SIGNS TRANSLATIONS (DECALS)
Follow the instructions on all the Machine Signs (Decals) thatare on the excavator. Replace any damaged machine signs
and be sure they are in the correct locations. Machine signs are available from your Bobcat Hydraulic Excavator dealer.
6643358
6537456 (U.S.) 6537587 (I.S.O.)
6537476

6536127
6643361
6577754
6643354
N–11918

Revised
13 of 340Feb. 94 v Service Manual
MACHINE SIGNS TRANSLATIONS (DECALS) (Cont’d)
231ServiceManual#6722178S/N508912000&Above–ContentsSection
6537457 (U.S.) 6537588 (I.S.O.)
6565990 6561379
*6643356

6643355
*6577754
CAB MODELS 6586563
CANOPY MODELS 6586564
6534739
* Decal Located In Engine Compartment 6537595
N–11919

Revised Feb.
14 of94
340 vi Service Manual
PREVENTIVE MAINTENANCE PREVENTIVE
MAINTENANCE
Page
Number
AIR CLEANER SERVICE
Replacing the Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–2
..
COOLING SYSTEM
Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–8
...
Coolant Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–8 ...
ENGINE COVER
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2
....
ENGINE LUBRICATION SYSTEM

Checking the Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6
...
Engine Oil and Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 ..
FINAL DRIVE CASE
Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–14
...
Draining Final Drive Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–14..
FUEL SYSTEM

Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5
....
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4 ...
Fuel System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–4 ...
In–line Fuel Filter (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–5 ..
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . .1–5 .
HYDRAULIC SYSTEM
Checking and Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–9 ..
Diagnostic Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–10
...
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–10
...
Replacement of the Hydraulic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9 ..
LUBRICATION OF THE HYDRAULIC EXCAVATOR

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12
....
SERVICE SCHEDULE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1–1
....
USING A BOOSTER BATTERY (JUMP STARTING)

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–11
....

15 of 340 –1––1– Service Manual

16 of 340 –1–0– Service Manual
SERVICE SCHEDULE
Maintenance work must be done at regular intervals.
Failure to do so may result in excessive and early failures.
The Service Schedule is a guide for correct maintenance
of the Hydraulic Excavator.
Instructions are necessary before operating
or servicing machine. Read Operation &
Maintenance Manual, 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. Failure to follow instructions can
cause injury or death.
W–2003–0797
ITEM SERVICE REQUIRED 8–10 50 100 250 500 1000

Engine Air Cleaner Check & empty dust cup as required.
Engine Oil Check the oil level & add oil as needed.
Engine Coolant System Check coolant recovery bottle.

Indicator Lights Check for correct operation.
Operator Cab Check the fastening bolts, nuts, & condition of cab.
Seat Belt Check the condition & that fasteners are tight.
Safety Signs (Decals) Check for damaged signs (decals) replace as needed.
Tracks Check & adjust tension.
Hydraulic Reservoir Check fluid level.
All Machinery Pivot Points Lubricate 24 grease fittings.
Fuel Tank/Fuel Filters Drain water and sediment from fuel tank/filter. Check fill neck
strainer.
Swing Circle Lubricate two grease fittings.
Swing Pinion Lubricate one grease fitting.
Alternator Belt Check & adjust tension. *
Engine Oil & Filter Replace oil & filter element. *
Final Drive Case Check fluid level & add oil as needed.
Hydraulic Filter Replace filter element. *
Fuel Filters Replace filter elements.
Battery Check & clean cable ends & check electrolyte level.
Air Cleaner Replace the filter element.
Cooling System Clean the radiator fins.
Alternator & Starter Check the condition.
Engine Valve Clearance Check & adjust valve clearance. **
Cooling System Drain, flush & add new coolant to the cooling system.
Hydraulic Tank Change the fluid, clean fill neck strainer.
Final Drive Case Change the oil. **
*After the first 50 hours of machine operation do the following:

• Replace the hydraulic fluid filter.
• Check condition of fan belt.
• Replace the engine oil and filter.
**After the first 250 hours of machine operation do the following procedures:
• Change oil in final drive case.
• Check and adjust engine valve clearance.
Or every 12 months.

Revised Feb. 94
ENGINE COVER
A
Procedure
AVOID INJURY OR DEATH

Never service or adjust the machine when the
engine is running unless instructed to do so in
the manual.
W–2012–0290 N–11937
Keep the engine cover closed when operating
the machine.
B
W–2141–0189
Open the engine cover to service the engine. Pull on the

latches and lift the engine cover up until it is fully open[A].
AIR CLEANER SERVICE

Replacing the Filter Element
See the Service Schedule (Page 1–1) for the correct
service interval.
Replace the filter element when the red ring shows in the N–08175
window of the condition indicator located at the top of the
filter inlet.
NOTE: Push the button on the condition indicator C
and start the engine. If the red ring does not
show, do not replace the filter element.
Service the air cleaner as follows:

Loosen the clamp on the dust cup [B].
Remove the dust cup.
Remove the rubber cup to clean the dust cup [C].
N–10430
Remove the wing nut (Item 1) [D].

D
N–08178

AIR CLEANER SERVICE (Cont’d)
A
Replacing the Filter Element (Cont’d)
Remove the filter element [A].
Check the air cleaner housing for damage.
1
Check the condition of the element replace if necessary.
Check the seal (Item 1) [A].
nstall a new filter element. Install and tighten the wing
nut.
Install the dust cup so the arrow points up.
N–08179
Check that all the air cleaner hose clamps are tight.
Push the button on the condition indicator (Item 1)[B] so

B
the red ring does not show. 1

N–09362

FUEL SYSTEM
A
Fuel Specifications
Use Number 2 diesel fuel in the engine. During very cold
temperatures, Number 1 fuel can be used.
Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can
N–11924
cause an explosion or fire.
W–2063–0887
Fuel System Service

B
The fuel level in the tank is indicated by the fuel gauge
(Item 1) [A] when the key is on.
Use the key to unlock the fuel fill cap and turn the fill cap
to remove it [B].

N–11938
Remove and inspect the fill neck screen [C].

Use a clean, approved safety container to add fuel to the
C
tank.
Add fuel only in an area that has a free movement of air
and no open flames or sparks. NO SMOKING!
After the tank is full, install and tighten the fuel fill cap.
N–11939
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
D
which can result in injury or death.
W–2103–1285
To remove the water and sediment from the fuel tank, 1

open the drain (Item 1) [D] on the bottom of the tank.
N–10433

FUEL SYSTEM (Cont’d)
A
Fuel Filters
service interval.
To remove the water from thefuel filter element, open the
drain valve (Item 1) [A] at the bottom of the fuel filter
element.
When fuel, free of water emerges from the drain valve, 1
close the drain valve.
CD–13231

service interval for fuel filter element replacement. B
Remove the hose (Item 1) [B] from the filter housing and
plug the hose, or firmly squeezethe hose, to eliminate the 1
fuel from siphoning out of the tank when the element is
removed.
Remove the fuel filter element (Item 2)[B]. Clean thearea
around the filter housing. Put oil on the seal of the new
3

filter element. Install the new fuel filter element and hand
tighten only.
CD–13230
In–line Fuel Filter (If Equipped)

Remove the in–line fuel filter (Item 1) [C] and replace it
C
with a new fuel filter.
(In–line fuel filters used on early models only.)
CD–13232
Removing Air From The Fuel System D

Loosen the bleed screw (Item 3)[B] on the filter housing.
Pump the priming ball (Item 1) [D] until fuel, free of air
bubbles emerges from the bleed screw.
Tighten the bleed screw. 1
N–11963

Revised Feb. 94
ENGINE LUBRICATION SYSTEM
A
Checking The Engine Oil
Check the engine oil every day.
Stop the engine. Open the engine cover.
Remove the dipstick [A].
N–11943
Keep the oil between the marks on the dipstick [B].

Use a good quality motor oil that meets API Service
B
Classification of CC or CD. (See Fuel, Coolant and
Lubricants Chart, Page 8–8.)

N–11944
Engine Oil and Filter Replacement

C
service interval.
Use the following procedure to change the oil and filter:
Run the engine until it is at operating temperature.
Turn the upper works so there is clearance for the engine
oil drain plug. Stop the engine.
Remove the drain plug (Item 1) [C]. Drain the oil into a 1
container.
CD–09266
Remove the oil filter (Item 1) [D], using a filter wrench. D

Clean the filter housing surface. Put clean oil on the filter
gasket. Install the new filter and hand tighten only.
Install and tighten the oil drain plug.
1
N–11945

ENGINE LUBRICATION SYSTEM (Cont’d)
A
Engine Oil and Filter Replacement (Cont’d)
Remove the oil fill cap[A]. Put 9.0 quarts (8,5 L.) of oil into
the engine. (See Fuel, Coolant and Lubricants Chart,
Page 8–8.)
Start the engine and let it run for several minutes. Stop the
engine. Check for leaks at the oil filter.
Check the oil level and add oil as needed to bring it to the
TOP mark on the dipstick.
N–11946

Revised Feb. 94
COOLING SYSTEM
A
Coolant Level
When engine is cool, the coolant level in the recovery tank
(Item 1) [A] must be half full.
If the coolant level is low, add pre–mixed coolant (50%
water and 50% ethylene glycol) to the recovery tank.
1
Coolant Replacement
N–11947
Do not remove radiator cap when the engine is

B
hot. You can be seriously burned.
W–2070–1285
Turn the upper works so there is access tothe engine and

radiator from underneath. Stop the engine.

Loosen and remove the radiator cap [B].
N–09363
Open the radiator drain valve (Item 1) [C].

Drain all the coolant from the system.
C
When all the coolant is removed, close the drain valve.
Pre–mix 50% water and 50% ethylene glycol in a
separate container. This mixture will protect the cooling
system to approximately –30° F (–34° C). Fill the radiator
with the pre–mixed coolant until it is full. Add
coolant to the 1
recovery tank until it is half full.
Run the engine at idle speed for about 5–10 minutes to
remove the air from the cooling system (leave the radiator
cap off during this operation).
Stop the engine. Check the coolant level and add as N–11948
needed to bring it up to the radiator filler neck. Install the
radiator cap and tighten.

HYDRAULIC SYSTEM
A
Checking and Adding Fluid
To check and add hydraulic fluid to the reservoir, use the
following procedure:
Put the machine on a flat level surface. 1
Retract the arm and bucket cylinders, put the bucket on
the ground and raise the blade. Stop the engine.
Check the hydraulic fluid level, it must be visible in the
right gauge (Item 1) [A].
N–11959
If fluid level is not correct, remove the reservoir cap [B].

B

N–11960
Remove and inspect the fill neck screen. Install the

screen [C]. C
Add the correct fluid to the reservoir until it shows in the
sight gauge. (See Fuel, Coolant and Lubricants Chart,
Page 8–8.)
Install the reservoir cap.
N–11961
Replacement of the Hydraulic Filter

D
service interval.
Open the engine cover.
Use a filter wrench and remove the filter element Item 1)
[D].
Install the new filter element and hand tighten only. 1
Start the engine. Run the machine through the hydraulic
functions. Stop the engine. Check the fluid level at the
reservoir and add as needed. Check around the filter for
leaks. N–10450

HYDRAULIC SYSTEM (Cont’d)
A
Hydraulic Reservoir
service interval.
Move the upper works so the reservoir is between the
tracks at the rear of the machine. 1
Retract the dipperstick and bucket cylinders, lower the

bucket to the ground. Stop the engine.
Remove the drain plug (Item 1) [A] and drain fluid into a
container.
Install the drain plug. N–11962
Add approximately 12 gals. (45,4 L.) of fluid to the

reservoir. (See Fuel, Coolant and Lubricants Chart, Page
8–8.)
B
Run the machine through the hydraulic functions. Check
the fluid level and add as needed.
Remove the plate (Item 1) [B] to remove the oil and any
debris from the radiator/cooler area.
1

N–11964
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
C
which can result in injury or death.
W–2103–1285
Diagnostic Couplers 1
The diagnostic couplers (Item 1) [C] located on each

hydraulic pump are used to check circuit pressures.
N–11965

USING A BOOSTER BATTERY (JUMP STARTING)
A
Procedure 2
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! Make sure the control lock is
engaged.
The key switch must be in the OFF position.
The booster battery must be 12 volt.
1
Connect the end of the first cable to the positive (+)
terminal of the booster battery. Connect the other end of
N–11953
the same cable to the positive (+) terminal (Item1) [A] of
the machine 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 machine frame (Item 2) [A].
NOTE: See Cold Starting Procedure, in Operation &

Maintenance Manual.
Keep arcs, sparks, flames and lighted tobacco
Start the engine. After the engine is running, remove the away from batteries. When jumping from
cable (Item 2) [A] connected to the frame first. booster battery make final connection

Disconnect the cable from the machine battery (Item 1) (negative) at engine frame.
[A].
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60 °F. (16°C.) 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
Damage to the alternator can occur if: injury.
W–2066–1296
• 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

LUBRICATION OF THE HYDRAULIC EXCAVATOR
A
Procedure
Lubricate the Hydraulic Excavator as specified in the
Service Schedule (Page 1–1) for the best performance of 1
the machine.
2
Always use a good quality lithium based multi–purpose 2
grease when lubricating the machine. Apply the lubricant
until extra grease shows.
Ref. Description (# of Fittings) 3
1. Blade Cylinder Rod End (1) [A].

2. Blade Pivots (2) [A].
N–10454
3. Blade Cylinder Base End (1) [A].
4. Boom Base Pivot (1) [B].
5.
6.
Boom Swing Bracket Pivot (2) [B].
Boom Cylinder Base End (1) [B].
B 4
7. Boom Swing Cylinder Rod End (1) [B].

8. Swing Circle Pinion (1) [B]. 5
9
9. Swing Shaft (1) [B].
7 6
8

5
N–11966
10. Boom Cylinder Rod End (1) [C].

11. Arm Cylinder Base End (1) [C]. C 11
10
N–11967
12.
13.
Arm Cylinder Rod End [D].
Arm Base Pivot (1) [D].
D 12
14. Bucket Cylinder Base End (1) [D].
13
14
N–11968

LUBRICATION OF THE HYDRAULIC EXCA VATOR
(Cont’d) A
Procedure (Cont’d) 16
15
Ref. Description (# of Fittings)
15. Bucket Cylinder Rod End (1) [A]. 17
16. Bucket Link Pivots (2) [A].
17. Bucket Pivots (3) [A].
N–11969
18. Swing Circle Ball Bearings (2) [B].

B
18

N–09289
19. Boom Swing Cylinder Base End (1) [C] (under

the right front of upper frame). C
19
N–11970

FINAL DRIVE CASE
231ServiceManual#6722178S/N508912000&Above–PreventiveMaintenanceSection
A
Checking Oil Level
Put the machine on a flat level surface with the plugs
positioned as shown in figure [A].
Remove the top plug (Item 1) [A]. 1
Add SAE 90 gear lube through the hole if the oil level is 2
below the hole. (See Fuel, Coolantand Lubrication Chart,
Page 8–8.)
Install and tighten the plug.
Repeat the procedure for the other side.
N–11971
Draining Final Drive Case

service interval.
Put the machine on flat level surface with the plugs
positioned as shown in figure [A].
Remove the bottom plug (Item 2) [A] and top plug (Item
1) [A].

After all the oil is removed, install and tighten the bottom
plug.
Add 0.55 quarts (0,5L) of SAE 90 gearlube to the top plug
hole. Install the plug.

HYDRAULIC SECTION
Page
Number
ACCUMULATOR/VALVE
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–50
....
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–55
....
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–46
.... HYDRAULIC
Setting The Safety Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–54 .. SYSTEM
ARM CYLINDER
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–67
...
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–66 ..
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–74 ..
AUXILIARY SELECTOR VALVE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–56
..
BLADE CYLINDER
...
BOOM CYLINDER
...

BOOM SWING CYLINDER
...
BUCKET CYLINDER
...
HYDRAULIC CONTROL VALVE (Three Spool)
...
Pressure Build–up Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–44 ..
HYDRAULIC CONTROL VALVE (Six Spool)
...
HYDRAULIC FILTER ASSEMBLY
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–63
..
HYDRAULIC PUMP
...
HYDRAULIC PUMP FLOW TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11
...
Continued On Next Page

Revised July 97
HYDRAULIC SECTION
Page
Number
HYDRAULIC RESERVOIR AND FUEL RESERVOIR
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–61
...
HYDRAULIC SERVICE INFORMATION
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3
....
JOYSTICK CONTROL CHANGE
ISO to Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–81
...
Standard to ISO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–82
...
MAIN RELIEF VALVES
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4
...
Checking the Relief Valve Pressure Settings . . . . . . . . . . . . . . . . . . . . . 2–3 .
Three–Spool Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–5 ..
Six–Spool Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5
...
OIL COOLER
...
PORT BLOCK
...

PRESSURE REDUCING VALVE WITH ACCUMULATOR
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2–45
...
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–45 ...
TWO SPEED VALVE
...

Revised July
32 97
of 340 –2–2– Service Manual
33 of 340
34 of 340
35 of 340
36 of 340
37 of 340
38 of 340
39 of 340
40 of 340
41 of 340
42 of 340
43 of 340
44 of 340
HYDRAULIC SERVICE INFORMATION
A
When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
I–2003–0888
N–12299
Description
There are three relief valves, five port relief valves, one
joystick relief valve and one unloading relief valve in the
hydraulic system.
See hydraulic schematic for relief valve locations.
NOTE: At S/N 508912381, dual pressure relief valves

were added to the six spool valve on all 231
Excavators as standard equipment. When

ever the travel levers are moved, the dual
pressure relief valves are activated and are
engaged into the high pressure range. This
increases the systems hydraulic pressure to
3000 PSI (20682 kPa) which increases the
travel motors drive torque.
MAIN RELIEF VALVES

(Six Spool Valves W/Single Pressure Relief
Valves – S/N 508912001–12380) and
(Three Spool Valves W/Single Pressure Relief
Valve – S/N 508912001 & Above)
NOTE: All three spool valves use the single pressure
relief valve.
Checking the Relief Valve Pressure Settings
Checking Relief Valves at Diagnostic Coupler can be
done by using the following tools:
MEL1355–Test Kit
MEL1355–3–5000 PSI Gauge
MEL1355–12–Coupler
NOTE: The test can be done by one person in the

operator’s seat if the hose from the kit is
used.
Install the correct coupler from the tool kit to the gauge.
The following list shows the pump and cylinder af fected
and the relief valve setting [A].
SINGLE PRESSURE
PUMP CYLINDER RELIEF VALVE SETTING
One Boom 2500 PSI (17235 kPa)
Two Arm 2500 PSI (17235 kPa)
Three Blade 2500 PSI (17235 kPa)
Stop the engine and connect the gauge to the diagnostic
coupler on the pump being tested [A].
Revised July 97
MAIN RELIEF VALVE (Cont’d)
A R.H. Main Relief
Six–Spool Valve
(With Single Pressure Relief Valves) (Cont’d)
Start the engine and run at full RPM. Warm the hydraulic
fluid to 140° F (60° C). Record the free flow reading.
Retract the cylinder shown for the pump being tested to
open the relief valve.
Record the reading.
1
Add or remove shims to the relief valve(See Below) until
the test gauge reads the relief valve setting PLUS the free
flow reading.
EXAMPLE: N–12307
Relief Valve Setting . . . . . . . . 2500 PSI (17235 kPa)
Free Flow Reading . . . . . . + 150 PSI (1034 kPa)
ACTUAL DESIRED
GAUGE READING 2650 PSI (18268 kPa)
B L.H. Main Relief
Six–Spool Valve
Repeat the procedure for each pump.

1
If the relief valves need to be adjusted, remove the
floormat, the seat, the floorboards and the swing motor
cover. (See Pages 5–1 and 5–3.)

Adjustment Procedure
To adjust the main relief valves, loosen the plug (Item 1)
[A], [B] & [C] on the relief valve.
N–13183
C Main Relief
Three–Spool Valve
Remove the plug (Item 1) [D] and the spring (Item 2) [D].
Make sure no shims are stuck to the end of the spring.
Add shims (Item 3) [D] to increase pressure or remove 1
shims (Item 3) [D] to decrease the pressure setting.
The following list is the approximate pressure change per PI–12308
shim thickness:
Shim 0.010 inches (0,25 mm) thick (896265) = 75 PSI (517 kPa)
Shim 0.020 inches (0,50 mm) thick (896264) = 200
PSI (1379 kPa) D
Shim 0.040 inches (1,01 mm) thick (896263) = 300 PSI (2069 kPa)
Check the outer relief body O–ring for damage, replace

the O–ring (79K–10) if necessary. 3
Reinstall the plug. Retest the relief valves to make sure 2
that the pressure settings are correct.
After all the relief valves have been tested and/or
adjusted, install the swing motor cover , the rear 1
floorboards, the floormat and the seat.
Check the hydraulic fluid reservoir and add fluid as
necessary. (See Page 1–9.) CD–13273

Revised July
46 97
MAIN RELIEF VALVES (Cont’d)
A
(With Dual Pressure Relief Valves) (S/N 508912381 &
Above)
2
Checking the Dual Pressure Relief Valves at 1
Diagnostic Couplers can be done by using the following
tools:
MEL1355–Test Kit
MEL1355–3–5000 PSI Gauge
MEL1355–12–Couplers
Remove the floor mat, the seat, the floorboards and the
swing motor cover. (See Pages 5–1 thru 5–3.) 3
Install the 5000 PSI pressure gauge (MEL1355–2) into N–12299

the coupler (MEL1355–12).
Install the coupler/pressure gauge onto the diagnostic
coupler (Item 1) [A] on the pump that is closest to the
B
engine.
Disconnect the four hoses that are going to the left hand
and right hand travel sections [B]. Mark the hoses for
ease of assembly.
NOTE: For safety purposes, when doing any testing
and/or adjusting of the dual pressure relief

valves, make sure that the four travel section
hoses are removed from the valve. Plug the
hoses and cap the tee fittings. This will
prevent the excavator from accidently being
moved during the pressure tests.
Install plugs into the hose ends andcap the tee fittings on CD–13212
travel section with steel caps [C].
NOTE: Make sure that the swing lock is in
engaged position. Make sure that no
the
C
unauthorized personnel are in the work area.
Start the engine.
Run the engine at high idle and warm the hydraulic fluid
to 140° F (60° C).
With the engine running at high idle and with a second
person watching the pressure gauge, record the system
back pressure on pump, section one (this isthe six spool
valve right hand side system back pressure) [A].
NOTE: The back pressure is the pressure shown on
the gauge with the engine at full RPM and all
levers in the neutral position, 150–250 PSI PI–13213
(1034–1724 kPa) is normal.
Raise the boom. Curl the bucket until the bucket cylinder
is fully extended and continue to apply hydraulic pressure
until the relief valve opens. Record the pressure gauge
reading. Repeat this five times to get the average
pressure reading (this is the right hand side, low pressure
setting of the dual pressure relief valve).
Lower the boom to the ground.
Move the RIGHT HAND travel lever forward and hold in
the forward position until the relief valve opens. Record
the pressure gauge reading. Repeat this five times to get
the average pressure reading (this is the right hand side,
high pressure setting of the dual pressure relief valve).
Stop the engine.
Revised July 97
A
Above)
2
Move the coupler/pressure gauge onto the diagnostic 1
coupler at the center pump section (Item 2) [A].
Start the engine.
With the engine running at high idle, record the system
back pressure on pump, section two (this is the six spool
valve left hand side system back pressure) [A].
Raise the boom. Move the arm towards the excavator 3
until the arm cylinder is fully extended and the relief valve
N–12299
opens. Record the pressure gauge reading. Repeat this
five times to get the average pressure reading (this is the
left hand side, low pressure setting, of the dual pressure
relief valve).
Move the LEFT HAND travel lever forward and hold in the
forward position until the pressure relief valve opens.
Record the pressure gauge reading. Repeat this five
times to get the average pressure reading (this is the left
hand side, high pressure setting, of the dual pressure

relief valve).
Stop the engine.

NOTE: For testing the three spool valve relief valve.
(See Page 2–3.)

Revised July
48 97
A
Above)
To determine the actual relief valve pressure setting, the
system back pressure must be added to the factory
specified relief valve setting. Do the following calculation
to determine the correct pressure setting range. (This
must be done for both the right and left side six spool relief
valves and the three spool relief valve.)
Low Pressure Setting: The specified relief valve setting is
2500–2650 PSI (17235–18269 kPa) plus (+) the system
back pressure, will equal (=) the correct low pressure
setting range.
CD–13202
EXAMPLE:
Specified Pressure Range; Measured Back Pressure; Correct Pressure Range
Spring
2500 PSI (17235 kPa)
2650 PSI (18269 kPa) + 200 PSI (1379 kPa) =
2700 PSI (18613 kPa)
2850 PSI (19647 kPa) B Outer Body
High Pressure Setting: The specified relief valve setting

is 3000–3150 PSI (20682–21716 kPa) plus (+) the
system back pressure, will equal (=) the correct high
pressure setting range.
B–13843
EXAMPLE:
Specified Pressure Range; Measured Back Pressure; Correct Pressure Range

3000 PSI (20682 kPa) 3200 PSI (22060 kPa)
3150 PSI (21716 kPa) + 200 PSI (1379 kPa) = 3350 PSI (23094 kPa)
If the low and high pressure recorded (at the pump gauge)
fall within the correct pressure range on all the pump
sections, then the four hoses can be reinstalled onto the CD–13214
control valve. Install the swing motor cover , the rear
floorboard, the seat and the floormat.
If the pressures recorded do not fall within the correct
pressure range, the relief valve(s) must be adjusted, do
the following procedure:
Six Spool Dual Pressure Relief Valve Procedure:
Remove the tube(s) from the relief valve(s) [A].
Plug the tube(s).
NOTE: Adjust the high pressure relief valve(s) first
(if needed) and then adjust the low pressure
relief valve(s).
High Pressure Adjustment Procedure (Six Spool

Only):
Remove the outer portion of the relief valve body and the
spring [B].
NOTE: Make sure that no shims are stuck to the end

of the spring when it is removed from the
relief valve. If shims are attached, remove
them and install them back onto the relief
valve poppet.

Revised July 97
A Poppet
Shims
Above) (Cont’d)
Add shims to increase the pressure or remove shims to
decrease the pressure setting from the relief valve poppet
[A]. Poppet B–13844
The following list is the approximate pressure change per
shim thickness:
Shim
Shim 0.010 inches (0,25 mm) thick (896265) = 75 PSI
(517 kPa)
(1379 kPa)
CD–13215
(2069 kPa)
Check the outer relief body O–ring for damage, replace
the O–ring (79K–10) if necessary.
B
Install the spring and outer portion of the relief valve [B].
Tighten the outer portion of the relief valve to 20 ft.lbs. (27
Nm) torque.

DO NOT over tighten.
CD–13214

Revised July
50 97
A
Above)
Install the tubes onto the adapters.
Install the coupler/pressure gauges onto the pump
section (Item 1) [A] closest to the engine for checking the
right hand relief valve and onto the center (Item 2) [A]
pump section for checking the left hand relief valve.
Start the engine and warm the hydraulic fluid to 140 °F
(60°C).
With the engine running at high idle, retest the high
pressure relief settings by pushing the right hand or the N–12299
left hand travel levers forward and record the pressure
gauge readings when the relief valves open. Repeat the
check five times to get the average relief valve pressure
settings. B
If the settings are correct (per information on Page 2–5),
the low pressure settings of the relief valve can now be
set. If the pressure settings are not correct, repeat the
steps needed to add or remove shims as necessary until
pressure settings are correct.
Low Pressure Adjustment Procedure (Six Spool

Only):
NOTE: Make sure the high pressure setting(s) are
correct before adjusting the low pressure
setting(s).
Remove the tube(s) from the relief valve adapter(s) [B]. CD–13202
Plug the tube(s).
Install the coupler/pressure gauge ontothe pump section
(Item 1) [A] closest to the engine for checking the right
hand relief valve and/or the center (Item 2) [A] pump
section for checking the left hand relief valve [A].
Start the engine and warm the hydraulic fluid to 140 ° F
(60°C).
Raise the boom.
Run the engine at high idle.
If testing the right hand relief valve, curl the bucket and
extend the cylinder until the low pressure relief valve
opens and record the pressure reading. Repeat this five
times to get the average pressure reading.
If testing the left hand relief valve, extendthe arm cylinder
until the low pressure relief valve opens and record the
pressure reading. Repeat this five times to get the
average pressure reading.
Stop the engine.

Revised July 97
A
Above)
If relief valve adjustment is required, loosen the relief
valve jam nut [C].
Turn the adjusting screw clockwise to increase the
pressure or turn the adjusting screw counterclockwise to
decrease the pressure [D].
NOTE: Turning the adjusting screw one turn (360 °)
will change the pressure setting
approximately 700 PSI (4827 kPa).
Readjust and retest the low pressure relief valves until CD–13216
pressure settings are correct. (Per Information on Page
2–7.)
Tighten the jam nut while holding the adjusting screw from B
turning [C].
Install the tube(s) [B].
Install the four hoses onto the control valve.
After all the relief valves have been tested and/or
adjusted, install the swing motor cover , the rear

floorboards, the floormat and the seat.
Check the hydraulic fluid reservoir and add fluid as
necessary. (See Page 1–9.)
CD–13217

Revised July
52 97
HYDRAULIC PUMP FLOW TEST
A
The Hydraulic Pump Flow T est can be done by using
one of the following tools:
OEM1238–Hydraulic Tester (Shown)
OEM1239–Hydraulic Tester
Stop the engine and raise the engine cover. 3
Disconnect the outlet hose from the hydraulic pump being
tested and connect that hose to the outlet of the tester. 2
Connect the inlet hose of the tester to the pump outlet 1
fitting. (Items 1, 2 & 3) [A].
N–10597
NOTE: The tester connections will be the same for
each pump.
NOTE: Open the flow control knob (Item 1) [B] fully
to prevent pump damage.
B
NOTE: Refer to the hydraulic flow chart valve
section.
Start the engine and run at low RPM. Make sure the tester
is connected correctly. If no flow is indicated at the tester,
the hoses are connected wrong.

The pump must be tested with the hydraulic fluid at
operating temperature approximately 140°F (60°C).
1
Increase the engine speed to full RPM. W arm the
hydraulic fluid to 140 °F (60°C) by turning the restrictor
valve (Item 1) [B] until the gauge reads about 1000 PSI N–10595
(6895 kPa). Do not exceed system relief pressure. Open
the valve after oil is warm.
Record the pump free flow at high idle with restrictor valve
(Item 1) [B] fully open.
Turn the restrictor valve (Item 1)[B] until the gauge reads
2500 PSI (17235 kPa) and record the pump flow.
The rated pump flow is 9.500 GPM (35 l/min.) at 2500
RPM and at 2500 PSI (17235 kPa).
The high pressure flow should be at least 80% of free flow
.
HIGH PRESSURE FLOW (GPM)

%= X 100
FREE FLOW (GPM)
If the high pressure flow is less than 80% of free flow , it

is recommended to remove the hydraulic pump for repair
or replacement.
Repeat the testing procedure on the other pumps as
required.

Revised July 97
HYDRAULIC PUMP
A
Removal And Installation

the system. N–12301
I–2003–0888
NOTE: Mark the hoses and tubelines for correct

installation.
B
Drain the hydraulic fluid into a container.
Disconnect the pressure hoses [A].
Disconnect the inlet hoses (Item1) [B] from the hydraulic
pump.
1 2

Loosen the pump mounting bolts (Item 2) [B].
Remove the bolts.
Installation: Tighten the bolts to 13–14 ft.–lbs. (18–24
Nm) torque.
PI–12304
Parts Identification
TRIPLE GEAR PUMP
1. Plate 7
2. O–ring 2
3. Gears
4. Body
5. Seal 3 4
6. Gasket 2 8
7. End Cap 4
8. Center Body 2
2
1
3 3
5
4 4
6 1
1
2 5
5
6
6 2
2 7
5
1
D–02106

Revised July
54 97
HYDRAULIC PUMP
A
Disassembly And Assembly

the system. P–01119
I–2003–0888
Clean the external pump surfaces. Mark the pump B

sections for ease of assembly [A].
Clamp the pump in a vise with protective jaws [A].
NOTE: Do Not over tighten the vise or pump

distortion may occur.

Loosen the eight bolts from the front pump cover [A].
Nm) torque.
Remove the pump from the vise.
P–01121
Remove the eight bolts and remove the front pump cover
[B].
Remove the pump end cover (Item 1) [C], pump body
C
(Item 2) [C], drive gear (Item 3)[C], idler gear (Item 4)[C],
wear plate (Item 5) [C] and the dowel key (Item 6) [C]. 6
3
NOTE: The dowel key (Item 6) [C] must be removed
from the shaft so that the shaft can be 1 2
removed from the next pump section.
4
P–01118
Remove the adapter plate (Item 1) [D], pump body (Item

2) [D], drive gear (Item 3)[D], idler gear (Item 4)[D], wear D
plate (Item 5) [D] and the dowel key (Item 6) [D].
6
3 2
1
4
P–01120

Revised July 97
HYDRAULIC PUMP (Cont’d)
A 3
Disassembly And Assembly (Cont’d)
5
Remove adapter plate (Item 1) [A], pump body (Item 2) 1
[A], drive gear and shaft assembly (Item 3)[A], idler gear 2
(Item 4) [A] and the wear plate (Item 5) [A].
NOTE: The drive gear can be removed from the drive

shaft (Item 3) [A] but these parts are not
serviceable separately and must be replaced
as an assembly if damaged. 4
P–01122
Remove the O–ring from the two center adapter plates

and the front cover [B]. B

P–01125
Remove the gasket (Item 1) [C] and the molded O–ring

(Item 2) [C] from the two center adapter plates and the
front cover.
C 1
P–01123
Remove the gasket from the two center adapter plates

and the front cover [D]. D
P–01124

Revised July
56 97
A
Remove the O–ring from the rear cover [A].
P–01128
Clamp the front pump cover in a vise with protective jaws

and remove the shaft seal and the back–up washer [B]. B
Turn the front pump cover over and re–clamp the cover
in the vise.
Install the back–up washer into the front cover seal
opening.
NOTE: The seal is not to be installed so that it is

flush with the inner front cover flange. The
back–up washer will have some free play
between the front cover flange and the seal.
P–01129
Use a seal installation driver and install the front cover

seal to the depth of 0.220–0.250 inch (5,5–6,4 mm) from C 0.220”
the front edges of the seal opening [C]. 0.250”
B–13815
P–01126
Measure the seal depth [D].

The seal must not be pressed completely into the
D
housing.
P–01133

Revised July 97
A
Inspect for wear on the gear tooth contact points on the
internal diameters of the pump bodies [A].
P–01131
Inspect the side faces of the adapter plates for wear [B].
B

P–01127
Check all bushings for excessive wear [C].
NOTE: The bushings are not replaceable. If the

C
bushings need replacing, order a complete
adapter plate, end cover or front cover from
Melroe Parts.
Install new seals (Lubricated with oil) and reassemble

pump in reverse order.
NOTE: When installing wear plates, the wear plates

are installed so that they contact thegaskets.
The gaskets and the molded O–ring maintain
a slight amount of pressure against the wear
plate and the gears.
P–01130
After the pump has been reassembled and the bolts have
been torqued, rotate the pump shaft. The rotating torque
will be approximately 108 in.–lbs. (12 Nm) and make sure
that there is no binding.

Revised July
58 97
A

I–2003–0888
Remove the rear floor panel. (See Page 5–3.)

B
Remove the seat. (See Page 5–1.)
Remove the swing motor cover. (See Page 5–3.)
Remove the left control console. (See Page 3–2.)

Mark all the hoses for correct installation.
Disconnect the hand control lever hoses [B].
Disconnect the inlet and outlet hose from the control
valve.
CD–12302
Disconnect the hoses from the control valve [A].
Remove the three mounting bolts from the control valve
[C].
C
P–04442
Remove the control valve [D].

D
CD–12306

Revised July 97
HYDRAULIC CONTROL VALVE (Six Spool) (Cont’d)
CONTROL VALVE ASSEMBLY

(Six Spool) 3
2
1. Main Relief Valve
2. Port Relief Valve
3. R.H. Travel 1 9
4. Boom
5. Bucket 4
6. Auxiliary
7. Arm 11 2
8. L.H. Travel
9. Restrictor Location 5
10. Block Off Plate 11
11. O–rings 6
2
10 11
7
9
8 11

11
11
1
11
D–02176

Revised July
60 97
A

the system. CD–13247
I–2003–0888
Disassembly: B
Mark the valve sections for ease of assembly [A].
Remove the nuts from the valve bolts [A].
Position the valve assembly on its end and remove the
end cover from the valve.
Remove the O–rings from the side face of the valve

section [B].
NOTE: Always use new O–rings during the
assembly of the control valve.
Remove the block off disc that is located between section
five (Auxiliary) and section six (arm) [C]. CD–13248
See the following pages for the disassembly and

assembly of the individual valve sections.
C
Assembly:
Clean the side faces of the valve sections and the O–ring
glands of any contamination.
Apply grease to the O–rings and install the O–rings into
the O–ring glands [B].
Install the three bolts through the end cover and position
the end cover on its end, with the O–rings facing upwards.
Install all the valve sections onto the end cover in the
order as marked during disassembly.
CD–13249
NOTE: Make sure that the O–rings are properly
seated in the O–ring glands before installing
the sections. D
Install the block off disc between section five (Auxiliary)
and section six (Arm) [C].
Install the nuts onto the bolts, finger tight.
Set the valve assembly on a flat surface and evenly
tighten the nuts to 32 ft.–lbs. (43 Nm) torque [D].
After the nuts are properly torqued, check the exposed
spools to make sure that they move freely in and out of
the valve sections.
NOTE: If the nuts are not tightened properly , the
spools may bind in the housings. Loosen the
nuts and re–torque if spool binding occurs. CD–13250

Revised July 97
A
Right Hand Travel
Clamp the valve section in a vise with protective jaws[A].
Remove the load check plug from the valve section [A].
Installation: Tighten the load check plug to 20 ft.–lbs. (28
Nm) torque.
CD–13251
Remove the back–up ring (Item 1) [B], O–ring (Item 2)

[B], O–ring (Item 3) [B], back–up ring (Item 4)[B] and the B
O–ring (Item 5) [B] from the load check plug (Item 6)[B]. 6
Seal Installation: The back–up rings can become hard 5
and brittle in dry air conditions. For ease of installing the
back–up rings, it is recommended to remove them from 4
the seal kit and insert them and a few drops of water into 3
a sealed plastic bag. Leave them in the bag overnight, this 1
will soften the back–up rings andmake them more pliable 2

for ease of installation. If time will not permit this, the
back–up rings can be placed in hot water and allowed to 1
soften for approximately one hour before installation.
CD–13252
Remove the two bolts and lock washers and the

positioner cover from the valve [C]. C
Installation: Tighten the bolts to 10 ft.–lbs. (14 Nm)
torque.
P–01240
Install a rod through the hole in the spool

the spring retainer bolt [D].
clevis and loosen
D
NOTE: The spool spring is under pressure, use care
when removing the bolt from the spool end.
P–01241

Revised July
62 97
A
Right Hand Travel (Cont’d) 7
6 5
Remove the bolt (Item 1) [A], spring retainer (Item 2)[A],
spring (Item 3) [A], spring retainer (Item 4) [A], retainer 4
(Item 5) [A], spool wiper (Item 6) [A] and the spool seal 3
(Item 7) [A] from the valve. 2
1
Installation: Tighten the bolt (Item 1)[A] to 10 ft.–lbs. (13
Nm) torque.
NOTE: For ease of removal of the retainer (Item 5)
[A], spool wiper (Item 6) [A] and the spool
seal (Item 7) [A], push the spool into the valve P–01242
housing until the spool end is to the inside
edge of the spool seal. DO NOT scratch the
spool surfaces with any type of tool during
seal removal. B
NOTE: Early model valves used a back–up washer in
place of spool wiper (Item 6) [A] and O–ring
in place of the spool seal (Item7) [A]. Replace
the back–up washer and O–ring with the
spool wiper and spool seal.
Loosen the two bolts from the spool seal cover plate[B].

torque.
Remove the bolts (Item 1) [C], coverplate (Item 2) [C],
retainer (Item 3) [C], spool wiper (Item 4) [C] and the P–01243
spool seal (Item 5) [C] from the valve.
NOTE: For ease of removal of the retainer (Item 3) C

[C], spool wiper (Item 4) and the spool seal
(Item 5) [C], push the spool into the valve
until the tapered section of the spool is to the 4 5
inside edge of the spool seal. DO NOT
scratch the spool surface with any type of 2 3
tool during seal removal.
place of the spool wiper (Item 4) [C] and an
O–ring in place of the spool seal (Item 5) [C].
Replace the back–up washer and the O–ring
with the spool wiper and the spool seal.
1
NOTE: The spool and the valve housing are not
serviceable, they are a matched set. It is not P–01244
necessary to remove the spool from the
housing unless contamination is found in
the valve. If the spool is removed, use
extreme care not to scratch the spool surface
and do not intermix the spool and the
housing.

Revised July 97
A Seal (Installed Into
Retainer
Plate
Tool–Open End
To Outside)
Spool Wiper and Spool Seal Installation Valve Seal
Housing Washer
NOTE: Spool seal installation tool (MEL1421) is
available from OTC Tool and is necessary for Counterbore
proper spool seal installation.
Clean the valve housing seal gland of any contamination.

Spool
Apply clean oil to the clevis end of the spool surface.
Install the spool seal into the tool, with the open end of the
seal facing out [A]. Be sure the seal is completely inside Installation Tool B–13930
the tool.
Apply oil to the inner diameter of the seal.
Carefully push the tool (with the spool seal installed) over
the end of the spool and into the counterbore of the valve
housing [A].
Hold the tool tight against the valve housing and hit the
end of the tool with the palm of the hand, driving the seal
into the spool seal gland.

Remove the tool and inspect the spool seal to make sure
that the seal is not rolled or twisted.
Apply oil to the spool wiper and position it onto the end of
the spool with the wiper lip facing out. Position the retainer
plate over the wiper lip and push the wiper and retainer
plate onto the spool until the retainer plate is flush into the
counterbore of the valve housing.
Install the cover plate and bolts.
Repeat this procedure for the positioner end of the spool.
Install the positioner components in reverse order from
which they were removed.

Revised July
64 97
A
Boom, Bucket and Arm
Remove the relief valve assembly from the valve section
(for Boom, Bucket and Arm) and/or the load check plug
assembly (for Bucket only) [A].
NOTE: Do Not intermix the relief valve assemblies
that are of different pressure settings. Mark
the end of the valve section and the relief
valve to make sure it is installed into the
same
end of the valve section. CD–13253
Installation: Tighten the relief valve and/or the load

check plug assembly to 20 ft.–lbs. (27 Nm) torque. B
Relief Valves
Remove the poppet retainer, spring and the poppet from
the relief valve cavity in the end of the valve section [B].

NOTE: Use care when removing the spring, the
spring can drop into the spool gland.
CD–13254
Clamp the relief valve into a vise with protective jaws and
loosen the end plug [C]. C
Installation: Tighten the relief valve plug to 14 ft.–lbs. (19
Nm) torque.
Remove the poppet (Item 1) [D], spring (Item 2) [D],

back–up rings (Item 3) [D], O–ring (Item 4) [D], poppet
retainer (Item 5) [D], spring (Item 6) [D], poppet (Item 7)
[D], O–ring (Item 8)[D], back–up ring (Item 9)[D], O–ring
(Item 10) [D], relief housing (Item 1 1) [D], relief poppet
(Item 12) [D], shims (Item 13) [D], spring (Item 14) [D],
O–ring (Item 15) [D] and end plug (Item 16) [D]. CD–13255
NOTE: Check the poppets (Item 1, 7 & 12) [D] for

surface wear and indentations. If the poppet
wear is excessive, order a new relief valve
D 12
16
assembly from Melroe Parts Operations. The
11
15
seal on the relief poppet (Item 12) [D] is not 10 14
serviceable, if the seal is damaged, order a 9
new relief valve assembly.
13
8
Seal Installation: The back–up rings can become hard
and brittle in dry air conditions. For ease of installing the 4
back–up rings, it is recommended to remove them from 3 7
the seal kit and insert them and a few drops of water into 2 6
a sealed plastic bag. Leave them in the bag overnight, this 1 5
will soften the back–up rings andmake them more pliable
for ease of installation. If time will not permit this, the 3
back–up rings can be placed in hot water and allowed to
soften for approximately one hour before installation. CD–13256

Revised July 97
Disassembly and Assembly (Cont’d)
A 5
3
Boom, Bucket and Arm (Cont’d)
Load check plug assembly. 7
1 2 6
Remove the poppet (Item 1) [A], spring (Item 2) [A], 1
back–up washer (Item 3) [A], O–ring (Item 4) [A], O–ring
(Item 5) [A], back–up washer (Item 6) [A], O–ring (Item 4
7) [A] from the load check plug.
NOTE: Check the poppet (Item 1)[A] for surface wear
and indentations. If the poppet wear is
excessive, order a new load check relief valve
assembly from Melroe parts operations. CD–13257

and brittle in dry air conditions. For ease of installing the B
back–up rings, it is recommended to remove them from
the seal kit and insert them and a few drops of water into
a sealed plastic bag. Leave them in the bag overnight, this

Clamp the valve section in a vise with protective jaws[B].
Loosen the four bolts from the positioner cover [B].
Installation: Tighten the bolts to 4–6 ft.–lbs. (6–8 Nm)
torque.
P–01237
Remove the bolts (Item 1) [C], lock washers (Item 2) [C],

washers (Item 3) [C], positioner cover (Item 4) [C] and
seal (Item 5) [C] from the valve section.
C
1
5
4
3
2
P–01239
Remove the four bolts, lock washers, washers and the

positioner cover form the opposite end of the valve
section.
D
torque.
Install a rod through the clevis end of the spool and loosen
the bolt in the opposite end of the spool [D].
Do Not grip the spool with any type of tool.
NOTE: The spool springs are under pressure, use

care when removing the bolt from the spool
end.
P–01236

Revised July
66 97
A
Disassembly And Assembly (Cont’d) 7 6
Boom, Bucket and Arm (Cont’d) 5 4
Remove the bolt (Item 1)[A], washer (Item 2) [A], spacer 3 2
(Item 3) [A], spring (Item 4)[A], spring (Item 5)[A], spring
retainer (Item 6) [A] and the seal (Item 7) [A] from the 1
valve section.
Installation: Put LOCTITE #272 on the threads of the
bolt (Item 1) [A] and tighten the bolt to 10–12 ft.–lbs.
(14–16 Nm) torque.
Check the seal cavity in the valve housing for
contamination and clean as necessary. P–01238
NOTE: The seal and the valve housing are not

serviceable, they are a matched set. It is not
B
and do not intermix the spool and housing. 1
Clean the valve housing seal cavities of any

contamination. 2

Apply oil to the seals and assemble in reverse order.
The boom and arm assembly use a one way restrictor
(Item 1) [B] and spring (Item 2) [B] installed in the B port
(rear port) of the valve section. CD–13258
Check the restrictor orifice for contamination and install.

Revised July 97
A
Auxiliary
Remove the load check plug assembly from the valve
section [A].
Nm) torque.
CD–13251
Remove the poppet (Item 1) [B], spring (Item 2) [B],

back–up ring (Item 3) [B], O–ring (Item 4) [B], O–ring B 5
(Item 5) [B] back–up ring (Item 6) [B] and the O–ring
(Item 7) [B] from the load check plug (Item 8) [B]. 3
8
and brittle in dry air conditions. For ease of installing the 1 2
back–up rings, it is recommended to remove them from 6
the seal kit and insert them and a few drops of water into 1

will soften the back–up rings andmake them more pliable 4
CD–13257
Remove the two bolts and lock washers and the

positioner cover from the valve [C]. C
torque.
P–01240

the spring retainer bolt [D].
clevis and loosen
D
P–01241

Revised July
68 97
A
Auxiliary (Cont’d) 7 6
Remove the bolt (Item 1) [A], spring retainer (Item 2)[A], 4
spring (Item 3) [A], spring retainer (Item 4) [A], retainer 5
(Item 5) [A], spool wiper (Item 6) [A] and the spool seal
3
2
(Item 7) [A] from the valve. 1
Nm) torque.
[A], spool wiper washer (Item 6) [A] and the
spool seal (Item 7) [A], push the spool into P–01242
the valve housing until the spool end is to the
inside edge of the seal. Do Not scratch the
spool surfaces with any type of tool during
seal removal. B
place of the spool wiper (Item 6) [A] and an
O–ring in place of the spool seal (Item 7) [A].
with the spool wiper and spool seal.

torque.
Remove the bolts (Item 1) [C], coverplate (Item 2) [C],
retainer (Item 3) [C], spool wiper (Item 4) [C] and the P–01243
spool seal (Item 5) [C] from the valve.
NOTE: For ease of removal of the retainer (Item 3) C

[A], back–up washer (Item 4) [A] and the
O–ring (Item 5) [A], push the spool into the
valve until the tapered section of the spool is
to the inside edge of the O–ring. Do Not
scratch the spool surface with any type of
tool during O–ring removal.

O–ring in place of the spool seal (Item 7) [A]. 5
with the spool wiper and spool seal. 4
3
1 2
NOTE: The spool and the valve housing are not P–01244
the valve, If the spool is removed, use
housing.

Revised July 97
A Seal (Installed Into Retainer
Plate
Disassembly And Assembly (Cont’d) Tool–Open End
Valve To Outside)
Spool Seal and Spool Wiper Installation Housing Seal
Washer
NOTE: Spool seal installation too (MEL1421) is

Spool
seal facing out [A]. Be sure the seal is completely inside Installation Tool
the tool. B–13930

housing [A]. Hold the tool tight against the valve housing
and hit the end of the tool with the palm of the hand,
driving the seal into the spool seal gland.


Revised July
70 97
A
Left Hand Travel
Remove the relief valve from the spool end of the valve
section and/or the load check plug from the positioner end
of the valve section [A].
Installation: Tighten the relief valve and/or the load
check plug to 20 ft.–lbs. (27 Nm) torque.
Relief Valve (single pressure relief valve) CD–13259
Clamp the relief valve into a vise with protective jaws and
loosen the end plug [B]. B
Installation: Tighten the relief valve plug to 14 ft.–lbs. (19
Nm) torque.
Remove the back–up rings (Item 1) [C], O–ring (Item 2)

[C], O–ring (Item 3)[C], back–up ring (Item 4)[C], O–ring
(Item 5) [C], relief housing (Item 6)[C], relief poppet (Item

7) [C], shims (Item 8) [C], springs (Item 9) [C], O–ring
(Item 10) [C] and the end plug (Item 11) [C].
NOTE: Check the relief poppet (Item 6) [C] for

surface wear and indentation. If damage is
found, order a new relief valve assembly from CD–13260
Melroe Parts operations. The seal on the
relief poppet (Item 6) [C] is not serviceable, if
the seal is damaged, order a new relief valve
assembly from Melroe parts.
C 8
7 11
and brittle in dry air conditions. For ease of installing the 9
a sealed plastic bag. Leave them in the bag overnight, this 3
for ease of installation. If time will not permit this, the 1
back–up rings can be placed in hot water and allowed to 6
5
NOTE: The relief valve pressure setting must be 4
checked and/or readjusted after the valve 2
assembly has been reassembled. (See Page CD–13261
2–3 for information on testing and setting the
relief pressure.)
Load Check Plug Assembly
D 5
3
Remove the poppet (Item 1) [D], spring (Item 2) [D], 8
back–up washer (Item 3) [D], O–ring (Item 4) [D], O–ring
(Item 5) [D], back–up washer (Item 6) [D], O–ring (Item 7
7) [D] from the check plug housing (Item 8) [D]. 1 2 6
1
NOTE: Check the poppet (Item 1) [D] for surface wear
and identations. If damage is found, order a
new load check plug assembly from Melroe 4
Parts Operations.
See Seal Installation information above for installing
back–up rings.
CD–13257

Revised July 97
231ServiceManual#6722178S/N508912000&Above–HydraulicSystemSectionPart1of3
A
Left Hand Travel (Cont’d)
10 9 8
Clamp the valve section in a vise with protective jaws.
7 6
Remove the two bolts (Item 1) [A], lock washers (Item 2)
[A], and the positioner cover (Item 3) [A]. 5

torque. 3
Install a rod through the hole in the spool clevis and
remove the spring retainer bolt (Item 4) [A], spring 2 1 4
retainer (Item 5) [A], spring (Item 6) [A], spring retainer P–01242
(Item 7) [A], retainer (Item 8) [A], spool wiper (Item 9)[A]
and the spool seal (Item 10) [A].
NOTE: The spool spring is under pressure, use care B
Nm) torque.
seal (Item 10) [A], push the spool into the

valve housing until the spool end is to the
spool surface with any type of tool during
seal removal.
NOTE: Early model valves used a back–up washer in P–01243

O–ring in place of the spool seal (Item 10)[A].
with the spool wiper and spool seal. C
Loosen the two bolts from the spool seal coverplate [B].
4 5
Installation: Tighten the bolt to 10 ft.–lbs. (13 Nm)
torque. 2 3
Remove the bolts (Item 1) [C], cover plate (Item 2) [C],

retainer (Item 3) [A], spool wiper (Item 4) [C] and the
spool seal (Item 5) [A] from the valve.

[C], spool wiper (Item 4) [C] and the spool
seal (Item 5) [C], push the spool into the valve
1
until the tapered section of thespool is to the P–01244
seal removal.
with the spool wiper and spool seal.
housing.

Revised July
72 97
A Seal (Installed Into
Tool–Open End
Retainer
Plate
Valve To Outside)
Spool Seal and Spool Wiper Installation Seal
Housing
Washer
NOTE: Spool Seal installation tool (MEL1421) is
Spool
seal facing out [A]. Be sure the seal is completely inside Installation Tool
the tool. B–13930

Carefully push the tool (with the seal installed) over the
end of the spool and into the counterbore of the valve


Revised July 97
A
End Cover – Supply (With Single Pressure Relief
Valve)
Clamp the end cover in a vise with protective jaws [A].
Remove the relief valve from the end cover [A].
P–01230
The relief valve O–ring and back–up ring usually remain

inside the end cover cavity when the relief valve is
removed. Remove the O–ring from the end cover [B].
B

P–01232
Clamp the relief valve housing in a vise and loosen the

end plug [C]. C
P–01234
Remove the end plug (Item 1) [D], O–ring (Item 2) [D],

spring (Item 3) [D], shim(s) (Item 4) [D], poppet assembly D 3
1
(Item 5) [D], relief housing (Item 6) [D], O–ring (Item 7)
[D], back–up washer (Item 8) [D] and the O–ring (Item 9)
[D].
5
NOTE: The poppet (Item 5) [D] has an O–ring and a
back–up ring which are not serviceable. If 7
these components are damaged, order a new 9 2
relief valve assembly from Melroe Parts
Operations. 4
NOTE: The relief valve pressure setting must be

assembly has been reassembled. (See Page 8
relief pressure.) P–01231

Revised July 97340
74 of –2–32– Service Manual
A
End Cover
[A].
Remove the power beyond sleeve from the end cover
Installation: Tighten the power beyond sleeve to 20
ft.–lbs. (27 Nm) torque.
CD–13262
Remove the back–up ring (Item 1) [B] & [C] and the
O–ring (Item 2) [B] & [C] from the end cover cavity. B
NOTE: These parts remain inside the end cover
housing when the power beyond sleeve is
removed.

2
1
CD–13263
Remove the O–ring (Item 1) [C], back–up washer (Item

2) [C], O–ring (Item 3) [C] from the power beyond sleeve C
(Item 4) [C].
3
4
1
2
CD–13264

Revised July 97
HYDRAULIC CONTROL VALVE (Three Spool)
A
The Three Spool Control Valve contains two valves, a
2500 PSI (17235 kPa) Main Relief Valve and a 200 PSI
Pressure Build–up Valve.
After engine start–up, the pressure builds in the system
to charge an accumulator and a 200 PSI the Pressure 1
Build–up Valve opens and allows excess oil to return to
tank.
CD–12309
B
the system.
I–2003–0888

Remove the center floor panel. (See Page 5–2.)
Remove the front floor panel. (See Page 3–14.)
Mark all hoses for correct installation.
CD–12310
Remove the cotter pin (Item 1) [A] and linkage pin from
the boom swing spool.
C
Remove the lock nuts (Item 2)[A] and bolt from the blade
spool.
1
Remove the hoses from the control valve [B].
Remove the two hand control hoses (Item 1)[C] and inlet
and outlet hoses from the control valve.
1
CD–12311
Remove the three mounting bolts from the control valve

[D].
D
Remove the control valve.
CD–12312

Revised July 97340
HYDRAULIC CONTROL V ALVE (Three Spool)
(Cont’d)
CONTROL VALVE ASSEMBLY (Three Spool) 5
1. Pressure Build–Up Valve

2. Boom Swing 7
3. Blade
4. House Swing Motor
5. Main Relief Valve
6. Lock Valve (4)
7. Load Check Valve (2)
6
4
7

6
2 2
1 C–03295

Revised July 97
(Cont’d) A

ports to keep dirt out. Dirt can quickly damage P–01225
the system.
I–2003–0888
B
Disassembly
Mark the valve sections for ease of assembly [A].
Remove the nuts from the valve bolts [A].
Position the valve assembly on its end and remove the
end cover from the valve bolts [B].

Remove the O–rings from the side face of the valve
section [C].
NOTE: Always use new O–rings during the

assembly of the control valve.
P–01229
Remove the remaining valve section and O–rings.
See the following pages for the disassembly and
assembly of the individual valve sections.
C
Assembly
Clean the side faces of the valve sections and the O–ring
glands of any contamination.
Apply grease to the O–rings and install the O–rings into
the O–ring glands.
Install the three bolts through the end cover and position
the end cover on its end, with the O–rings facing upwards.
Install all the valve sections onto the end cover in the P–01228
order as marked during disassembly.
NOTE: Make sure that the O–rings are properly D

seated in the O–ring glands before installing
the sections.
Install the nuts onto the through bolts finger tight.
Set the valve assembly on a flat surface and evenly
tighten the nuts to 32 ft.–lbs. (43 Nm) torque [D].
After the nuts are properly torqued, check the exposed
spools to make sure that they move freely in and out of
the valve sections.
NOTE: If the nuts are not tightened properly , the
spools may bind in the housings. Loosen the
nuts and re–torque, if the spool binding P–01226
occurs.
Revised July 97340
(Cont’d) A
House Swing Section
Remove the load check plug from the valve section [A].
Nm) torque.
P–01235
Remove the poppet (Item 1) [B], spring (Item 2) [B],

back–up washer (Item 3) [B], O–ring (Item 4)[B], O–ring
(Item 5) [B], back–up washer (Item 6) [B] and O–ring
B 5
(Item 7) [B] from the load check plug (Item 8) [B]. 3
8
NOTE: Check the poppet (Item 1) [B] for surface wear
and indentation. If the poppet wear is 7
excessive, order a complete load check plug 1 2 6
assembly from Melroe Parts Operations. 1

4
for ease of installation. If time will not permit this, the CD–13257
C
Loosen the four bolts from the positioner cover [C].
P–01237
Remove the bolts (Item 1) [D], lock washers (Item 2) [D],

washers (Item 3) [D], positioner cover (Item 4) [D] and D
seal (Item 5) [D] from the valve.
Remove the four bolts, lock washers, washers and the
position cover from the opposite end of the valve section. 4 5

torque.
1
3
2
P–01239

Revised July 97
(Cont’d) A
House Swing Section (Cont’d)
Install a rod through the clevis end of the spool and loosen
the bolt in the opposite end of the spool [A].
Do Not grip the spool with any type of tool.
NOTE: The spool springs are under pressure, use

care when removing the bolt from the spool
end.
P–01236
Remove the bolt (Item 1)[B], washer (Item 2) [B], spacer

(Item 3) [B], spring (Item 4)[B], spring (Item 5)[B], spring B
retainer (Item 6) [B] and the seal (Item 7) [B] from the 7
valve section. 6
5
Installation: Install LOCTITE #242 to the threads of the 4 3
bolt (Item 1) [B] and tighten the bolts to 10–12 ft.–lbs.
(14–16 Nm) torque. 2
1
Check the seal cavity in the valve housing for

contamination and clean as necessary.

housing unless contamination is found in P–01238
and do not intermix the spool and housings.
Clean the valve housing seal cavities of any

contamination.
Apply oil to the seals and assemble in reverse order.

Revised July 97340
(Cont’d) A
Blade and Boom Swing Section
Remove the check valve assembly fromthe valve section
[A].
Installation: Tighten the check valve assembly to 20
P–01233
Clamp the check valve in a vise with protective jaws and

B
loosen the check valves [B].
Installation: Tighten the check valve to 14 ft.–lbs. (62
Nm) torque.

CD–13265
Remove the check valve (Item 1)[C], O–ring (Item 2) [C],

spring (Item 3) [C] and ball (Item 4) [C] from the check
C 3 1
valve plug (Item 5) [C]. 4
5
Remove the back–up ring (Item 6)[C], O–ring (Item 7)[C]
and the O–ring (Item 8) [C] from the check valve plug 8
(Item 5) [C].
7
Clean and inspect all the parts. If any of the check valve 6
assemblies parts are damaged, order a new check valve 2
assembly from Melroe Parts.

back–up rings, it is recommended to remove them from CD–13266
for ease of installation. If time will not permit this, the D
Remove two bolts and lock washers and the positioner

cover [D].
torque.
P–01240

Revised July 97
(Cont’d) A
7
Blade and Boom Swing Section (Cont’d) 6
clevis and loosen 5 4
the spring retainer bolt. 3
2
when removing the bolt from the spool end. 1

Nm) torque.
Remove the bolt (Item 1) [A], spring retainer (Item 2)[A], P–01242
spring (Item 3) [A], spring retainer (Item 4) [A], retainer
(Item 5) [A], spool wiper (Item 6) [A], and the spool seal
(Item 7) [A] from the valve.
B
seal (Item 7) [A], push the spool into the valve
housing until the spool end is to the inside
edge of the seal. Do Not scratch the spool
surface with any type of tool during seal
removal.

O–ring in place of the spool seal (Item 7) [A].
Replace the back–up washer and O–ring with
the spool wiper and spool seal.
P–01243
torque. C
Remove the bolts (Item 1) [C], cover plate (Item 2) [C],
retainer (Item 3) [C], spool wiper (Item 4) [C] and the
spool seal (Item 5) [C] from the valve. 5
3 4
2
[C], spool wiper (Item 4) [C] and the spool
seal (Item 5) [C], push the spool into the valve
until the tapered section of thespool is to the
seal removal. 1
NOTE: Early model valves used a back–up washer in P–01244
with the spool wiper and the spool seal.
housing.

Revised July 97340
(Cont’d) A Seal (Installed Into Retainer
Tool–Open End Plate
Disassembly And Assembly (Cont’d) To Outside)
Valve
Housing Seal
Spool Seal and Spool Wiper Installation Washer
NOTE: Spool Seal installation tool (MEL1421) is Counterbore
available from OTC Tool and is necessary for

Spool
seal facing out [A]. Be sure the seal is completely inside Installation Tool B–13930
the tool.


Revised July 97
(Cont’d) A
Disassembly And Assembly (Cont’d
)
End Cover – Supply
Remove the relief valve from the end cover [A].
P–01230
The relief valve O–ring and back–up ring usually remains

inside the end cover cavity when the relief valve is
removed. Remove the O–ring from the end cover [B].
B

P–01232
Clamp the relief valve housing in a vise and loosen the

end plug [C]. C
P–01234
Remove the end plug (Item 1) [D], O–ring (Item 2) [D],

spring (Item 3) [D], shim(s) (Item 4) [D], poppet assembly
(Item 5) [D], relief housing (Item 6) [D], O–ring (Item 7) D 1
[D], back–up washer (Item 8) [D] and the O–ring (Item 9) 3
[D].
5
NOTE: The poppet (Item 5) [D] has an O–ring and a
back–up ring which are not serviceable. If
these components are damaged, order a new 7 2
relief valve assembly from Melroe Parts 9
Operations. 4
NOTE: The relief valve pressure setting must be
assembly has been reassembled. (See Page 8
relief pressure.) P–01231

Revised July 97340
(Cont’d) A
End Cover
Remove the pressure build–up valve assembly from the
end cover [A].
Installation: Tighten the pressure build–up valve to
18–22 ft.–lbs. (24–30 Nm) torque.
CD–13267
Pry the cap loose from the end of the pressure build–up
valve assembly [B]. B
Clamp the pressure build–up valve in a vise and loosen
the end plug [B].
Installation: Tighten the plug to 18–22 ft.–lbs. (24–30
Nm) torque.

CD–13269 CD–13268
Clamp the end plug into the vise and loosen the poppet
seat [C]. C
Installation: Put LOCTITE #242 on the threads of the
poppet seat and tighten to 4–6 ft.–lbs. (6–8 Nm) torque.
Do Not allow LOCTITE to contact any of the components
during assembly of the poppet seat.
CD–13270
Remove the snap ring (Item 1) [D], screen (Item 2) [D],

snap ring (Item 3) [D], O–ring (Item 4) [D], O–ring (Item D 14
16
5) [D], housing (Item 6) [D], poppet (Item 7) [D], spring 13 15
(Item 8) [D], O–ring (Item 9) [D], back–up ring (Item 10) 12
[D], poppet seat (Item 1 1) [D], poppet (Item 12) [D],
poppet retainer (Item 13) [D], spring (Item 14) [D], pin 11 21
(Item 15) [D], O–ring (Item 16) [D], pressure adjusting 10 20
screw (Item 17) [D], O–ring (Item 18) [D], end plug (Item 9 19
19) [D], jam nut (Item 20) [D] and cap (Item 21) [D]. 18
5 17
4
NOTE: The pressure build–up valve must be 2 3
readjusted after the valve has been 8
reassembled. See next page for adjustment 1 7
procedure.
6
CD–13271

Revised July 97
(Cont’d) A
3
Pressure Build–up Valve Adjustment Procedure
Pressure build–up valve set at . . . 200 PSI (1379 kPa) 2
The pressure build–up valves function is to create 200

PSI (1379 kPa) back pressure in order the charge the
accumulator.
To test the pressure build–up valves pressure setting,
disconnect the inlet tube (Item 1) [A] from the elbow on
the Three Spool Control Valve. Remove the elbow from 1
the valve. Install a tee (Item 2) [A] (21K–7) into the valve
and reinstall the inlet tube (Item 1) [A] onto the tee.
B–13911
Install a pressure gauge (5000 PSI, 34482 kPaminimum)
(Item 3) [A] onto the tee.
Start the excavator.
B
Warm the hydraulic fluid to 140°F (60°C).
Run the engine at high idle and record the pressure gauge
reading. If the build–up valve needs to be reset, pry fofthe
end cap from the build–up valve [B].
Loosen the adjusting screw jam nut [C].

Turn the adjusting screw clockwise to increase the Pry Off
pressure or counterclockwise to decrease the pressure The End
[C]. Cap
When the pressure gauge reading is correct, tighten the B–13910
jam nut while holding the adjusting screw from turning.
Stop the engine. C
Remove the pressure gauge and the tee.
Reinstall the elbow, previously removed, and install the
tube to the elbow.
Jam Nut
Turn
Adjusting
Screw
B–13909

Revised July 97340
PRESSURE REDUCING V ALVE WITH
ACCUMULATOR A
The Pressure Reducing valve body contains two valves,
the Pressure Reducing valve and a Safety Relief valve.
The valve body is connected to the accumulator.

The pressure reducing valve maintains approximately
363 PSI to supply oil to the joysticks for activating the
control valve spools.
The accumulator provides short term reserve pressure
for joystick function with engine off.
CD–12313


the system.
I–2003–0888

Mark the hoses for correct installation. CD–12314
Remove the two mounting bolts from under the swing

frame [A].
Remove the hoses and tubelines from the reducingvalve
[B].
1. Accumulator
2. Pressure Reducing Valve – 363 PSI(2500kPa)
3. Valve Body
4. Safety Valve – 508 PSI (3499 kPa)
5. Spool
2
1
4
5
C–03279

Revised July 97
ACCUMULATOR/VALVE
A
Disassembly
1
Clean the outside of the valve. 2
Disassemble the valve in a clean area.
Use a vise with protective jaws to clamp the valve body.
Remove the accumulator (Item 1) [A] and seal (Item 2)
[A].
NOTE: The accumulator does not need to be

discharged before removal.
P–08148
Remove the adaptor (Item 1) [B].

B

P–08149
Remove the O–ring (Item 1) [C] from the adapter.

C
1
P–08154
Remove the spring (Item 1)[D] and seat (Item 2)[D] from
the spool. D
NOTE: Be careful when removing the seat and spool
so as not to scratch the polished surfaces.
Scratches in the polished surface will cause
internal leakage. 2
1
P–08151

Revised July 97340
ACCUMULATOR/VALVE (Cont’d)
A
Disassembly (Cont’d)
° bend on the
Using two pieces of 0.090 inch wire with a 90
end, remove the spool by inserting the wires through the
center orifice and engaging two of the ports [A].
P–08152
Remove the spool by pulling straight up on the wires[B].

B

P–08153
Remove the O–ring (Item 1) [C] from the spool.

C
1
P–08166
Remove the copper seal (Item 1)[D] from the valve body.
D
P–08155

Revised July 97
A
2
Cut and remove the wire seal (Item 1) [A].
3
Loosen the locknut (Item 2) [A] and remove the adjusting
screw (Item 3) [A].
NOTE: The safety relief valve must be reset to the

correct pressure setting if it is removed from
the valve body.
1
P–08156
Remove the spring (Item 1) [B] and valve (Item 2) [B].

B
2
1

P–08157
Remove the plug (Item 1)[C] and copper washer from the
accumulator end of the valve body. C
P–08158
Remove the spool from the valve body [D].

D
P–08159

Revised July 97340
A
Remove the plug (Item 1) [A] and washer (Item 2) [A]
from the adjustment end of the valve body.
P–08160
Remove the shim (Item 1) [B], spring (Item 2) [B] and

spring seat (Item 3) [B] from the valve body. B
2 3

P–08161
Remove the plug (Item 1) [C], washer (Item 2) [C] and

check ball (Item 3) [C] from one side of the valve body. C
2
1
3
P–08162
Remove the plug (Item 1) [D] and washer from the

opposite side of the valve body.
D
P–08150

Revised July 97
A 1
Remove the plug (Item 1)[A] and washer from the bottom
of the valve body.
Assembly
Before assembly:
Clean all parts in solvent and drywith compressed air.
Inspect all valves, seats and spools for wear.
P–08163
Install the bottom plug (Item 1) [A] and a new washer in
the bottom of the valve body.
B
Install the side plug (Item 1) [B] and a new washer in the
side of the valve body.

P–08150
Install the check ball (Item 1) [C] into the valve body.
Install a new washer (Item 2)[C] and plug (Item 3)[C] into
C
the valve body.
2
3
1
P–08162
Install the spring seat (Item 1)[D] , spring (Item 2)[D], and
spring shim (Item 3) [D] into the valve body. D
1
2
3
P–08161

Revised July 97340
A
Assembly (Cont’d)
Install the new washer (Item 1) [A] and plug (Item 2) [A]
on the valve body.
P–08160
Put clean hydraulic fluid on the spool (Item 1) [B].

Install the spool (Item 1) [B] in the valve body.
B

P–08159
Install a new copper washer and plug (Item 1) [C] in the

valve body. C
1
P–08158
Put clean hydraulic fluid on the valve (Item 1) [D].

D
Install the valve (Item 1) [D] and spring (Item 2) [D] in the
valve body.
NOTE: The safety relief valve must be reset to the 1

correct pressure setting before the 2
accumulator valve can be put back in service.
(See page 2–54 for adjustment procedure.)
P–08157

Revised July 97
A
Assembly (Cont’d)
Install the adjustment screw (Item 1)[A], locknut (Item 2) 2
[A], and washer (Item 3) [A] in the valve body. 3
P–08156
Install a new washer (Item 1) [B] in the valve body.

B

1
P–08155
Apply oil and install a new O–ring (Item 1) [C] on the

spool. C
Put clean hydraulic fluid on the spool.
Install the spool in the valve body.
1
P–08166
Apply clean hydraulic fluid on the seat.

Install the seat (Item 1) [D] in the spool. D
Install the spring (Item 2) [D] in the seat (Item 1) [D].
1
2
P–08151

Revised July 97340
A
Assembly (Cont’d)
Use care when installing the O–ring so the threads do not
cut the O–ring.
Apply oil to the new O–ring (Item 1) [A] and install the
O–ring (Item 1) [A] on the adapter.
1
P–08154
Install the adapter (Item 1) [B] in the valve body.

B
1

P–08149
Install the seal (Item 1) [C] and accumulator (Item 2) [C]

on the adaptor. C
NOTE: The accumulator pressure should be 2
checked before putting the accumulator
valve back in service. (See Page 2–54 for the 1
procedure.)
P–08148

Revised July 97
ACCUMULATOR/VALVE (cont’d )
A
Setting The Safety Relief Valve
1
2
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. CD–12314
• Engine is running.
• Tools are being used.
W–2019–1285
Remove the tank return line and install aclear line leading
to a drain pan in its place.
Start the excavator and run at low idle. Engage the blade
lever until the blade is fullyraised. Continue to engage the
blade lever.

Loosen the locknut (Item 1) [A], and turn the adjustment
screw (Item 2) [A] counterclockwise until hydraulic fluid
starts to leak out the tank return line (clear line installed
previously).
Slowly turn the adjustment screw (Item 2) [A] clockwise
until the flow out the tank return line stops.
Turn the adjustment screw an additional 3/4 of a turn
clockwise and tighten the locknut.

Revised July 97340
ACCUMULATOR
A
Charging
The hydraulic accumulator provides 200 PSI (1379 kPa)
short term reserve pressure for joystick function with the
engine off.
The following tool will be needed to test and service the
accumulator: MEL1435 accumulator servicing and test
kit.
Remove the pressure reducing valve and accumulator
from the excavator. 1
Install the accumulator in a vise with protective jaws.

B–14476
Remove the protective cover (Item 1) [A] from the
accumulator.
Install the hand wheel, bleed screw and gaugeassembly
B
(Item 1) [B] on the accumulator. 5
NOTE: Before installing the gauge assembly on the

accumulator, be sure the hand wheel (Item 4)
[B] is open and the bleed screw (Item 5) [B]is 1
closed.
3

Connect the nitrogen bottle adapter (Item 2) [B] to the
gauge assembly (Item 1) [B] with the hose (Item 3) [B]. 4
Open the nitrogen bottle.
2
Slowly close the hand wheel (Item 4) [B] until 200 PSI
B–14477
(1379 kPa) is reached. Increase the pressure until its
slightly higher than needed. Close the nitrogen bottle.
Bleed off the excess pressure by openingand closing the
bleed screw (Item 5) [B].
Recheck the pressure after allowing the accumulator to
stabilize for five minutes.
Bleed off or add more nitrogen into the accumulator as
needed.
NOTE: Use only nitrogen for charging the

accumulator to prevent explosions and fire
hazards.

Revised July 97
AUXILIARY SELECTOR VALVE
A
The auxiliary selector valve is used to change two way
auxiliary flow to one way auxiliary flow when an optional
breaker is used. With one way flow, return fluid flow from
the breaker is directed back to the tank with reduced back
pressure.
The selector valve is located under the right front corner
of the machine beside the boom swing cylinder.
Mark the hoses before removal.
Remove the hoses from the selector valve [A].
Remove the bolts and nuts (Item 1) [A] and remove the
valve.
1
CD–12315
Disassembly And Assembly B

Remove the snap rings (Item 1) [B].

Push the knob in until the rear seal (Item 2) [B] is
exposed. Remove the rear seal. 1
Remove the spool from the valve body. Remove the front
seal (Item 3) [B] from the spool.
To prevent cutting the new seal on sharp edges, wrapthe 2

spool in three or four layers of glossy paper . Leave the
front seal groove exposed.
3
Install the new seal over the paper and into the front seal
groove. B–13660
Put clean grease on the new seal. Remove the paper and
install the spool in the body.
With a rotating action push the spool until the front seal
is in the body and the rear seal groove is exposed.
Install the rear seal in the groove.
Put clean grease on the rear seal.
Install the rear snap ring and pull the spool toward the
front until it stops.
Install the front snap ring.

Revised July 97340
TWO SPEED VALVE
A
Mark the hoses before removal.
Remove the spring from the lever and bracket [A].
N–12316
Remove the two mounting bolts [B].

B

N–12317
Remove the bolt from the lever [C].

C
N–12318
Remove the hoses from the two speed valve [D].

D
N–12319

Revised July 97
TWO SPEED VALVE (Cont’d)
1. Body
2. O–ring 4
3. Washer
4. Snap Ring 3
5. Pin 2
6. Spool 1

6
2
4
C–03282

Revised July
10097
PORT BLOCK
A
The port block is used to combine the return hydraulic
fluid flow and direct it back to the cooler and filter and to
the tank.
Mark the tubelines for the correct installation.
Remove the hoses from the port block [A].
N–12320
Remove the mounting bolts [B].

B

N–12321
Remove the port block and the lower hose [C].

C
N–12322

Revised July 97
OIL COOLER
A

I–2003–0888
B
Raise the engine cover.
Remove the hoses from the oil cooler [A].
Remove the four mounting bolts [B].

N–12324
Remove the oil cooler [C].

C
NOTE: Do not damage the radiator fins when
removing the oil cooler.
N–12325

Revised July
10297
HYDRAULIC RESERVOIR AND FUEL RESERVOIR
A

I–2003–0888
Remove the drain plug from the bottom of the hydraulic B

reservoir [A]. Drain the fluid into a container.
Remove the drain plug from the bottom of the fuel

reservoir [B].
Drain the fluid into a container.

N–10433
Disconnect the reservoir supply line [C].

C
N–12326
Remove the mounting bolts from the reservoir base [D].

D
N–12327

Revised July 97
HYDRAULIC RESERVOIR AND FUEL RESER VOIR
(Cont’d) A
Removal And Installation (Cont’d)
Remove the return line from the hydraulic reservoir [A].
N–12328
Move the reservoir away from the ROPS.

Remove the fuel return hose (Item 1) [B] from the fuel
B
reservoir. 1
Remove the wires (Item 2) [B] from the fuel level sender.
Disconnect the wire (Item 3)[B] from the low level sender.

3
N–12329
Remove the supply hose from the fuel reservoir [C].

C
N–12330

Revised July
10497
HYDRAULIC FILTER ASSEMBLY
A
Remove the inlet and outlet hoses from the filter [A].
Drain the fluid into a container.
CD–13238
Remove the mounting bolts from the filter assembly [B].

B

N–10641

Revised July 97
BOOM CYLINDER
A
See Pages 2–74 – 2–80 for disassembly and assembly
procedure.
Put the bucket on the floor. Stop the engine.
Move the hydraulic control to release the hydraulic
pressure.
N–12331

B
the system.
I–2003–0888

Disconnect the two hoses from the boom cylinder [A].
Remove the nut from the hose clamp [B].
N–12332
Remove the retainer bolt and nut from the cylinder rod
end pin [C]. C
Remove the cylinder rod end pin.
N–12333
Remove the retainer bolt and nut from the base end pin
[D]. D
Remove the cylinder base end pin.
Remove the boom cylinder.
N–12334

Added July106
BOOM CYLINDER (Cont’d)
1. Seal
2. Bushing
3. Rod 1
4. Head
5. O–ring 2
6. Piston 3
7. Nut
8. Housing 4
5

C–03295

Added July
107 of 340 97 –2–65– Service Manual
ARM CYLINDER
A
procedure.
Support the boom with a chain hoist.
Move the hydraulic controls to release the hydraulic
pressure.
N–12335
B
disassembly and keep all parts clean. Always 1
the system.
I–2003–0888

Disconnect the two hoses from the arm cylinder [A].
Remove the retainer bolt (Item 1) [B] and nut from the
cylinder base end pin. N–12336

C
Remove the retainer bolt (Item 1) [C] and nut from the 1
cylinder rod end pin.
Remove the cylinder from the arm.
N–12337

Added July108
ARM CYLINDER (Cont’d)
1. Seal
2. Bushing 1
3. Rod 2
4. Head
5. O–ring 3
6. Piston
7. Nut 4
8. Housing
5

8
C–03283

Added July
BUCKET CYLINDER
A
procedure.
Move the hydraulic controls to release the hydraulic
pressure. 1
N–12338

B
the system.
I–2003–0888

Disconnect the two hoses from the bucket cylinder [A].
Remove the retainer bolt and nut from the cylinder rod
end pin [B].
Remove the cylinder rod end pin. N–12339
Remove the retainer bolt and nut from the cylinder base
end pin [C].
C
Remove the bucket cylinder.
PI–12340

Added July110
BUCKET CYLINDER (Cont’d)
1. Seal 1
2. Bushing 2
3. Rod
4. Head 3
5. O–ring
6. Piston
7. Nut 4
8. Housing
5

C–03286

Added July
BLADE CYLINDER
A
procedure.
Put the blade on the floor . Stop the engine. Move the
blade control lever to release the hydraulic pressure.
Loosen the four bolts on the cylinder guard [A].
CD–12341
Remove the two guards [B].

B

N–12342
Remove the cotter pin from the rod end pin [C].
Remove the rod end pin from the blade cylinder.
C
Lower the base end to the floor.
N–12344
Remove the cotter pin from the base end of the pin [D].
Remove the pin.
D
Remove the cylinder.
N–12343

Added July112
BLADE CYLINDER (Cont’d)
1. Seal 1
2. Bushing
3. Rod 2
4. Head 3
5. O–ring
6. Piston
7. Nut 4
8. Housing
5

8
C–03284

Added July
BOOM SWING CYLINDER
A
procedure. 1
1
N–08548
the system.
I–2003–0888
B
Lower the boom and bucket to ground.

Disconnect the hoses (Item 1) [A] from the cylinder.
Remove the retainer bolt from the cylinder base end pin.

Remove the cylinder base end pin [B].
N–08207
end pin [C].

Remove the retainer bolt from the cylinder rod
C
Remove the boom swing cylinder.
N–08549

Added July114
BOOM SWING CYLINDER (Cont’d)
1. Seal
2. Bushing 1
3. Rod 2
4. Head 3
5. O–ring
6. Piston 4
7. Nut
8. Housing 5

8
C–03287

Added July
HYDRAULIC CYLINDER
A
Disassembly
NOTE: The drawings may not show the cylinder

exactly as it appears, but the procedure is
correct for all cylinders.
Put the base end of the hydraulic cylinder in a drain pan.

Move the rod in and out to remove the fluid from the
cylinder. Move the rod slowly so the fluid will go directly
into the drain pan.
Put the base end of the cylinder in a vise.
Use the adjustable gland nut wrench (MEL1075) to B–07000
loosen the head [A].
Remove the rod assembly from the cylinder case [B]. B

Remove the cylinder case from the vise.
Put the rod end in the vise.

B–07001
Remove the nut from the piston end of the rod [C].
C
B–13816
Pull the piston off the rod (Item 1) [D].

D
Pull the head (Item 2) [D] off the rod.
B–13817

Added July116
HYDRAULIC CYLINDER (Cont’d)
A
Remove the O–ring (Item 1) [A] and back–up washer
(Item 2) [A] from the head with seal hook (MEL1074).
1
Remove the O–ring (Item 3) [A] from the head.
2
B–13743
Remove the wiper seal [B].

B

B–07005
Remove the oil seal from the head [C].

C
B–07006
Cut the old T eflon seal and remove the seal from
piston [D].
the
D
B–03689

Added July
A
Remove the O–ring from the piston [A].
Wash the cylinder parts in solvent and air dry them.
While servicing the cylinder do not damage the parts.
Inspect for nicks, scratches or otherwise damaged or
bent parts before assembling the cylinder. Replace parts
that appear damaged in any way. The cylinder may not
function correctly if there is damage to any of the parts.
Destroy all the O–rings and seals and replace them with
NEW O–rings and seals.
B–03703
Assembly
Install the O–ring on the piston [B].
B

B–12812
NOTE: Do not overstretch the seal.

C
Install the seal on the tool (MEL1396) and stretch it until
it fits the piston [C].
Allow the seal to stretch for 30 seconds before removing
it from the tool.
B–12809
Install the seal on the piston [D].

D
B–12813

Added July118
A
Assembly (Cont’d)
Use a ring compressor to compress the seal to the correct
size [A].
Leave the piston in the ring compressor for three minutes.
B–12811
Install the oil seal on the rod seal tool (MEL1033) [B]. B
NOTE: The O–ring side of the oil seal goes toward
the inside of the cylinder.

O–ring
Side
B–03702
Install the oil seal in the head [C].

C
B–03671
Install the wiper seal with the lip toward the outside of the
head [D]. D
B–03682

Added July
A
Assembly (Cont’d)
Install the O–ring (Item 1) [A] onto the head.
CD–12674
Install the back–up washer (Item 1) [B] and O–ring (Item

2) [B] onto the head. B
2

CD–12675
Apply grease to the inside of the head and to the lips of

the seals. C
Inspect the beveled edge of the rod for nicks or sharp
edges [C]. Remove these with a file prior to installing the
gland on the rod or damage to the seals may occur.
Install the head on the rod [C].
CD–12676
Install the piston on the rod [D].

D
B–07198

Added July120
A
Assembly (Cont’d)
Clean and dry the cylinder rod threads and install the new
nut (supplied with the seal kit) [A].
Tighten the nut to the following torque.
Cylinders with 1.000 inch thread diameter, tighten the nut
to 400 ft.–lbs. (542 Nm) torque.
to 750 ft.–lbs. (1017 Nm) torque.
to 850 ft.–lbs. (1153 Nm) torque. B–07002
Inspect the inside of the cylinder case for nicks and

scratches. If the cylinder case has minor scuf fing the
cylinder case can be honed [B]. Use a flexible hone and
B
lubricate with oil during the honing process.
Thoroughly wash the inside of the cylinder case after the
honing process.
The following hones can be ordered from OTC Service
Tools:

MEL1418 2.0 inch diameter hone
OEM6275 2.750–3.0 inch diameter hone
OEM6270 3–3.500 inch diameter hone
OEM6271 3.500–4.0 inch diameter hone
CD–12678
Put oil on the seal surface of the cylinder case [C].

C
B–07013
Put oil on the Teflon seal on the piston [D].

D
B–07012

Added July
A
Assembly (Cont’d)
Install the rod assembly in the cylinder case [A].
B–07001
Put oil on the seals on the head [B].

Put oil on the threads of the head.
B

B–07014
Use the adjustable gland nut wrench (MEL1075) to

tighten the head [C]. C
NOTE: The gland is to be tightened until it is flush
with the end of the cylinder case.
Move the rod in and out of the cylinder case and make
sure that it moves freely.
B–07000
Replace the seal on the rod end (if so equipped) if it shows

signs of wear or damage [D]. D
B–07015

Added July122
JOYSTICK CONTROL CHANGE ISO PATTERN
To change from I.S.O. to STANDARD joystick controls do
A Control
Valve
the following procedure:
1 4
Remove the seat. (See Page 5–1.) R.H. Travel
Remove the center floor panel. (See Page 5–2.) Boom
Bucket
Remove the swing motor cover and rear floor panel. (See
Page 5–3.) Auxiliary
Arm
Remove the left control panel base. (See Page 3–2.)
L.H. Travel
To change I.S.O. to ST ANDARD control pattern do 2
the following: 3
B–13429
Mark the hoses on the end of each valvespool as shown
[A].
Remove the boom control hoses (Item 1)[A] and the arm
B STANDARD PATTERN
Control
Valve
control hose (Item 2) [A] and relocate (switch) these
hoses on the control valve [B]. 2 3
R.H. Travel
Remove the arm control hose (Item 3) [A] and the boom
control hose (Item 4) [A] and relocate (switch) these Boom
hoses on the control valve [B].
Bucket

After the hoses have been switched, the hoses must be Auxiliary
as shown [B].
Arm
The R.H. joystick will now control the arm (Arm out and L.H. Travel
Arm in) and the bucket curl.
4 1
The L.H. joystick will now control the boom (Boom up and B–13429
Boom down) and the upper works swing.
Do not exchange any of the hoses on the top of the
control valve to the work cylinders. Switch only the
hoses that connect the joystick to the control valve
spools.
Clean the existing decals on the control consoles with
soap and water and dry.
Install the standard control pattern decals (P/N 6537457
for R.H. console and P/N 6537456 for the L.H. console)
on top of the existing control pattern decals.

Added July
JOYSTICK CONTROL CHANGE (Cont’d)
A STANDARD PATTERN
Control
To change STANDARD to I.S.O. control pattern do Valve
the following:
2 3
Mark the hoses on the end of each valvespool as shown R.H. Travel
[A].
Boom
Remove the arm control hose (Item 1) [A] and the boom
control hose (Item 2) [A] and relocate these hoses on the Bucket
control valve [B]. Auxiliary
Remove the boom control hose (Item 3) [A] and the arm Arm
control hose (Item 4) [A] and relocate these hoses on the L.H. Travel
control valve [B].
4 1
After the hoses have been switched, the hoses must be B–13429
as shown [B].
ISO PATTERN
The R.H. joystick will now controlthe boom (Boom up and
Boom down) and the bucket curl.
B Control
Valve
The L.H. joystick will now control the arm (Arm out and 1 4
Arm in) and the upper works swing.
R.H. Travel
Do not exchange any of the hoses on the top of the Boom
control valve to the work cylinders. Switch only the
hoses that connect the joystick to the control valve Bucket
spools.

Auxiliary
Clean the existing decals on the control consoles with Arm

soap and water and dry. L.H. Travel
Install the I.S.O. control pattern decals (P/N 6537588 for 3 2
the R.H. console and P/N 6537587 for the L.H. console) B–13429
on top of the existing control pattern decals.

Added July124
DRIVE SECTION
Page
Number
CONTROL CABLES
Blade Cable and Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14 ...
Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–14
....
FINAL DRIVE
...
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–17 ... DRIVE
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19
.... SECTION
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–35
....
FOOT PEDAL AND STEERING LEVERS

Bushing Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–16 ..
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15
...
LEFT CONSOLE
Cylinder Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 ..
Lockout Valve Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . .3–1 .
...

LEFT JOYSTICK
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–4 ..
...
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3 ...
RIGHT CONSOLE
...
RIGHT CONSOLE COVER

...
THROTTLE LEVER
High Idle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–13
...
Low Idle Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–12
...
...
TRAVEL MOTOR
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3–35
....
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–19
....

Revised Aug. 92

LEFT CONSOLE
Lockout Valve Removal and Installation
A
Raise the console control cover.
1
Remove the mounting bolts (Item 1) [A].
Mark the hoses for correct installation.
E–02380
Remove the hoses from the lockout valve [B]. B 1

Remove the nuts (Item 1) [B] from the mounting bolts.
Remove the lockout valve.
Installation: Use mounting plate slots to adjust lockout
valve plunger (Item 1) [A] to fully depressed position
when console is in lowered position.

CD–10615
Cylinder Removal and Installation

Remove the cotter pins (Item 1) [C] from the base end C
and rod end of the cylinder.
Cylinder contains high pressure gas. Do not

open. Opening cylinder can release rod and
W–2113–0288
CD–10616

LEFT CONSOLE (Cont’d)
Removal and Installation
A
Lower the boom and blade to the ground.
Stop the engine.
Remove the swing motor cover and the rear floor panel.
(See Page 5–3.)
Remove the left console hose from the right console tee
fitting [A].
Mark the hoses for correct installation. CD–10617
Remove the hand control lever hoses from the six–spool

and the three–spool control valves two hoses each
B
control valve [B].

Left Control
Lever Hoses
N–12345
Remove the left console mounting bolts [C].

C
CD–10618
Remove the right console hose (Item 1) [D] from the left
console tee fitting. D
Remove the left console.
CD–10619

LEFT JOYSTICK
A
Remove the control panel cover mounting bolts [A].
N–12468
Loosen the arm rest mounting bolts and remove the arm
rest [B].
B
Remove the control panel cover.

CD–12469
NOTE: Mark the hose locations for

installation.
correct C
Remove the hose from the joystick [C].
N–12470
Remove the mounting bolts from the joystick flange [D].

D
N–12471

LEFT JOYSTICK (Cont’d)
Removal and Installation (Cont’d)
A
Remove the joystick from the mount [A].
Disassembly and Assembly
NOTE: The right joystick is equipped with a horn

button [B]. The valve body disassembly and
assembly procedure is the same for both
joysticks.
N–08507
Remove the cap from the joystick [B]. B RIGHT JOYSTICK SHOWN
Right Joystick Only: Remove the horn wires from the cap
[B].
NOTE: Mark the wires for correct installation.

CD–11679
Remove the screws from the handle [C].

C
Remove the handle.
N–08509
Remove the rubber boot from the joystick [D].

D RIGHT JOYSTICK SHOWN
CD–11680

A RIGHT JOYSTICK SHOWN
Remove the joystick lever and the lock nut (Item 1) [A].
1
Remove the adjustment nut (Item 2) [A] and the horn
wires. 2
Remove the push rod disc (Item 3) [A].
3
NOTE: To test the joystick for proper rod disc
adjustment. Blow air at 10 PSI into the P port
of the joystick and adjust the disc downward
until air starts to flow out of the 1, 2, 3 & 4
ports. Back off the rod disc until the air flow
stops. Tighten the adjustment nut to 43.0 CD–11681
in.–lbs. (5 Nm) torque.
Remove the joint [B]. B

Installation: Tighten the joint to 30.0 in.–lbs. (3,4 Nm)
torque.

CD–11682
Remove the plate [C].

C
Installation: Align the hole in the plate with the valve
body hole.
CD–11683
Use screwdrivers to remove the plugs [D]. D
CD–11684

A
Remove the push rod from the plug [A].
Check the push rod crown for wear.
CD–11685
Remove the O–ring (Item 1) [B] and seal (Item 2) [B]

from the plug.
B
2
1

CD–11686
Installation: Be sure the seal lip is toward the valve body

[C]. C Seal Lip
O–Ring
B–13517
Remove the spool assembly from the valve body [D].

D
NOTE: Install the spool assemblies in the same
location from where they are removed.
CD–11687

A 1
Push the spring seat down to remove the washers (Item
1) [A].
CD–11688
Remove spring seat, spring and washers from the spool

[B]. B

CD–11689
Remove the two bolts from the port plate [C].

Installation: Tighten the bolts to 26.0 in.–lbs. (3,0 Nm)
C
torque.
CD–11690
Remove the port plate (Item 1)[D] and O–ring (Item 2)[D]
from the valve body. D
1
Use a new O–ring during assembly.
Installation: Align the dowel pin (Item 3) [D] with the
dowel pin hole in the valve body. 3
2
Dowel Pin
Hole
CD–11691

NOTE: Left Joystick parts identification and

assembly is the same without horn
button and wires.
RIGHT JOYSTICK SHOWN

1. Plug
2. Rod
3. Seat
4. Spring
5. Bellows
6. Nut
7. Actuator
8. Joint
9. Plate
10. Bolt
11. Handle Assembly

11
6
1
8
3 9
10
D–01972
RIGHT CONSOLE
A
Remove the console cover. (See Page 3–11.)
Remove the fuse panel mounting bolts [A].
CD–10632
Remove the ground wire [B]. B

CD–10633
Disconnect the horn wire [C]. C
CD–10634

D
Remove the right hand control drain hose (Item 1) [D]
from the tee below the console.
CD–10635

RIGHT CONSOLE (Cont’d)
A
Remove the hand control hoses from the six–spool
control valve [A].
CD–12302
Remove the mounting bolts from the right console [B]. B

Remove the right console.

CD–10637

RIGHT CONSOLE COVER
A
Loosen the two bolts to remove the arm rest [A].
CD–10620
Remove the blade knob and throttle knob [B]. B

Remove the mounting screws from the console cover.

N–10621
Remove the instrument panel mounting screws [C]. C

Remove the instrument panel.
N–10622
Remove the wire harness from the instrument panel

socket [D]. D
N–10623

RIGHT CONSOLE COVER (Cont’d)
A
Remove the mounting screws and nuts from the
hourmeter [A].
N–12472
NOTE: Mark the hourmeter wires for correct

installation on the + or – terminals.
B
Remove the wires from the hourmeter [B].

N–12473
Remove the nut from the ignition switch [C].

Push the ignition switch into the console cover.
C
Remove the console cover.
N–10624
THROTTLE LEVER
Low Idle Adjustment
D
In low idle position the throttle lever should stop against
the throttle stop bolt when the engine is reduced to 1000
RPM. 2
To adjust the low idle, start the engine and loosen the jam
nut (Item 1) [D] and move the throttle lever to 1000 RPM.
Turn the idle bolt (Item 2) [D] to touch the throttle lever
and tighten the jam nut. 1
N–12474

THROTTLE LEVER (Cont’d)
High Idle Adjustment
A
2
In high idle position the throttle lever should stop against
the bolt (Item 1) [A] and the high idle screw on the fuel
injection pump at the same time.
To adjust high idle, loosen the jam nut (Item 2) [A] and
move the lever so the cable touches the stop screw on
the fuel injection pump. 1
Move the stop bolt to touch the lever and tighten the jam
nut (Item 2) [A].
N–12475

Disconnect the throttle cable from the lever.
B
Remove the lock nut from the lever [B].

P–10058
Remove the flat washer, wave washer and lever [C].

C
N–12477
Remove the friction pad [D].

D
Installation: With the engine running tighten the lock nut
so a slight drag is felt on the lever.
N–12478

CONTROL CABLES
A
Throttle Cable
Loosen the lock nut (Item 1) [A] to remove the throttle
cable from the right console.
1
CD–12479
Blade Cable and Lever

Remove the cable bolt from the blade lever [B].
B

N–12480
Loosen the jam nut (Item 1) [C] to remove the blade

cable. C
Remove the lever mounting bolt to remove the blade
lever [C].
N–12481
Loosen the jam nut and move the lower nut to adjust the
blade cable [D]. D
N–12482

FOOT PEDAL AND STEERING LEVERS
A
Disconnect the linkage rods (Item1) [A] from the control
valve spools.
1
1
P–04444
Remove the mounting bolts from the front floor panel.

Remove the boom swing linkage from the right foot pedal
B
[B].

P–04445
Lift the steering levers and floor panel from themachine

[C].
C
N–12348
Remove the nuts (Item 1) [D] from the linkage bolts. D

Remove the linkage bolts from the bracket.
1
CD–10650

FOOT PEDAL AND STEERING LEVERS (Cont’d)
A
Bushing Removal and Installation
Remove the nut from the pivot bolt [A].
CD–10651
Remove the pivot bolt and washers from the pedal

bushing [B]. B
NOTE: Install the washers in the same location
during assembly of all pivot bushings.

CD–10652
Remove the pivot bushing [C]. C

NOTE: Put oil on the O–rings during assembly .
Remove the bolt (Item 1) [C] from the top side of thefloor
plate.
CD–10653

FINAL DRIVE
A
Remove the bolts from the track frame cover [A].
Nm) torque.
CD–08564
Remove the cover.

Lift and block the side of the track frame where the final
B
drive will be removed.
Release the track tension and remove the track. (See
Page 5–10.)

When making repairs on hydrostatic and
hydraulic systems, clean the work area before CD–12349
the system.
C
I–2003–0284

Disconnect the hoses from the drive motor [B].
Loosen and remove the final drive mounting bolts [C].

Installation: Put LOCTITE on the bolts and tighten to
80.0 ft.–lbs. (108,0 Nm) torque.
PI–12350
Remove the motor , sprocket and reduction gear

assembly from the track frame [D]. D
CD–08568

FINAL DRIVE (Cont’d)
TRAVEL MOTOR (With Brake) 4
1. Plate 2
2. Spring 2
3. Block 1
4. Piston
5. Seal 2
6. Disc
7. Retainer
8. Bearing 3 5 10
9. Nut
10. Gear
11. Cover
8 1
4
9
6
7
4
10

1
1
11
5 D–02170
2
TRAVEL MOTOR (Without Brake)
6
1. Plate 2
1
2. Spring
3. Block 6
4. Retainer 2
5. Shaft 9
6. Bearing
7. Seal 3 7
8. Nut
9. Gear
10. Cover 1
4
6
5 1 10
6
7
D–02172

TRAVEL MOTOR
A
Disassembly

the system. P–00431
I–2003–0888
B
Remove the four bolts from the relief block assembly[A].
Remove the relief valve assembly from the drive motor

[B].

P–00434
Remove the five O–rings from the relief valve assembly
[C].
C
P–00436
Clamp the relief valve assembly in a vise and remove the
two relief valves [D].
D
P–00437

Added Aug.
TRAVEL MOTOR (Cont’d)
231ServiceManual#6722178S/N508912000&Above–DriveSectionPart1of3
A
Remove the plug (Item 1)[A], spring (Item 2) [A] and the
relief assembly (Item 3) [A] from each end of the valve 3 1
block. 2
P–00438
Remove the two back–up rings (Item 1) [B] and O–ring

(Item 2) [B] from the spool (Item 3) [B]. Slowly turn the
piston (Item 4) [B] and remove it from the spool (Item 3)
B
[B]. Remove the two back–up rings (Item 5)[B] and the
O–ring (Item 6) [B] from the inner diameter of the piston 3 7
(Item 4) [B]. Remove the O–ring (Item 7) [B] from the 2 5
plug.
NOTE: Check the poppet movement inside the spool

(Item 3) [B]. The poppet must move freely .

The poppet cannot be removed from the
spool and if poppet is lodged or damaged a
new relief valve will need to be ordered. 1 4 6
P–00440
Loosen the two plugs from each end of the valve body
[C].
C
P–00443
Remove the plugs (Item 1) [D] and remove the O–ring

(Item 2) [D] from the plug. Remove the springs (Item 3) D
[D], retaining washers (Item 4) [D] and slowly turn the
spool (Item 5) [D] and remove it from the valve body.
1 1
3 5 3 2
2 4 4
P–00441

Added Aug.146
92of 340 –3–20– Service Manual
A
To disassemble the spool, insert a hardened dowel pin
thru the hole in the spool gland and use a vise with
protective jaws to hold the spool [A].
Remove the two end plugs from the spool [A].
NOTE: Do Not use any type of clamp tool on the

spool. Any marring or scratches in the spool
and the spool must be replaced.
P–00446
Disassemble the spool by removing the O–rings (Item 2)

[B] from the end plugs (Item 1) [B]. Remove the springs
B
(Item 3) [B] and the poppets (Item 4) [B] from the spool
(Item 5) [B].
Use solvent and clean and dry all spool components. 1
1 3 5 3

2 4 4 2
P–00435
Loosen the plug from the end of the valve body [C].
C
P–00444
Loosen the adapter from the opposite end of the valve

body [D]. D
P–00442

Added Aug.
147 of 340 92
–3–21– Service Manual
A
Remove the O–ring (Item 2) [A] from the end of the plug 4
(Item 1) [A]. 6 1
Remove the O–ring (Item 3) [A] from the end of the
adapter (Item 4) [A].
Remove the spring (Item 5)[A] and the spool (Item 6)[A].
Use solvent and clean and dry all components. 5
3 2
P–00439
Remove the orifice from each end ofthe internal diameter

of the spool body [B]. B

P–00445
Remove the two plugs from the edge face of the valve
body [C]. C
P–00447
Remove the two orifice plugs from each of these plug

holes [D]. (Total of four orifice.) D
NOTE: Do not intermix these orifice plugs with
orifice plugs removed from different
locations on the travel motor.
P–00448

Added Aug.148
A
Inspect the orifice in the center of each plug from
contamination [A].
If orifice is plugged, clean with an appropriate sized
oxy/acetelen torch tip cleaner or replace if necessary.
Orifice
P–00451
Remove the six bolts holding the valve body to the drive
motor [B]. B

P–00449
Lift the valve body off of the drive motor [C].

If the valve body is stuck to the drive motor
, lightly tap the
C
edge of the valve body with a plastic hammer to loosen.
P–00454
Remove the O–rings from the valve body face [D]. D

NOTE: Travel motors with brakes will have three
O–rings and travel motors without brakes
will have two O–rings.
P–00462

Added Aug.
149 of 340 92
A
Remove the bearing from the valve body with a slide
hammer type puller [A].
NOTE: The dowel pin in the face of the valve body is

staked to the valve body. Do Not remove the
dowel pin unless it is damaged.
P–00457
Remove the O–ring and the two dowel pins [B]. B
Dowel Dowel
Pin Pin

P–00450
Remove the valve plate from the rotating group [C].

C
NOTE: The bronze side of the valve plate goes
towards the rotating group.
P–00452
The following four steps (Page 3–24 [D] thru Page 3–25
[C]) are for drive motors with brakes; for drive motors D
without brakes, skip to Step [D] on Page 3–25.
Remove the ten springs from the brake piston [D].
B–13758

Added Aug.150
A
Remove the brake piston from the drive motor hub by
blowing compressed air into the park brake release port
[A].
B–13759
Remove the back–up ring (Item 1) [B], O–ring (Item 2)

[B], back–up ring (Item 3) [B] and the O–ring (Item 4)[B]
B
from the brake piston.
4
3

1
B–13760
Remove the brake disc from the drive motor hub [C]. C
B–13761
The following information is for either drive motors with or

without brakes. The photos may not appear to look D
exactly like the components being removed but the
procedure is the same.
Remove the rotating group from the drive motor hub[D].
P–00456

Added Aug.
151 of 340 92
A 5
Disassemble the rotating group by removing the pistons
(Item 1) [A], piston retainer (Item 2) [A], conical spacer 2
(Item 3) [A] and the three plugs (Item 4) [A] from the
piston housing (Item 5) [A].
1 3
4
P–00459
Turn the piston housing over and remove the snap ring
from the housing [B]. B
NOTE: The spring inside the piston housing is
under pressure, use care when removing the
snap ring from the piston housing.

P–00456
Remove the snap ring (Item 1) [C], collar (Item 2) [C],

spring (Item 3) [C] and the collar (Item 4) [C] from the C
piston housing.
3
1
4
2
P–00463
Remove the swash plate (Item 1) [D] and the two steel
balls (Item 2) from the drive motor hub. D
2
1
P–00458

Added Aug.152
A
Remove the two pistons and springs from the drive motor
hub [A].
P–00460
Clamp the housing flange into a vise and remove the plug
from the side of the housing [B].
B

P–00464
If the drive motor lube oil has not already been drained,
do so now. C
Remove the two plugs from the cover of the drive motor
housing [C]. Drain the fluid into a container. Dispose of
this fluid properly.
P–00433
Install two bolts (PT 3/8 threads) into the plug holes in the
cover [D]. Install a flat blade screw driver tip into the hole D
in the side of the housing and use a bar to turn the end
cover [D]. Turn the end cover until the lock wire starts to
come out of the housing hole.
P–00466

Added Aug.
153 of 340 92
A
Use a plier to pull out on the lock wire while turning the end
cover until the wire is completely removed from the
housing [A].
P–00468
Remove the drive motor from the vise and set onto a flat
surface.
B
Remove the end cover from the drive motor housing[B].

P–00461
Remove the O–ring from the edge of the cover [C]. C
P–00472
Remove the thrust plate from the planetary assembly[D].

D
P–00473

Added Aug.154
A
Remove the three planetary gears from the planetary
holder [A].
P–00475
Remove the drive gear shaft from the housing [B].

B

P–00474
Remove the planetary holder from the housing [C].

C
P–00477
Remove the three needle bearings and bearing races

from the holder [D]. D
Spring
NOTE: The spring pins do not need to be removed or Pins
replaced unless damaged.
P–00479

Added Aug.
155 of 340 92
A
Remove the drive gear from the center of the planetary
gears [A].
NOTE: The snap ring does not need to be removed

from the gear unless it is damaged.
Snap Ring
P–00470
Remove the four screws holding the retaining ring to the

inner planetary [B]. B

P–00478
Remove the retaining ring [C].

C
P–00481
Remove the four gears, needle bearings, bearing races D

and the thrust washers [D].
P–00480

Added Aug.156
A
Remove the plug from the notched area in the travel
motor flange [A].
P–00485
Remove the 131 or 132 steel balls that retain the drive
motor housing to the drive motor hub [B] & [C]. B
The balls must be removed thru the plug hole. Use solvent
and flush oil off of the steel balls and the mating surfaces
of the bearing and housing.
Use a magnet and remove the exposed steel balls from
the plug hole. Use short bursts of compressed air to force
the first few steel balls to the plug hole and remove these

with the magnet. Continue this process until no more balls
will appear at the plug hole.
NOTE: Use care with the following process not to
allow the wire to become lodged or to break
off inside the motor.
P–00487
Use a length of 16 gauge mechanics wire and bend a

tight, close loop at one end of the wire. Insert the wire into C Wire
the plug hole and carefully feed the wire around the
diameter of the bearing and force the steel balls to the
hole. Steel
Balls
Remove the exposed balls with a magnet and continue
this process until all 132 balls are removed and the end
of the wire is visible thru the hole. Carefully remove the
wire. DO NOT break the wire off inside the housing when
removing the wire [C].
NOTE: If balls seem to be lodged in the housing, it

may be necessary to use a press or a 3 jaw
puller to center the ball bearing groove into
the center of the plug hole.
MC–01678
Use a three jaw puller and remove the travel motor

housing [D]. D
P–00488

Added Aug.
157 of 340 92
A
Remove the three set screws that retain the bearing nut
from turning [A].
P–00486
Use the bearing nut socket [C], and remove the bearing
nut from the drive motor hub [B]. B
Bearing
Nut
Socket
Bearing
Nut

B–13762
Bearing nut socket dimensions [C]. C 12.8

13 mm
This tool can be made at a local machine shop.
16 mm Weld
4 Places
152 mm 90 mm
146 mm
10 mm
9 mm
100 mm
MC–01696
Carefully remove the double race bearing from the hub

[D].
D
NOTE: The inner and outer races of this bearing are
not permanently retained to each other. If not
lifted off as an assembly , the races will
separate and the steel balls will come loose.
P–00483

Added Aug.158
A
Remove the top half of the floating seal from the hub[A].
P–00490
Pry the lower half of the floating seal from the hub [B]. B

P–00492
Use a punch and tap the rotating group drive shaft and
bearing out of the hub [C].
C
P–00491
Remove the drive shaft and bearing from the hub [D].
D
P–00493

Added Aug.
159 of 340 92
A
Remove the seal from the hub [A].
P–00496
Use a press and press the drive shaft out of the bearing
[B].
B

P–00497

Added Aug.160
A
Assembly
Install a new bearing onto the rotating group drive shaft
[A].
NOTE: Use a press tube that contacts the inner

bearing race.
P–00494
Floating seal installation tool [B].

B 7.87’’ (200 mm)
This tool can be made by a local machine shop or use
tool
(MEL1412). 7.13’’ (181 mm)
6.73/6.74’’ (171,0/171,2 mm)
0.27’’
(6,8 mm) 6.64/6.65’’ (168,7/168,9 mm)
0.34’’ (8,6 mm) 6.22/6.23’’

0.20’’ (5 mm) (157,9/158,1 mm)
0.67’’ (17 mm) 6.73/6.74’’
(171,0/171,2 mm) 15°
RO 0.12’’ (,3 mm)
RO 0.08’’ (,2 mm)
MC–01678
Apply grease to the floating seal O–ring and to the floating C

seal surface of the drive motor hub.
Install the floating seal into the installation tool [C].
P–00333
Turn the seal and installation tool over and set it in place
in the hub [D]. D
Using both hands, evenly press down on the installation
tool to insert the floating seal into the hub [D].
P–00498

Added Aug.
161 of 340 92
Assembly (Cont’d)
A
Apply grease to the O–ring of the other halfof the floating
seal.
Install the top half of the floating seal onto the previously
installed floating seal half [A].
NOTE: The O–ring of this half of the floating seal

faces upwards.
P–00490
Carefully install a new double roller bearing onto the hub

[B]. B
Install the bearing nut onto the bearing, tighten the nut so
that the bearing is seated against the hub but not tight.
The bearing nut will be tighten more in a later step.

P–00483
Press the drive motor housing onto the hub [C].

C
NOTE: Make sure that the housing is positioned
over the bearing and the top half floating
seal.
P–00499

Added Aug.162
A
Assembly (Cont’d)
Use a spring scale to check the housing start up load[A].
Use the bearing nut socket to tighten the bearing nut until
there is 10.0–15.0 ft.–lbs. (1.5–2.0 kgf) force needed for
housing start up load.
P–00504
After the correct start up load has been established,

install the three set screws to retain the bearing nut [B]. B
Tighten the set screws to 21.0–29.0 ft.–lbs. (29–39 Nm)
torque.

P–00502
Use a center punch and stake the hub to the set screw so
that the set screws will not work loose [C]. C
P–00503
Turn the motor on its side and install the 132 steel balls
into the housing hole [D]. D
P–00487

Added Aug.
163 of 340 92
A
Assembly (Cont’d)
Install the plug into the housing [A].
Tighten the plug to 5.0–6.0 ft.–lbs (6–8 Nm) torque.
P–00485
Apply a light coating of petroleum jelly to the needle

bearing and install the bearings into the gears [B]. B
Install the bearing race into the needle bearings [B].

P–00482
Apply a light coating of petroleum jelly to the thrust

washer and install the thrust washer into the notched
groove in the side of the gear and the beveled edge of the
C Beveled Edge
thrust washer will face upwards as viewed in [C].
Turn the gear assemblies over and install them onto the
pinion stub shafts on the hub. The beveled edge of the
thrust washer must match up to the beveled edge ofthe
stub shaft at the hub face and the thrust washers must Notched Groove
remain seated in the notched groove of the gear.
If installed properly, the top face of the gear will be
slightly
lower than the top face of the stub shaft.
P–00484
Install retaining ring onto the top of the stub shafts [B].
D
P–00481

Added Aug.164
A
Assembly (Cont’d)
Clean the screw threads of any dried on thread locking
compound and inspect the screws. Replace screws ifany
damage is found.
Apply LOCTITE #262 to the threads of the screws. Install
the four screws thru the retainer ring [A].
Tighten the screws to 3.0–6.0 ft.–lbs. (4–8 Nm) torque.
P–00476
Install the snap ring onto the drive gear (if previously
removed) and install the drive gear into the center of the
planetary gears [A].
B
NOTE: The gear must be installed with the narrow
section of the gear upwards (when viewed
using the snap ring as the dividing line).
Snap Ring

P–00470
Install new spring pins into the stub shafts (if the spring
pins were removed) and install the planetary holder onto C
the drive gear [C].
P–00477
Install the bearing race onto the stub shafts [D]. Apply a
light coating of petroleum jelly to the needle bearings and D
install over the bearing races [D]. Install the planetary
gears over needle bearings [D].
P–00475
165 of 340
Added Aug. 92 –3–39– Service Manual
A
Assembly (Cont’d)
Install the drive shaft into the planetary gears [A].
P–00474
Position the four holes in the thrust plate over the spring
pins in the stub shafts [B]. B

P–00473
Apply petroleum jelly and install a new O–ring onto the

end cover [C]. C
P–00471
Install the end cover onto the housing [D]. D
P–00467

Added Aug.166
A
Assembly (Cont’d)
Clamp the travel motor in a vise and install two bolts (3/8
PT thread) into the end cover [A].
Bend a 1/4 inch hook in the end of the lock wire. Insert the
hook end of the lock wire into the hole in the side of the
motor and into the slot on the edge of the end cover.
Turn the end cover with a bar and insert the lock wire into
the hole as it wraps around the end cover [A].
P–00469
Install the plug into the lock wire hole [B]. B

Tighten the plug to 6.0–8.0 ft.–lbs. (8–10 Nm) torque.

P–00464
Remove the travel motor from the vise. C

Set the motor on the end cover on a flat surface.
Apply a light coating of petroleum jelly to the outer
diameter of the seal and install the seal into the travel
motor [C].
NOTE: The lip side of the seal faces upward as

viewed in [C].
Apply a light coating of petroleum jelly to the seal lips.
P–00501
Apply a light coating of petroleum jelly to the end of the

rotating group drive shaft and press the shaft and bearing
D
into the hub [D].
NOTE: Make sure that the end of the shaft is
positioned thru the center of the seal prior to
pressing the shaft in place.
P–00495

Added Aug.
A
Assembly (Cont’d)
Apply oil to the piston holes in the motor hub and to the
piston side and face.
Install the piston and the spring into the piston holes[A].
P–00460
Apply a light coating of petroleum jelly to the steel balls

[B]. B
Install the steel balls into the swash plate and install the
swash into the travelmotor hub [B]. Rock the swash plate
back and forth to check for binding and to make sure the
pistons and springs move freely under the swash plate.

P–00458
Install the collar (Item 4) [C], spring (Item 3) [C], collar

(Item 2) [C] and the snap ring into the piston housing. C
Use an arbor press with a press tube that fits loosely
inside the snap ring but will contact the collar.
3 4
Compress the collar and spring down intothe housing and 2
install the snap ring. 1
P–00463
Apply petroleum jelly to the three pins (Item 4) [D] and

insert the three pins into the holes in the piston housing D 5
(Item 5) [D].
Install the conical spacer (Item 3) [D] on top of the pins 2
(Item 4) [D] and piston housing (Item 5) [D].
Install the pistons (Item 1) [D] into the piston retainer
(Item 2) [D].
Apply oil to the piston holes in the piston housing (Item 5)
[D] and insert the pistons into the piston housing.
1 3
4
P–00459

Added Aug.168
A
Assembly (Cont’d)
Apply oil to the face of the swash plate and to the pistons.
Install the rotating group into the travel motor [A].
P–00456
The following four steps are for travel motors with

brakes. (See Page 3–43 [B] thru 3–44 [A].) For travel
motors without brakes, skip to step [B] on Page 3–44.
B
Install the brake disc plate overthe splined surface of the
rotating group [B].

B–13761
Install new O–ring (Item 4)[C], back–up washer (Item 3)

[C], O–ring (Item 2) [C] and back–up washer (Item 1)[C]
C
onto the brake piston.
4
3
2
1
B–13760
Apply oil to the inner and outer diameter of the

piston and to the O–rings and back–up rings.
brake
D
Install the brake piston into the travel motor hub [D].
B–13759

Added Aug.
A
Assembly (Cont’d)
Install the ten springs into the brake piston [A].
The following steps apply to travel motorswith or without
brakes.
B–13758
Press a new bearing into the valve body[B]. Use a press

tube that contacts the external bearing race only. B

P–00500
Install the new O–rings (quantity 3 for travel motor with

brakes or quantity 2 for travel motors without brakes)into
the valve body [C].
C
Dowel
Pin
NOTE: If a new valve body is being used or if the
locating dowel pin was removed, install a
new dowel pin and use a center punch to
stake the valve body to the dowel pin.
P–00462

Added Aug.170
A
Assembly (Cont’d)
Install a new O–ring onto the motor hub and install the two
dowel pins [A].
Dowel Dowel
NOTE: On travel motors with brakes, these pins are Pin Pin
installed into the brake piston.
P–00450
Apply petroleum jelly to the valve plate (steel side) and

install the valve plate onto the valve body.
B
The notch in the valve plate will line up with the locating
dowel pin and the bronze side of the valve plate must be
facing outwards from the valve body.
Install the valve body onto the travel motor [B].

P–00610
Install the six bolts into the valve body [C]. C

Tighten the bolts to 43.0–50.0 ft. lbs. (58–68 Nm) torque.
P–00453
[D].
Install the orificed plugs into the side of the valve body
D
Tighten the plugs to 1.500 – 2.0 ft.–lbs.(2–3 Nm) torque.
P–00448

Added Aug.
A
Assembly (Cont’d)
Install the plugs into the orifice ports [A].
Tighten the plugs to 6.5–8.0 ft.–lbs. (9–10 Nm) torque.
P–00447
Install the orificed plugs into both ends of the valve body
[B]. B
Tighten the plugs to 1.500–2.0 ft.–lbs. (2–3 Nm) torque.

P–00445
Install new O–rings onto the plug (Item 2)

adapter (Item 4) [C].
[C] and the C
Install the adapter (Item 4) [C] into the valve body.
4 2
Tighten the adapter to 36.0–43.0 ft.–lbs. (49–58 Nm) 3 6 5 1
torque.
apply oil to the spool and install the spool and the spring.
P–00439
Install the plug into the valve body [D]. D

Tighten the plug to 36.0–43.0 ft.–lbs. (49–58 Nm) torque.
P–00444

Added Aug.172
A
Assembly (Cont’d)
Install new O–ring (Item 2)[A] onto the plugs (Item 1)[A].
Apply oil to the poppets (Item 4) [A] and install the
poppets (Item 4) [A] and the springs (Item 3) [A] into the 1 5 4
spool (Item 5) [A]. 3 2
Install the plugs (Item 1) [A] into the spool (Item 5) [A].
Tighten the plugs to 21.0–25.0 ft.–lbs. (29–33 Nm)
torque.
1
2 4 3
P–00435
Install new O–rings (Item 2) [B] onto plugs (Item 1) [B]. B

Apply oil to the spool (Item 5)[B] and install the spool into
the valve body.
Install the washers (Item 4) [B] onto the ends of the spool 1 1
and install the springs (Item 3) [B] over the ends of the 3 5 3
spool. 2
Install the plugs (Item 1) [B] into the valve body [C].

torque.
2 4 4
P–00441
P–00432
Install new back–up washers (Item 5) [D] and O–ring

(Item 6) [D] into the piston (Item 4) [D]. D
Install new back–up washers (Item 1) [D] and O–ring
(Item 2) [D] onto the spool (Item 3) [D].
Apply oil to the spool (Item 3) [D] and to the inside 3 7
diameter of the piston (Item 4) [D]. 2 5
Install the piston (Item 4) [D] onto the spool (Item 3) [D].
1 4 6
P–00440

Added Aug.
A
Assembly (Cont’d)
Apply oil to the spool and piston (Item 3) [A]. Install the
spool and piston (Item 3) [A] into the valve body (both
ends).
3
Install the spring (Item 2) [A] into the end of the spool. 2
P–00438
Install a new O–ring onto the plug (Item 1)[B] and install
the plug into the valve body.
B
torque.

P–00437
Install the three new small O–rings and the two large
O–rings into the valve body [C].
C
P–00436
Install the valve body [D].

D
P–00434

Added Aug.174
A
Assembly (Cont’d)
Install the four bolts into the valve body [A].
Tighten the bolts to 20.0–23.0 ft.–lbs. (27–31 Nm)torque.
P–00431

Added Aug.

UPPER WORKS AND SWING SECTION
231Service Manual #6722178 S/N 508912000 & Above – Upper Works & Swing Section Part 1 of 2
Page
Number
CENTER SWIVEL JOINT
...
CROSS–OVER RELIEF VALVE

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–13
....
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–11
....
UPPER WORKS &
SWING GEAR BOX ASSEMBLY (With or Without Brakes) SWING SECTION
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–25
....
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–16
....
SWING MOTOR
...
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4
....
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4–7
....
UPPER WORKS AND SWING CIRCLE GEAR
...
Swing Bearing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–42
...

Swing Bearing Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–41
...

Revised
177 of July
340 97 –4–1– Service Manual

Revised July
17897
SWING MOTOR
A
1
Remove the seat and swing motor cover
. (See Page 5–1.)

N–12351
the system.
I–2003–0888 B
NOTE: Use caps and plugs on all hydraulic hoses

and fittings.
Remove the pressure hoses (Item 1) [A] from the swing

motor.
Remove the center swivel joint drain hose [B].
N–12352
Remove the swing motor drain hose (Item 1) [C].

C
CD–12353
Remove the mounting bolts from the swing motor [D].

D
Nm) torque.
Remove the swing motor [D].
CD–12354

Revised
179 of July
SWING MOTOR
A 1
Disassembly
Prior to disassembly:
2
Clean the outside of the swing motor assembly. 3

Drain the oil from the motor casing.
Select a clean environment.
Handle with care.
Clamp the swing motor assembly in the vise with padded
jaws and mark the housing for ease of assembly [A].
Remove the three bolts (Item 1)[A] and lift the cross–over
relief valve (Item 2) [A] and block (Item 3) [A] from the
swing motor. P–08341
Remove the four bolts (Item 1) [B] and lift off the housing
(Item 2) [B].
B 1
NOTE: Take care not to lose inner parts.

P–08342
Remove the O–ring (Item 1)[C] and plug (Item 2)[C] from
the housing. C
1
P–08343
Remove the springs (Item 1) [D] the pins (Item 2) [D] and
the balance plate (Item 3) [D] from the swing motor (Item
4) [D].
D 1 1
2
2
3
P–08344

Revised July
18097
SWING MOTOR (Cont’d)
A
Remove the inner seal, from the balanceplate [A]. Notice
how the seal was installed.
Balance
Outer Plate Outer
Seal Seal
Pin Inner Seal Pin B–03046

B–08733
Remove the outer seal from the balanceplate [B]. Notice

how the seal was installed. B
Balance
Outer Plate Outer
Seal Seal

Pin Inner Seal Pin B–08732
B–03046
Remove the valve (Item 1) [C] from the valve plate.

NOTE: See assembly procedure Page 4–8 for timing
C 1
the motor when installing the valve, valve
drive and geroler.
P–08345
Remove the valve plate (Item 1) [D] from the assembly.

D 1
P–08346

Revised
181 of July
A
Remove the large O–ring (Item 1) [A] from the valve
plate. 1
P–08347
Remove the valve drive (Item 1) [B].

B
1

P–08348
Remove the geroler (Item 1) [C].

C 1
P–08349
Remove the drive shaft (Item 1) [D].

D 1
P–08350

Revised July
18297
A 3
1
Remove the large O–ring (Item 1) [A] and the small 2
O–ring (Item 2) [A] from the housing (Item 3) [A].
Assembly
Prior to assembly:
Clean all parts with solvent and dry with compressed
air.
Put grease on O–rings.
Lubricate parts with oil.
Install a new large O–ring (Item 1) [A] and a new small P–08351
O–ring (Item 2) [A] in the housing (Item 3) [A].
Install the drive shaft (Item 1) [B] into the housing. B 1

P–08350
Install the geroler (Item 1)[C] on the wear plate, engaging

the teeth of the drive shaft. C
1
P–08349

Revised
183 of July
A
Assembly (Cont’d)
Timing the hydraulic motor.
The timing of the motor controls the direction of rotation
of the drive shaft. The timing parts are as follows:
Geroler assembly 1
Valve drive
Valve plate
Valve
Find the largest opening in the geroler assembly (Item1)
[A]. Mark the outside of the geroler at this point.
P–08352
Install the valve drive (Item 1) [B].

B
1

P–08348
Install a new O–ring (Item 1) [C] on the valve plate.

C
P–08347
Make sure one of the ports on the valve plate is aligned

with the largest opening (marked earlier) of the geroler D
[D].
Install the valve plate (Item 1) [D].
1
P–08353

Revised July
18497
A 1
Assembly (Cont’d)
Install the valve (Item 1) [A] on the valve plate (Item 2)
[A]. Align one of the side ports with the mark on the 2
geroler housing. Turn the valve clockwise a small amount
until the teeth on the valve engage.
P–08354
Install the two springs and pins in the valve housing [B].
B

P–08355
Lubricate the inner and outer seals and install on the
balance ring as shown [C].
C Outer Face
Inner Face Seal
Seal Pin Notch
Balance Ring
B–13495
Install the balance ring in the valve housing, and engage

the alignment pins [D].
D
P–08356

Revised
185 of July
Assembly (Cont’d)
A
3
Install a new O–ring on the housing (Item 1)[A]. Install a
new O–ring on the plug (Item 2) [A] and install in the
housing.
Slide a finger in the side port (Item 3) [A] and hold 1
pressure on the valve, while tipping it upside down and
lowering it onto the housing. This will prevent the valve
and spring from falling out.
2
P–08343
Install the housing (Item 1)[B] on the assembly and install

the four bolts (Item 2) [B]. Tighten the bolts to 37 ft.–lbs.
B 2
(50 Nm) torque.

P–08342
NOTE: To ensure that the timing of the swing motor

is correct, put the swing motor in a vise. Fill
the port hole (Item 1) [C] with clean oil and
C 1
use a pipewrench to turn the shaftclockwise.
If timed correctly the oil will go down in the
port as the shaft is turned clockwise.
P–08420
Clamp the swing motor assembly in a vise with padded

jaws. D 3
Align the marks and install the cross–over relief valve 1

(Item 1) [D] and block (Item 2) [D] on the swing motor.
Install the three bolts (Item 3) [D].
2
Tighten the bolts to 52 ft.–lbs. (71 Nm) torque.
P–08341

Revised July
18697
CROSS–OVER RELIEF VALVE
A 1
Disassembly
2
Prior to disassembly:
Clean the outside of the swing motor assembly.
Drain the oil from the swing motor.
Select a clean environment. 3
Handle with care.

jaws and mark the housing for ease of assembly [A].
Remove the three bolts (Item 1)[A] and lift the cross–over
relief valve (Item 2) [A] and block (Item 3) [A] from the
swing motor. P–08341
Separate the cross–over relief valve (Item 1)[B] from the

block (Item 2) [B]. B 3
Remove the four O–rings (Item 3) [B].
3

1
2
P–08357
Remove the two relief valves (Item 1) [C] from the

cross–over relief valve. C
P–08358
Remove the large O–ring (Item 1) [D], the small O–ring

(Item 2) [D] and the back–up washer (Item 3)[D] from the D
relief valve.
1 2
P–08359

Revised
187 of July
CROSS–OVER RELIEF VALVE (Cont’d)
A
Remove the two plugs (Item 1) [A] from the cross–over
relief valve.
1 1
P–08360
Remove the plunger (Item 1) [B] the spring (Item 2) [B]

and the O–ring (Item 3) [B] from the plug. B
3 1
2

P–08361

Revised July
18897
Assembly
A
Prior to assembly: 1
Clean all parts with solvent and dry with compressed 3 4
air.
Put grease on O–rings.
Install a new O–ring (Item 1) [A] on the plug (Item 2) [A].

Install the spring (Item 3) [A] and plunger (Item 4) [A].
2
P–08361
Install the two plugs (Item 1) [B] in the cross–over relief

valve and tighten. B

1 1
P–08360
Install a new large O–ring (Item 1) [C], the small O–ring

(Item 2) [C] and the back–up washer (Item 3) [C] on the
relief valve. C
1 2
P–08359
Install the two relief valves (Item 1) [D] in the cross–over

relief valve and tighten. D
P–08358

Revised
189 of July
A 1
Assembly (Cont’d)
Install new O–rings (Item 1) [A] on the cross–over relief 1
valve housing (Item 2) [A] and on the block (Item 3) [A].
2
3
P–08357

jaws and align the marks on the housing with the marks
on the swing motor and block [B].
B 1
2
Install the three bolts (Item 1) [B] through the cross–over
relief (Item 2) [B] and the block (Item 3) [B].
Tighten the bolts to 52 ft.–lbs. (71 Nm) torque. 3

P–08341
The cross port relief valve used on the swing motor has
two relief valves (Item 1)[C] mounted on either side of the
valve body. These valves work to dampen the swing stop,
C
preventing damage to the swing motor. The relief valves
also prevent the upperstructure from independent 1
movement, or creeping, until the swing circuit is engaged.
1
P–08362
Connect a 5000 PSI gauge to the number three pump
section (Item 1) [D]. Warm the excavator hydraulic fluid
to operating temperature.
D
With the swing lock engaged, activate the swing circuit in
one direction.
Record the pressure.
Activate the swing circuit in the opposite direction.
Record the pressure.
The cross port relief valves are factory set at (1650 PSI 1
(11379 kPa) and are non–adjustable. If the valves do not
function correctly, remove, clean, install and retest. If the
valves do not function correctly after cleaning, replace the
relief valves. N–10597

Revised July
19097
SWING MOTOR (Without Brakes)
1. Snap Ring
2. Bearing
3. Coupling
4. O–ring 1
5. Flange 2
6. Spacer
7. Nut 3
8. Housing 7
9. Seal
10. Cover
11. Shaft 8
4
5 9
4
4
6
2
6
10

4
11
D–02175
SWING MOTOR (With Brakes)

1. Snap Ring 1
2
2. Bearing
3. Coupling 3
4. O–ring 2 5
5. Spacer 4
6. Piston
7. Housing
8. Disc, External Teeth
9. Disc, Internal Teeth 10
10. Gear
11. Nut 4
12. Seal
13. Cover 5 11
2
14. Shaft 6
7
4
12
7
5
8 2
9
10 13
5
14
D–02174

Revised
191 of July
SWING GEAR BOX ASSEMBLY
(WITH OR WITHOUT BRAKES) A
Disassembly
The following procedure contains information for the
repair of the gear box with or without brakes. The photos
used may appear different than the unit you are repairing,
but the procedure is the same. Some steps will be marked
as for units with brakes only or without brakes only so
follow the steps closely.
CD–13073

B
the system.
I–2003–0888

Drain the lubrication oil from the gearbox case by
removing one of the side plugs. Turn the case on its side
and drain the oil out of the drain hole.
1
Make an alignment mark down the side of the gear box
for ease of assembly. CD–13074
Remove the eight bolts from the top housing flange [A].
C
Remove top housing flange assembly [B].
Remove the O–ring (Item 1) [B] from the mating housing
face.
For With Brakes Only

Remove the eight bolts from the center housing flange
[C].
N–13075
Remove the center housing flange assembly [D]. D
CD–13076

Revised July
19297
SWING GEAR BOX ASSEMBLY (Cont’d)
A
Remove the brake coupling shaft from the top of the lower
housing [A].
N–13077
For Without Brakes Only

Remove the center spacer ring from the top of the lower
B
housing [B].

CD–13060
Remove the sun gear from the lower housing [C]. C
N–13078
Remove the ring gear spacer from the top of the lower
housing [D]. D
N–13079

Revised
193 of July
A
Remove the planetary gear assembly from the lower
housing [A].
NOTE: The planetary gear assembly components
are not serviceable separately. If any of these
parts are damaged, a complete planetary
gear assembly must be ordered from Melroe
parts.
CD–13080
The bearing retainer nut is staked to the output shaft. To

allow for easier removal of the nut, use a wedge shape B
chisel inserted into the groove in the output shaft. Drive
the chisel into the shaft groove to displace the metal from
the factory stake in the bearing retainer nut [B].

CD–13061
Use bearing nut removal tool (MEL1417) and removethe

bearing nut from the output shaft [C]. C
Use shaft retainer tool (MEL1419) to hold the gear end of
the shaft from rotating while removing the bearing nut.
bolt the housing to the shaft retainer tool and bolt the shaft
retainer tool to a stationary bench.
P–01918
Press the output from the lower housing [D]. D
CD–13082

Revised July
19497
A
Use a two or three jaw puller and remove the dust cap,
dust cup and the tapered bearing cone from the output
shaft [A].
CD–13083
Remove the tapered bearing cone from the lower housing

[B].
B

CD–13084
Remove the bearing spacer from the lower housing [C].

C
CD–13085
Remove the two O–rings from the internal diameter ofthe

bearing spacer [D].
D
CD–13062

Revised
195 of July
A
Use an internal puller and remove the lower bearing cup
from the lower housing [A].
CD–13063
Use a press and remove the opposite side tapered

bearing cup and the seal retainer [B]. B

CD–13064
Remove the O–ring from the outer diameter of the seal

retainer and remove the seal from the inner diameter of
the seal retainer [C].
C
CD–13065
The following eight steps; Page 4–7 [D] throughPage

4–9 [C] is for disassembly of gear boxes equipped D
with brakes. For gear boxes without brakes, go to
Page 4–9 [D].
Use a press and compress the spring retainer ring.
Remove the snap ring from the center housing [D].
Release the pressure on the press.
N–13086

Revised July
19697
A
Remove the spring retainer ring [A].
N–13087
Remove the six springs from the brake piston [B].

B

N–13088
Turn the center housing over and remove the snap ring
[C].
C
N–13089
Remove the brake disc retaining ring from the

housing [D].
center
D
N–13090

Revised
197 of July
A
Remove the brake discs from the center housing (six
external tooth and five internal tooth discs) [A].
N–13091
Use a press and remove the brake piston from the center
housing [B]. B

N–13092
Remove the two O–rings and the two back–up rings from
the internal diameter of the center housing [C].
C
N–13093
Remove the snap ring from the top housing flange [D]. D
CD–13094

Revised July
19897
A
Use a press and remove the input shaft and bearing from
top housing flange [A].
CD–13095
Remove the seal from the top housing flange [B]. B

CD–13096
Use a two or three jaw bearing puller and remove the two
bearings from the input shaft [C].
C
CD–13097
Remove the snap ring from the internal diameter of the

input shaft [D]. D
CD–13098

Revised
199 of July
A
Remove the plug from the input shaft [A].
CD–13099
Remove the O–ring from the internal diameter of the input

shaft [B]. B

CD–13100

Revised July
20097
A
Assembly
Install the seal into the output spacer ring [A].
Apply petroleum jelly to the inner diameter of the seal.
CD–13101
Apply petroleum jelly to the O–ring and install the O–ring

onto the outer diameter of the output spacer ring [B]. B

CD–13102
Place the output spacer ring assembly into the lower

housing [C]. Push the spacer ring in until it is flush with the
internal shoulder of the housing.
C
NOTE: The seal of the spacer ring assembly
contacts the internal shoulder of the
housing.
CD–13103
Install the outer bearing cup into the lower housing [D]. D
CD–13104

Revised
201 of July
A
Assembly (Cont’d)
Press the outer bearing cup into the lower housing until
it is flush with the spacer ring [A].
CD–13105
Turn the lower housing over and install the inner bearing
cup into the lower housing [B]. B

CD–13106
Press the inner bearing cup into the lower housing until it
is flush with the flange [C].
C
CD–13107
Place the outer bearing cone onto a support tube that

contacts only the inner bearing race [D]. D
CD–13108

Revised July
20297
A
Assembly (Cont’d)
Place the lower housing onto the bearing [A].
CD–13109
Do not install the O–rings into the bearing spacer at this

time. They will be installed later. B
Install the bearing spacer into the lower housing [B].
NOTE: The O–ring end of the bearing spacer will

face up.

CD–13110
Install the inner bearing cone into the top of the lower
housing [C]. C
CD–13111

Revised
203 of July
A
Assembly (Cont’d)
Press down on the top bearing cone using 1100 lbs. (500
Kg) of pressure [A].
Manually rotate the lower housing to determine the
smoothness and rotational resistance of the lower
housing.
CD–13112
If the rotation of the lower housing is difficult, install 0.039

inches (0,1 mm) shim(s) (Melroe P/N 13EM–4561)
between the bearing spacer ring and the bearing cone
B
[B].
If the lower housing rotates too easily
, remove the bearing
spacer ring and lap the end of the spacer ring until
rotational resistance is adequate [B].

CD–13113
Install the spacer onto the output shaft [C]. C
CD–13114
Install the outer dust cap onto the output shaft [D].
D
CD–13115

Revised July
20497
A
Assembly (Cont’d)
Install the inner dust cup onto the output shaft [A].
CD–13116
Fill the inner dust cup with a quality bearing grease [B]. B

CD–13117
Pack the bearing cone with a quality bearing grease and

install the outer bearing cone onto the output shaft [C].
C
CD–13118
Install the bearing spacer (and any bearing shims, if

needed) onto the output shaft [D]. D
The O–ring end of the spacer ring faces upwards.
CD–13119

Revised
205 of July
A
Assembly (Cont’d)
Apply petroleum jelly to the two O–rings. Carefully install
the two O–rings over the threaded shaft and down to the
bearing spacer.
Use a tool with a curved smooth end and push the
O–rings into the bearing spacer [A].
CD–13066
Apply a quality bearing grease to the two bearing cups.

Install the lower housing onto the output shaft [B].
B

CD–13120
Pack the bearing cone with a quality grease and install the
inner bearing cone onto the output shaft and down onto
the bearing cup [C].
C
CD–13121
Install the bearing nut onto the output shaft [D].

D
Use bearing nut tool (MEL1417) and tighten the bearing
nut to 324–400 ft.–lbs. (450–550 Nm) torque.
Use the shaft retainer tool (MEL1419) to hold the gear end
of the shaft from rotating while installing the bearing nut.
Bolt the housing to the shaft retainer tool and bolt the
shaft
retainer tool to a stationary bench.
P–01918

Revised July
20697
A
Assembly (Cont’d)
Use a center punch and stake the bearing nut to the
output shaft to prevent the nut from loosening [A].
CD–13123
The following twelve steps, Page 4–20 [B] through Page

4–23 [B] is for the assembly of gear boxes with brakes.
For gear boxes without brakes, go to Page 4–23 [C].
B
Apply petroleum jelly to the O–rings and back–up rings
and install the two O–rings and the twoback–up rings into
the center (brake) housing [B].
NOTE: The back–up rings are to the outer edges and

the O–rings to the inner edges of the O–ring

grooves.
N–13124
Apply petroleum jelly to the outer diameter of the brake

[C].
piston. Install the brake piston into the center housing C
N–13125
Use a press and push the brake piston in until it contacts

the inner housing flange [D]. D
PI–13126

Revised
207 of July
SING GEAR BOX ASSEMBLY (Cont’d)
A
Assembly (Cont’d)
Install the six springs into the brake piston holes [A].
N–13127
The springs should be installed into the brake piston as

shown [B]. B
Springs
Springs

MC–01761
Install the spring retainer into the housing [C].

C
N–13128
Use a press and compress the spring retainer and springs

downwards so the snap ring can be installed into the D
center housing [D].
N–13129

Revised July
20897
A
Assembly (Cont’d)
Rotate the mounting tabs of the snap rings so that they
are positioned in the housing drain port openings, as
shown [A].
N–13130
Use a portable hand pump using SAE 30 W motor oil and

apply 735 PSI (50 bar) pressure to activate the brake
piston and compress the brake springs [B].
B
This will allow easier assembly of the additional brake
components.

N–13131
Install the brake coupling shaft into the brake housing[C].

C
N–13132
Install an external tooth bronze brake disc into the

housing first, then install an internal tooth steel disc into
the housing and over the brake coupling shaft [D]. D
Alternate the brake discs until six external tooth and five
internal tooth discs are installed.
N–13133

Revised
209 of July
A
Assembly (Cont’d)
Install the spacer ring into the brake housing [A].
N–13134
Install the snap ring into the brake housing [B].

Release the pressure from the portable hand pump and
B
allow the brake piston to pressurize the brake discs.

N–13135

into the input shaft [C].
C
CD–13136
Install the plug into the internal diameter of the input shaft
[D]. D
CD–13137

Added July210
A
Assembly (Cont’d)
Install the snap ring into the input shaft [A].
CD–13138
Press the input shaft into the new bearing [B].

B

CD–13139
Turn the input shaft over and press the input shaft into the
second new bearing [C]. C
CD–13140
Apply petroleum jelly to the internal and external surfaces

of the new seal and install the seal into the top housing
flange [D].
D
CD–13141

Added July
A
Assembly (Cont’d)
Press the input shaft assembly into the top housing flange
[A].
CD–13142
Install the snap ring into the top housing flange to retain
the input shaft [B]. B

CD–13143

into the lower housing [C].
C
CD–13144
Install the planetary gear assembly intothe lower housing

[D]. D
CD–13145

Added July212
A
Assembly (Cont’d)
Install the ring gear spacer to the top of the housing and
onto the planetary gears [A].
CD–13146
Install the sun gear into the planetary gears [B].

B

CD–13147

Install the brake coupling onto the sun gear [C].
C
N–13148

D
into the center (brake) housing [D].
N–13149

Added July
A
Assembly (Cont’d)
Install the center (brake) housing onto the lower housing
[A].
Install the eight bolts into the center housing and tighten
the bolts to 29–37 ft.–lbs. (40–50 Nm) torque.
N–13150
For Without Brakes Only

Apply petroleum jelly to the O–rings and install theO–ring
B O–ring
into the center spacer.
Install the center spacer onto the lower housing and align
the bolt holes [B].

CD–13060

into the center (brake) housing or to the center spacer
ring.
C
Install the top housing onto the gear box [C].
O–ring
CD–13151
Install the eight bolts into the top housing[D]. Tighten the
bolts to 27–37 ft.–lbs. (40–50 Nm) torque. D
CD–13152

Added July214
UPPER WORKS AND SWING CIRCLE GEAR
A
This section involves the removal and installation of the
complete upperstructure from the track frame.
Connect a lifting sling to the excavator at the rear of the
swing frame and to the lift hook holes in the boom [A].
CD–12217
The boom must be in full raised position and centered to

the front of the excavator [B]. B 30”
(762 mm)
42”
(1067 mm)
NOTE: The dimensions shown are approximate
only, adjust the lifting sling until the
excavator is evenly supported.
31.25”
(794 mm)
108”
(3103 mm)

AVOID INJURY OR DEATH
• Use a lifting fixture with sufficient capacity
for the weight of the excavator plus any MC–01561
added attachments.
• Maintain center of gravity and balance when
•
lifting.
Do not swing boom or upperstructure.
C Upper Structure
Engage the swing locking lever.
• Never lift with operator on machine. Bearing
W–2202–0595
Track Frame
Mark the upperstructure to the swing bearing and to the
track frame for ease of assembly [C].
CD–13275
Partially disassemble the upperstructure from the swing

bearing by removing all but four bolts which are spaced D
at 90° from each other [D]. The upperstructure must be
rotated to gain access to the bolts for removal. Start the
engine and run it at idle. Remove a bolt from the swing
bearing, then move out of the way of upperstructure and
slowly rotate the excavator until access to the next bolt is
available. Remove this bolt and continue the above
procedure.
NOTE: For disassembly safety a minimum of 4
evenly spaced bolts must remain installed, to
be removed later.
Remove the floor mat and floor plate. (See Page 5–2.)
CD–13274

Added July
UPPER WORKS AND SWING CIRCLE GEAR (Cont’d)
A
Remove the swivel joint retainer bolt and jam nut [A].

disassembly and keep all parts clean. Always N–13277
the system.
I–2003–0888 B
Mark the eight hoses and fittings on the top portion of the
swivel for correct installation[B]. Remove the hoses from
the swivel joint.
Apply a slight amount of lifting pressure to the
upperstructure with the lift sling. Remove the four

remaining bolts holding the upperstructure to the swing
bearing.
N–13276
Lift the upperstructure off of the swing bearing. Position C

the upperstructure onto suitable supporting stands or
blocks [C].
CD–12222

Added July216
A
Swing Bearing Removal
Install a C–clamp or other suitable retainer to prevent the
swing bearing from turning while being removed [A].
CD–12224
Remove the 24 bolts and nuts that hold the swing bearing
to the track frame [B]. B

CD–12225
Mark the top surface of the swing bearing for ease of

reassemble. Remove the swing bearing from the track
frame [C].
C
CD–12226
Remove the grease cover from the track frame. Clean

and inspect the grease cover for damage [D]. Replace if
necessary. D
CD–12227

Added July
A FRONT OF MACHINE
Swing Bearing Installation
If using the existing swing bearing, use topside and edge
aligning marks to correctly position swing bearing. If a
new swing bearing is being installed, locate soft zone area
[A]. INNER RACE
Soft zone is OUTER RACE
Install the swing bearing so that the soft zone is positioned identified by Soft zone is
to either the L.H. or R.H. side of the excavator. a letter S at the
stamped on Ball Bearing
ring filler plug
NOTE: DO NOT locate the soft zone to the front or
rear of excavator.
PI–13677
Install the 24 bolts and lock nuts [B]. B

Tighten the lock nuts to 90 ft.–lbs. (120 Nm) torque.

CD–12228
Run a tap (12 mm) into the tapped holes in the

upperstructure to remove any dried LOCTITE or burrs
C
[C].
CD–12229
Grease the swing bearing gear with lubriplate grease or D

equivalent [D].
CD–12231

Added July218
A
Swing Bearing Installation (Cont’d)
Make three alignment pins by using M12 x 110 mm (P/N
7GM–12110) long bolts. Cut the head off of these bolts at
3.500 inches (90 mm) and then taper this end ofthe bolts 3.50’’ (90 mm)
[A].
Install these three pins into the upperstructure a t
approximately 120° apart [A]. These will act as alignment
pins while lowering the house frame onto the swin g
bearing.
B–13678
Install the upperstructure onto the swing bearing using

the alignment marks and the alignment pins [B].
B
Make sure the swing motor gear teeth mesh with th e
swing bearing teeth and that the swivel joint is centere d
into the upperstructure access hole.

B–13693
Install the three tapered head alignment bolts (P/N

C
6535902) thru the swing bearing and into the
upperstructure [C]. These bolts should be spaced a t
approximately 120°. This procedure will properly align the
upperstructure for correct swing motor gear to the swing
bearing ring gear clearance.
Tighten these three tapered bolts to 60 ft.–lbs. (81 Nm )
torque.
Remove the three, 3.500 inches (90 mm) alignment pins
from the upperstructure.
These headless pins can be removed from the bottom.
N–13278
Install the swivel joint retainer bolt and jam nut. T ighten
the jam nut to 75 ft.–lbs. (100 Nm) torque.
Install the hoses and fittings that were removed earlier.
Start the engine and run at idle to rotate th e
upperstructure to gain access to the swing bearing bo lt
holes.
Apply LOCTITE 242 to the threads of the bolts. Install th e
bolts into all holes (except the three with the alignmen t
bolts installed). Tighten these bolts to 80 ft.–lbs. (108 Nm
)
torque.
Install the floor plate and floor mat.
Check the hydraulic fluid level and add as necessary.

Added July
CENTER SWIVEL JOINT
A
Removal And Installation (through upper access
removal)
Remove the upper works from the swing gear and track
frame. (See Page 4–39.)

systems, clean the work area before N–13279
the system.
B
I–2003–0888 1
Mark all the hoses for correct installation.

Disconnect the hoses from the swivel joint [A].

Remove the bolts from the plate (Item 1) [A] below the
center swivel joint. 2
Installation: Tighten the bolts to 48–55 ft.–lbs. (65 to 75
Nm) torque. Use LOCTITE #242 on the bolt threads. 1
Remove the center swivel joint from the track frame. C–03299
Removal And Installation (through bottom access

cover)
Lower blade and boom to the ground.
Stop Engine.
Put jackstands under the blade and front and

rear corners of the under carriage before
working under the machine. Failure to block
up the machine may allow itto move or fall and
result in injury or death.
W–2218–1195
Remove two and loosen two bolts (Item 1) [B] from the
access cover (Item 2) [B] and remove the access plate
(Item 2) [B]. The plate mounting holes are slotted so that
the plate can be slid out.
Nm) torque.

Added July220
CENTER SWIVEL JOINT (Cont’d)
A
Removal And Installation (through bottom access
cover) (Cont’d)
When making repairs on hydrostatic and

hydraulic systems, clean the work area before
ports to keep dirt out. Dirt can quickly damage C–03300
the system.
I–2003–0284
B
Mark or tag the hoses and fittings for correct installation
[A].
Remove the bottom eight hoses from the swivel joint[A].
Remove the six side elbows from the side of the swivel
joint.
NOTE: Mark fitting alignment angle for ease of

installation.
Remove the floor mat and floor panels. (See Page 5–2.)
Remove the top eight hoses from the swivel joint from the
top side [B]. N–13276
Remove the four bolts (Item 1)[C] holding the swivel joint
to the track frame. C
Installation: Tighten the bolts to 48–55 ft.–lbs. (65 to 75
Nm) torque. Use LOCTITE #242 on the bolt threads.
Rotate the swivel joint 90° [C]. Lower the swivel joint out
the bottom of under carriage.
Inspect the fitting O–rings for damage and replace as
necessary.
1
C–03301

Added July
CENTER SWIVEL JOINT (Cont’d)
231Service Manual #6722178 S/N 508912000 & Above – Upper Works & Swing Section Part 2 of 2
SWIVEL JOINT
1. Bolt
2. Rotor
3. Plug
4. O–rings
5. Seal 1
6. Body 6
7. Cap
8. Cover 2
9. Washer
3
4
4
7
4

4
8
4
9
5
D–02157

Added July222
MAIN FRAME AND TRACKS
Page
Number
ARM
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–6
...
BLADE
...
BOOM
...
BOOM SWING BRACKET
...
BUCKET
...
CENTER FLOOR PANEL
...
ENGINE COVER
... MAIN FRAME
& TRACKS
IDLER

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13a
....
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13d
....
INSPECTION COVER
...
REAR FLOOR PANEL
...
ROLLER
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14a
....
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14d
....
ROPS
...
SEAT AND MOUNTING FRAME
...
SWING MOTOR COVER
...
TOOL BOX
...
TRACK
Removal and Installation (Rubber Track) . . . . . . . . . . . . . . . . . . . . . . .5–12 .
Removal and Installation (Steel Track) . . . . . . . . . . . . . . . . . . . . . . . . .5–12 .
Track Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–10
..
TRACK FRAME
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5–13
..
WINDOW
...
WORK GROUP HOSE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . .5–8
.

Revised Feb. 95

ENGINE COVER
A
Remove the cotter pin from the rod end pin of the gas
cylinder [A].
N–12357
Remove the cotter pin from the base end pin of the gas
cylinder.
B
Hold the engine cover and remove the gas cylinder
. Close
the engine cover.

Cylinder contains high pressure gas. Do not
open. Opening cylinder can release rod and
W–2113–0288 N–12358
Remove the bolts from the hinge [B].

C
Installation: Tighten the bolts to 20–27 ft.–lbs. (27–34 2
Nm) torque.
Remove the engine cover from the machine.
1
SEAT AND MOUNTING FRAME
Remove the four mounting bolts (Item 1)[C] from the side 2
brackets.
N–12359
Remove the four bolts (Item 2)[C] from the seat mounting
bracket.
D
Remove the seat and mount [D].
N–12360

CENTER FLOOR PANEL
A
Remove the bolts from the floor mat molding [A].
Nm) torque.
1
N–12361
Remove the floor mat molding (Item 1) [B] from the floor
mat.
B
Remove the spacers (Item 2) [B].
2
Remove the floor mat.

1
N–12362
Remove the bolts from the center floor panel [C]. C

Nm) torque.
N–12363
Remove the knob from the two speed foot pedal [D].
D
N–12364

CENTER FLOOR PANEL (Cont’d)
A
Remove the screws from the foot pedal rubber boot [A].
N–12365
Remove the rubber boot from the foot pedal [B].

Remove the center floor panel.
B

N–12396
SWING MOTOR COVER

C
Remove the bolts from the swing motor cover [C].
Remove the swing motor cover.
Nm) torque.
N–12366
REAR FLOOR PANEL

D
Remove the bolts from the rear floor panel [D].
Remove the rear floor panel.
Nm) torque.
N–12367

INSPECTION COVER
A
Remove the seat and mounting frame. (See Page 5–1.)
Remove the mounting bolts [A].
Remove the inspection cover.
CD–10667
TOOL BOX
B
Remove the hydraulic oil filter bolts [B].

CD–12368
Remove the bolts from the tool box [C]. C

Move the filter and hose assembly from the tool box.
CD–12369
Remove the tool box [D].

D
N–10669

BUCKET
A
Remove the retainer clips from the bucket pins [A].
N–12370
Remove the bucket pins and plastic spacers (Item 1)[B].
NOTE: Install the spacers in the same location

B
during assembly.

1
N–12371
Remove the nuts and bolts from the bucket teeth [C]. C
N–08599
Remove the bucket teeth [D].

D
N–08600

ARM
A
Support the arm with a chain hoist.
Disconnect the bucket cylinder hoses. (See Page 2–1.)
Remove the rod end of the arm cylinder from the arm.
(See Page 2–1.)
Remove the nut from the arm pivot pin [A].
N–12372
Remove the arm pivot pin and plastic spacers [B].

B

N–12373

BOOM
A
Support the boom with a chain hoist.
Mark all boom hoses for correct installation during
assembly.
Remove all the cylinder hoses from the tubelines on the
boom [A].
Remove the boom cylinder rod end from the boom. (See
Page 2–1.)
N–12374
Remove the nut from the boom pivot pin [B]. B

N–12375
Remove the boom pivot pin [C]. C
N–12376
Remove the boom from the swing bracket [D].

D
N–12377

Revised
231 of Feb.
BOOM SWING BRACKET
A
Remove the boom. (See Page 5–7.)
Remove the boom swing cylinder base end pin. (See
Page 2–1.)
Remove the hose retaining bracket [A].
Pull the hoses out of the boom swing bracket.
N–12378
Remove the upper or lower snap ring from the boom

swing bracket pivot pin [B]. B
Remove the boom swing bracket pivot pin.
Remove the boom swing bracket.
WORK GROUP HOSE INSTALLATION

Hose Mounting and Dimensions

Whenever the work hoses (boom, arm auxiliary and
bucket) are removed from the tube lines and the hose
clamp is removed from the boom swing bracket, the
hoses must be positioned and mounted as follows.
N–12379
Position the hoses inside the nylon hose guard material

as shown [C]. C
Route the hoses around the boom swing bracket post
[C].
NOTE: All cylinder base end hoses are routed on the

right hand side of the swing bracket post and BOOM
all cylinder rod end hoses are routed on the HOSE
left hand side of the swing bracket post.
ARM
HOSE
BUCKET BOOM CYLINDER
HOSE
AUXILIARY
HOSE B–13828
Route the hoses under the hose clamp (Item 1)[D] in the
order shown.
D BUCKET
AUXILIARY
NOTE: Leave the hose clamp loose at this time.
ARM
P–04448

Revised Feb.
23294
WORK GROUP HOSE INSTALLATION (Cont’d)
A
Hose Mounting and Dimensions (Cont’d)
Measure the length of each of the work hoses from the
center of the clamp to the end of the hose [A].
Adjust the work hoses to the following dimensions:
HOSE
Bucket Hoses (rod & base end) 29.500 inches (749 mm) CLAMP
Arm Hoses (rod & base end) 28.500 inches (724 mm)
Auxiliary Hoses (pressure & return) 27.0 inches (686 mm)
NOTE: Boom hoses are not clamped to the boom

swing bracket.
B–13829
Tighten the hose clamp while maintaining the correct
hose dimensions.
Install the hoses onto the tube lines on the boom.
B
After the hoses have been installed and tightened,
operate the excavator and ensure that the hoses are free
to move around the boom without binding or stretching in
any position during the work cycle of the boom and boom
swing bracket.

BLADE
Lower the blade to the ground.
CD–08611
Remove the blade cylinder hoses. (See Page 2–1.)
Remove the cylinder. (See Page 2–1.) C
Remove the cotter pins from the blade arm pivot pins
(both sides) [B].
Remove the blade arm pivot pins [C].
CD–08612

Revised
233 of Feb.
TRACK
A
Track Tension Adjustment
NOTE: The wear of the pins and bushings on the

undercarriage vary with the work conditions
and different types of soil conditions. It is
necessary to inspect track tension to
maintain the correct tension. (See Service
Schedule Page 1–1 for the correct service
interval.)
[A].
Raise the machine using the boom and arm as shown
N–11972
Raise the blade and install jackstands under the blade

and swing frame [B]. B
Stop the engine.

AVOID INJURY
Keep fingers and hands out of pinch points
when checking the track tension.
W–2142–0189 N–10677
Rubber Tracks
C
Measure the rubber track sag at either middle track roller
[C].
Do Not get fingers into pinch points between the track and
the track roller. Use a bolt or a dowel of the appropriate
size to check the gap between the contract edge of the
roller and top edge of the track guide lug [C] and [D].
Rubber Track Gap . . . . . . . . . . . . . . .9/16 inch (15 mm)
P–02936
D Track Frame
Track Sag
1/2’’–9/16’’
(10–15 mm)
Track
Roller
Track B–14067

Revised Feb.
23494
TRACK (Cont’d)
A Steel Track
Steel Tracks
Measure the steel track sag at the center of the track,
between the lower edge of the track frame and the top 4.25’’–4.75’’
surface of the track [A]. (108–120 mm)
Steel Track Sag . . . 4.250–4.750 inches (108–120 mm)
Center of Track
CD–13227
To adjust the track tension, do the following:

Loosen the two bolts from the cover [B]. Pivot the cover
B
downwards.

P–02928
Add grease to the fitting(Item 1) [C] until the track tension

is correct. C 1
P–02940
Loosen the bleed fitting (Item 1) [D] to release tension

from the track. D
NOTE: Do not loosen the grease fitting (Item 2) [D].
1
NOTE: Left hand side track frame grease fitting and

bleed fitting are shown in photo [D]. For right
hand side track frame, the grease fitting(Item
2) [D] will be on the top and the bleed fitting
(Item 1) [D] will be on the bottom.
2
P–02937

Revised
235 of Feb.
TRACK (Cont’d)
A
Removal and Installation (Rubber Track)
Lift and block the side of the machine where the track
will
be removed.
Loosen the bleed fitting. (See Page 5–11.)
NOTE: Do not loosen the grease fitting.
NOTE: A chain hoist can be used to pull up on the

track so all the tension is released from the
recoil spring cylinder for easier removal of
the track.
N–10678
Remove the track from the front track idler [A].

Remove the track from the frame and rear drive sprocket. B
Removal and Installation (Steel Track)

AVOID INJURY
Keep fingers and hands out of pinch points
when checking the track tension. 1 B–13045
W–2142–0189
C
Lift and block the side of the machine where the track will
be removed.
Loosen the bleed fitting. (See Page 5–11.)
NOTE: Do not loosen the grease fitting.
NOTE: A chain hoist can be used to pull up on the

track so all the tension is released from the
recoil spring cylinder for easier track removal
or link removal.
The track or a single link can be removed by removing

the CD–09482
pin (Item 1) [B]. The track can be separated and removed
from the frame.
The track can be removed as an assembly by removing
the track from the front track idler [C].
Remove the track from the frame and rear drive sprocket.

Revised Feb.
23694
TRACK FRAME
A
Use the following procedure to remove the different parts
from the track frame:
Remove the track.
Slide the front track idler out of the track frame to remove
it [A].
See Page 5–13a for disassembly and assembly
procedure.
N–10679
Remove the sliding plate [B]. B

N–10680
Slide the recoil spring cylinder forward and remove it from

the track frame [C].
C
N–10681
Remove the drive sprocket bolts [D].

D
Installation: Put LOCTITE on the bolts and tighten to 80
Remove the drive sprocket from the drive motor and
planetary gear assembly.
CD–08617

Revised
237 of Feb.
231Service Manual #6722178 S/N 508912000 & Above – Main Frame & Tracks Section Part 1 of 5

TRACK IDLER
TRACK IDLER
1. Idler
2. Block
3. Pin
4. Seal
5. Snap Ring
6. Bearing
7. Shaft
3
2
4
5

6
1
7
6
5 3
4 2
D–01960
Added Feb.
239 of 340 95 –5–13a– Service Manual
TRACK IDLER (Cont’d)
A
The following tools must be fabricated for this procedure:
4.50”
1. Driver Tool–See [A] (115 mm)
2. Support Fixture–Tube, 3.0 inches ID x 0.250 inch
wall x 6.0 inches long. 3.50”
(90 mm)
0.03”
(0,75 mm) 1.60”
Chamfer (40 mm) Dia.
2.70”
3 places (70 mm) Dia. B–14205
Disassembly
Remove the roll pin and block from each end of the shaft
B
[B].

CD–00230
Use a wire brush to remove any corrosion or paint from

both ends of the exposed shaft that could affect seal
C
removal or damage the new seal during installation [C].
CD–00231
Apply penetrating oil to both ends of the exposed shaft to

ease removal of the inner part of the seal. D
Remove the inner part of the seal using two screwdrivers
[D].
CD–00232

Added Feb.240
95of 340 –5–13b– Service Manual
A
Remove the outer part of the seal from the idler using two
screwdrivers [A].
Pour the oil out of the idler . Discard the oil in an
appropriate manner.
Turn the idler assembly over and remove the other seal.
CD–00234
Remove the snap ring from each side of the idler [B].
B

CD–00239
Using the fabricated driver tool and support fixture, press

or drive the shaft and bearing assembly out of the idler
[C].
C Driver Tool
Support
Fixture
CD–00240
Inspect the bearings for rust or for rough spots. The

bearings must turn freely, If any damage is found, replace D
the bearings. If replacement of the bearings is necessary,
use a two or three jaw puller, remove the two bearings
from the shaft [D].
CD–00244

Added Feb.
241 of 340 95 –5–13c– Service Manual
A
Assembly
Remove all paint and corrosion from the seal surface on
both sides of the idler [A].
Be sure all parts are clean before assembly.
CD–00245
Using the driver tool, install a new bearing, with the

numbered side upward, onto the shaft [B]. Press only on
B
the inner diameter of the bearing.

CD–00246
Using the driver tool, install the shaft and bearing

assembly into the roller [C]. C
CD–00247
Install the snap ring [D].

D
CD–00248

Added Feb.242
95of 340 –5–13d– Service Manual
A
Assembly (Cont’d)
Turn the idler assembly over.
Using the driver tool, install the other bearing, with the
numbered side upward, into the idler [A].
CD–00249
Install the snap ring [B].

B

CD–0250
Using a dial indicator, check the endplay of the shaft [C].

If the endplay is greater than 0.030 inch (0,76 mm) then
C Install
the bearing must be shimmed. Shims
Between
Cut a shim from the necessary thickness shim stock and Bearings
install the shim between the bearing and the shoulder on and
Shaft
the shaft. Shoulder
B–14276
CD–00242
Separate the inner and outer halves of the seal.

Apply grease to the grooves on the outer part of a new D
seal [D].
CD–00238

Added Feb.
243 of 340 95 –5–13e– Service Manual
Assembly (Cont’d)
A
Apply a small bead of high temperature silicone sealant
around the flange surface of the seal [A].
CD–00237
Using the driver tool, install the outer partof the new seal
into the idler [B]. B
NOTE: The inner and outer parts of the seal must be
installed separately so the air will escape
from under the seal.

CD–00235
Using the driver tool, install the inner part of the new seal
over the shaft [C]. C
NOTE: The inner part of the seal must be pressed
down level with the outer part of the seal to
seal properly.
CD–00233
Turn the idler assembly over. Using a syringe add 80 cc

of SAE 10W/30 oil to the assembly [D]. D
Repeat Page 5–13e Step [D] thru Page 5–13f Step[C] to
install the remaining seal.
Check for leaks.
CD–00236

Added Feb.244
95of 340 –5–13f– Service Manual
A
Assembly (Cont’d)
[A].
Install the roller pin and block on each end of the shaft
The two blocks must point in the same direction.
CD–00230

Added Feb.
245 of 340 95 –5–13g– Service Manual
TRACK FRAME (Cont’d)
A
Remove the guide block bolts [A].
CD–08618
Loosen the nuts at the track roller on both sides of the

track frame [B].
B

CD–08619
Remove the track roller [C].

C
CD–08620

Revised Feb.
24694
TRACK ROLLER
TRACK ROLLER NOTE: For use on all steel tracks and on

interchangeable rubber track (6663906). (See
1. Spacer BTI E–030 for detailed information.) See Page
2. Nut 5–14h for track roller used with rubber tracks
3. Washer (6662301 & 6663953).
4. Washer
5. Snap Ring
6. Snap Ring
7. Seal
8. Bearing
9. Shaft
10. Roller
2
3
4
1
5
7
6
8

9
10
8
6
7
5
1
4
3
2
D–01958
Added Feb.
247 of 340 95 –5–14a– Service Manual
TRACK ROLLER (Cont’d)
The following tools must be fabricated for this procedure:
A
4.50”
1. Driver Tool–See [A]. (115 mm)
2. Support Fixture–tubing, 3.0 inches ID x 0.250inch
wall x 6.0 inches long 3.50”
(90 mm)
0.03”
(0,75 mm) 1.60”
Chamfer (40 mm) Dia.
2.70”
3 places (70 mm) Dia. B–14205
Disassembly B
Remove the snap ring and spacer from each end of the
shaft [B].

CD–00309
Use a wire brush to remove any corrosion or paint from

both ends of the exposed shaft that could af fect seal C
removal or damage the new seal during installation [C].
CD–00306
Apply penetrating oil to both ends of the exposed shaft

to ease removal of the inner part of the seal. D
Remove the inner part of the seal using two screwdrivers
[D].
CD–00305

Added Feb.248
95of 340 –5–14b– Service Manual
A
Remove the outer part of the seal from the roller using two
screwdrivers [A].
Pour the oil out of the roller. Discard the oil in an
appropriate manner.
Turn the roller assembly over and removethe other seal.
CD–00303
Remove the snap ring from each side of the roller [B]. B

CD–00299
Using the fabricated driver tool and support fixture, press

or drive the shaft and bearing assembly out of the roller
C
[C]. Driver Tool
Support
Fixture
CD–00298
Inspect the bearings for rust or for rough spots. The

bearings must turn freely. If any damage is found, replace D
the bearings. If replacement of the bearings is necessary,
use a two or three jaw puller, remove the two bearings
from the shaft [D].
CD–00292

Added Feb.
249 of 340 95 –5–14c– Service Manual
A
Assembly
Remove all paint and corrosion from the seal surface on
both sides of the roller [A].
Be sure all parts are clean before assembly.
CD–00293
Using the driver tool, install a new bearing, with the

numbered side upward, onto the shaft [B]. Press only on
the inner diameter of the bearing.
B

CD–00291
Using the driver tool, install the shaft and bearing

assembly into the roller [C]. C
CD–00294
Install the snap ring [D].

D
CD–00295

Added Feb.250
95of 340 –5–14d– Service Manual
A
Assembly (Cont’d)
Turn the roller assembly over.
Using the driver tool, install the other bearing, with the
numbered side upward, into the roller [A].
CD–00296
Install the snap ring [B].

B

CD–00299
Using a dial indicator, check the endplay of the shaft [C].

If the endplay is greater than 0.030 inch (0,76 mm) then
C Install
the bearing must be shimmed. Shims
Between
Cut a shim from the necessary thickness shim stock and Bearings
install the shim between the bearing and the shoulder on and
Shaft
the shaft. Shoulder
B–14276
CD–00301
Separate the inner and outer halves of the seal.

D
Apply grease to the grooves on the outer part of a new
seal [D].
CD–00238

Added Feb.
251 of 340 95 –5–14e– Service Manual
A
Assembly (Cont’d)
Apply a small bead of high temperature silicone sealant
around the flange surface of the seal [A].
CD–00237
Using the driver tool, install the outer part of the new seal
into the roller [B]. B
NOTE: The inner and outer parts of the seal must be
installed separately so the air will escape
from under the seal.

CD–00302
Using the driver tool, install the inner part of the new seal
over the shaft [C]. C
NOTE: The inner part of the seal must be pressed

down level with the outer part of the seal to
seal properly.
CD–00304
Turn the roller assembly over. Using a syringe add 100 cc

of SAE 10W/30 oil to the assembly [D]. D
Repeat Page 5–14e Step [D] thru Page 5–14f Step[C] to
install the remaining seal.
Check for leaks.
CD–00300

Added Feb.252
95of 340 –5–14f– Service Manual
A
Assembly (Cont’d)
Install the spacer and the snap ring on each end of the
shaft [A].
CD–00309

Added Feb.
253 of 340 95 –5–14g– Service Manual

254 of 340 –5–14h– Service Manual
ROPS
A
Remove the bolts from the rear deck of the ROPS (four
each side) [A].
Installation: Tighten the bolt to 29–37 ft–lbs. (40–50 Nm)
torque.
N–12380
Remove the bolts from the front of the ROPS (two each
side) [B].
B
Installation: Tighten the bolt to 48–55 ft.–lbs. (65–75
Nm) torque.
Disconnect the wire from the heater switch. (See Page
7–17.)

Remove the heater hoses from the heater core. (See
Page 7–17.)
Disconnect the cab wire harness located by the right
console.
N–12381
Use a chain hoist to remove the ROPS [C]. C
N–12382
Front Window Removal

D
Remove the four screws (Item 1) [D] from the window
frame.
1
NOTE: Cabs with S/N M8960B–1 & Above use a
single bead of urethane around the window
perimeter only.
NOTE: Cabs with S/N M8960A–50 & Below only, use 2

an extra bead of urethane under the window
flange.
D–02094

Revised
255 of Feb.
ROPS (Cont’d)
Front Window Removal (Cont’d)

A
All Cabs: Use a utility knife to cut the urethane from the
window perimeter [A].
Remove the window from the ROPS frame.
Cab S/N M8960A–50 & Above Only: From the inside of
the cab, force a corner of the window out slightly , use
wedges to hold window in position.
Cut the urethane bead from the window flange until the
window is free from the ROPS frame.
Remove the two screws (Item 2) [B] that holds the center N–11660
post in the window frame. Remove the center post.
Spread the frame remove the glass or clean the channel
of all broken glass particles, if necessary. B
Installation: Install the glazing vinyl on threesides of the
stationary glass. Hold the vinyl in place with tape during 1
installation.
Apply water diluted liquid soap on channels during
window installation.
Install the glass in one side of the channel, spread the 2

frame and use a putty knife to control glazing vinyl while
guiding window into position.
Push glass into bottom position.
Install the glazing vinyl and center post on top of
D–02094
stationary window.
Install the screws in the center post to hold frame. DO
NOT TIGHTEN. C
Install the sliding glass in one side of the frame, spread
the frame and use a putty knife to control glazing vinyl and
guide the window in position.
Tighten the screws into the center post.
Use a utility knife to cut the tape from the window.
Install the window in the opening, install the four screws
and apply a bead of urethane on the perimeter of the
window [C].
Side Window Removal
PI–11661
NOTE: The removal procedure for the side window
is the same as the front window . (See Page
5–14.)
Installation
Remove the glass or clean the channel of all broken
glass
particles, if necessary.
Install the locks on glass.
Install the sliding glass in one side of the frame, spread
the frame and use a putty knife to control glazing vinyl and
guide the window in position.
Install the window in the opening, install the four screws
and apply a bead of urethane on the perimeter of the
window [C].

Revised Feb.
25694
ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–6
...
BATTERY
Checking the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–5
...
...
ELECTRICAL SYSTEM
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3....
Electrical System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4 ...
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–4
....
Fuse Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–4 ...
FUEL LEVEL SENDER
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–9
....
HOURMETER
...

INSTRUMENT PANEL
...
STARTER ELECTRICAL
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–8
... SYSTEM
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–8 ..
...
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–3
....
WIPER MOTOR AND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6–11

..
257 of 340
Revised July 97 –6–1– Service Manual

Revised July 97340
259 of 340
260 of 340
TROUBLESHOOTING
The following troubleshooting chart is provided for assis-
tance in locating and correcting problems which are most
common. Many of the recommended procedures must be
done by authorized Bobcat Service personnel only.
Instructions are necessary before operating or
servicing machine. Read Operation &
Maintenance Manuals, 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. Failure to follow instructions can
W–2003–0797
PROBLEM CAUSE
Battery will not take a charge. 1, 2, 3, 4, 5

Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9

KEY TO CORRECT THE CAUSE
1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses
ELECTRICAL SYSTEM
Description
The excavator has a 12 volt, negative ground electrical
system. There are two main circuits.
1. The charging circuit has an alternator (with integral
regulator) and a battery.
2. The starting circuit has a starter motor, solenoid and
ignition switch for starting the engine.
Fuses protect the electrical system from an overload.
The reason for the overload must be found before
starting the engine.
261 of 340
ELECTRICAL SYSTEM (Cont’d)
A
Fuses
The fuses protect the electrical system from damage. To
replace the fuse(s), loosen the screw and remove the
cover [A].
Replace the fuse(s) with the same type and capacity.
NOTE: Before replacing any fuse(s), make sure the
key switch is in the OFF position.
N–11950
Fuse Arrangement [B] & [C]

Ref. Fuse Capacity Fused Area
B
1. 15 Amp. Heater, Horn
2. 20 Amp. Ignition 1 6
3. 10 Amp. Gauges, Warning Lamps
4. 10 Amp. Fuel Pump 2
5. 10 Amp. [C] Wiper
3

Store spare fuses in the fuse compartment (Item 6) [B].
4
Electrical System Service
Use the following procedure to service the electrical
system: N–11951
1. Check that the battery cable ends are clean and

tight. Remove any acid or corrosion from the battery
cable ends with baking soda and water solution[D].
C
Cover the battery terminals with grease to prevent
corrosion.
2. Check the electrolyte level in the battery . Add
distilled water as needed.
3. Check the alternator belt for wear and correct
tension.
5
4. Check that all wire connections are secure.
N–11952
D
Batteries contain acid which burns eyes and
skin on contact. W ear 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
C–02578

Revised July
26297
BATTERY
A
Checking the Battery
The tool listed will be needed to do the following
procedure:
MEL10004A – Battery Tester
To make a safe and complete check of the battery , see
the Melroe Battery Manual (P/N 6566047). The battery
manual has all the information needed for checking and
servicing the battery.
Raise the engine cover [A]. N–11937
B
1
Batteries contain acid which burns eyes and

skin on contact. W ear goggles, protective 3
clothing and rubber gloves to keep acid off
body.

2
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.
N–11954
If electrolyte is taken internally drink large
quantities of water or milk! DO NOT induce
vomiting. Get prompt medical attention.
W–2065–1296
C
Disconnect the negative (–) cable (Item 1) [B] first.

Disconnect the positive (+) cable (Item 2) [B].
Remove the wing nut and the battery holddown clamp
(Item 3) [B].
Use a battery removal strap to remove the battery from

the machine [C].
Always clean the terminals and cable ends, even when N–11956
installing a new battery.
Reverse the procedure for battery installation.

Revised July 97
263 of 340
ALTERNATOR
A
Belt Adjustment
Stop the engine. Open the engine cover.
the belt should deflect about 0.500 inch (13 mm) when
pressed between the water pump pulley and crankshaft
pulley with approximately 13 lbs. (58 N) force [A].
If the tension is not correct, loosen the alternator
mounting bolt.
N–11949
Loosen the adjustment bolt (Item 1) [B]. B

Move the alternator until the belt tension is correct.
Tighten the adjustment bolt and mounting bolt.
Replace the belt if it has stretched or there are cracks in
the belt. Check the pulley grooves, make sure the belt is
not in contact with the bottom of the grooves in the 1
pulleys.

CD–10443

Disconnect the negative (–) cable from the battery.
C
Disconnect the alternator wires [C].
Remove the adjustment bolt [B].
Remove the alternator belt.
Remove the mounting bolt.
Remove the alternator from the bracket.
CD–08624

Revised July
26497
STARTER
A
Remove the operator seat and seat mount to gain access
to the starter.
Disconnect the negative (–) cable from the battery.
Disconnect the wires from the starter [A].
N–08625
Remove the mounting bolts from the starter [B]. B

Remove the starter from the bell housing.

N–08626
265 of 340
STARTER (Cont’d) 4
A
3
Disassemble the starter as shown in figure [A]. 11
Cleaning and Inspection 1
2 8
10
7
9
• Flying debris or loose material is present.
W–2019–1285
1. Armature
2. Bearing 6
3. Yoke 5
Use a brush and air pressure toclean the drive, field coils, 4. Frame
armature and starter housing. 5. Bolt

6. Frame
NOTE: Do not use solvent to clean the drive 7. Clutch
assembly. The solvent will remove the 8. Gear
lubricant and the drive will slip. 9. Switch Assy.
10. Plunger
Check the following items: 11. Cover
B–13014
Armature
Broken or burned insulation.
Loose connections at commutator.
Open or grounded circuits.
Worn shaft or bearings.
Rough commutator
Field Coils
Broken or burned insulation.
Electrical continuity.
Brush connections.
Drive Gear
Worn teeth.
Tooth engagement (drive gear must engage ring gear
by 1/2 the depth of the ring gear tooth).
Brush Holders
Broken springs.
Broken insulation.
Spring tension.

Revised July
26697
FUEL LEVEL SENDER
A
Remove the reservoir. (See Page 2–1.) 2
Remove the wire from the fuel switch screw (Item 1)[A],
and the ground wire screw (Item 2) [A].
Remove the sender mounting bolts.
1
Remove the sender.
Checking
Use an ohmmeter to check the resistance of the fuel CD–10670
sender.
The resistance check should read as follows:
FULL: 39.527.5 Ohms.
HALF: 118/97 Ohms.
EMPTY: 260/240 Ohms.

Added July
267 of 340 97
INSTRUMENT PANEL
A
Remove the mounting screws from the instrument panel
[A].
Lift the instrument panel.
N–10622
Unplug the wire harness from the instrument panel socket

[B]. B
Refer to the Operation & Maintenance Manual for the
Instrument Panel Operation.

N–10623
HOURMETER
C
Remove the mounting screws and nuts from the
hourmeter [C].
NOTE: Mark the hourmeter wires for correct

installation.
N–12472
Remove the wires from the hourmeter [D]. D
N–12473

Added July268
WIPER MOTOR AND SWITCH
A 1
The wiper switch wiring connections are as shown in[A]:
2
1.) Red Wire . . . . . . . . . . . . . . . . .Wiper High Speed
2.) Yellow Wire . . . . . . . . . . . . . .Wiper Park Position
3.) Red/White Wire . . . . Power from the Fuse Panel 5
4.) Green Wire . . . . . . . . . . . . . . . . Wiper
. Low Speed
5.) Purple Wire . . . . . . . . . . . . .Washer (if equipped)
4
B–14786
On Excavators with the early style wiper motor (P/N

6654163) the wiring connections are as shown in [B]: B
1
1.) Green Wire . . . . . . . . . . . . . . . . Wiper
. Low Speed
2.) Red Wire . . . . . . . . . . . . . . . . .Wiper High Speed
2

3
B–14788
On Excavators with the new wiper motor (P/N 6664094)

the wiring connections are as shown in [C]: C
2.) Red Wire . . . . . . . . . . . . . . . . .Wiper High Speed 1
3.) Green Wire . . . . . . . . . . . . . . . . Wiper
. Low Speed
2
B–14787

Added July
269 of 340 97
231ServiceManual#6722178S/N508912000&Above–ElectricalSystemSection

Added July
27097
ENGINE SYSTEM
Page
Number
AIR CLEANER
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–15
..
CYLINDER HEAD
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–24
....
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–22
....
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–24
....
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21
....
Servicing the Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–22 ..
ENGINE
..
ENGINE ASSEMBLY
Installing the Camshaft and Timing Gear . . . . . . . . . . . . . . . . . . . . . . . .7–39 .
Installing the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–39 ..
Installing the Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–41 ...
Installing the Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–39
...
ENGINE COMPRESSION

Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3
.....
ENGINE FLYWHEEL
Flywheel Ring Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–20
...
..
ENGINE REPAIR
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–36
...
Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–37
...
Removing the Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–25 ..
Removing the Timing Gear, Camshaft and Oil Pump . . . . . . . . . . . . . . .7–28
Removing the Pistons and Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . .7–29 .
Servicing the Connecting Rods and Pistons . . . . . . . . . . . . . . . . . . . . . 7–32 .
Servicing the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–34 ..
Servicing the Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–35 .. ENGINE
Servicing the Timing Gear and Camshaft . . . . . . . . . . . . . . . . . . . . . . . .7–31 . SERVICE
Water Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–37
...
FUEL FILTER
Final Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4
.....
In–Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–4 ....
FUEL INJECTOR NOZZLES

Checking the Injector Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–10..
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–9
...
FUEL INJECTION PUMP
Checking the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–6 ...
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–7
...
Timing the Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–8
...

ENGINE SYSTEM (Cont’d)
Page
Number
FUEL SHUT–OFF SOLENOID
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–5
....
GLOW PLUGS
Checking the Glow Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–11
...
...
HEATER
...
MUFFLER
...
RADIATOR
...
TROUBLESHOOTING
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7–1
....
VALVE CLEARANCE

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2
....

TROUBLESHOOTING
The following troubleshooting chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4

Engine will not start. 2, 5, 6, 7, 8, 9, 11, 12, 13, 14, 15, 16, 17, 19, 27, 28, 29
Difficult to start. 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29
No power from engine. 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 20, 21, 22, 23, 27, 28, 29
Engine is mis–firing. 8, 9, 11, 12, 13, 15, 16, 17, 21, 22, 24, 25, 26, 28
Too much fuel consumption. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Black exhaust. 10, 12, 13, 15, 16, 17, 19, 20, 21, 23, 24, 25, 27, 28, 29
Blue/white exhaust. 4, 10, 15, 16, 17, 21, 23, 27, 29, 30, 50
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 52
Engine knocking. 13, 15, 16, 19, 22, 24, 25, 27, 29, 31, 40, 41, 53
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 17, 18, 22, 24, 25, 26, 29, 40, 53

Vibration. 12, 13, 17, 21, 22, 25, 26, 29, 40, 42, 43
High oil pressure. 4, 33, 36
Overheating. 10, 12, 13, 15, 16, 20, 21, 40, 44, 45, 46, 47, 48, 51
Too much crankcase pressure. 22, 27, 29, 30, 40, 49
Poor compression. 10, 16, 21, 24, 25, 27, 28, 29, 30, 41, 53
Start and stop 9, 10, 11
KEY TO CORRECT THE CAUSE

1. Battery capacity low. 28. Worn valves and seat.
2. Bad electrical connections. 29. Broken or worn piston rings.
3. Faulty starter motor. 30. Worn valve stems or guides.
4. Incorrect grade of oil. 31. Worn or damaged bearings.
5. Low cranking speed. 32. Not enough oil in the oil pan.
6. Fuel tank empty. 33. Switch is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is stuck open.
9. Plugged fuel filter. 36. Relief valve is stuck closed.
10. Restriction in the air cleaner. 37. Broken relief valve spring.
11. Air in the fuel system. 38. Faulty suction pipe.
12. Faulty fuel injection pump. 39. Plugged oil filter.
13. Faulty fuel injectors. 40. Piston seizure.
14. Broken injection pump drive. 41. Incorrect piston height.
15. Incorrect injection pump timing. 42. Faulty engine mounting.
16. Incorrect valve timing. 43. Incorrect alignment of flywheel.
17. Poor compression. 44. Faulty thermostat.
18. Plugged fuel tank vent. 45. Restriction in water jacket.
19. Incorrect grade of fuel. 46. Loose alternator belt.
20. Exhaust pipe restriction. 47. Plugged radiator.
21. Cylinder head gasket leaking. 48. Faulty water pump.
22. Overheating. 49. Plugged breather pipe.
23. Cold running. 50. Damaged valve stem oil deflectors.
24. Incorrect tappet adjustment. 51. Coolant level too low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect high pressure fuel lines. 53. Broken valve spring.
27. Worn cylinder bores.

VALVE CLEARANCE
A 0.006’’–0.007’’
(0,15–0,18 mm)
Adjustment
Adjust the valve clearance with the engine stopped and
cold.
The correct valve clearance is 0.006–0.007 inch
(0,15–0,18 mm) [A].
Make sure the piston is at T .D.C. when making the
adjustment for the valves of the particular cylinder.
A–02730
Put the correct size feeler gauge between the rocker arm
and valve stem. Turn the adjustment bolt until the
B
clearance is correct [B].

B–05893

ENGINE COMPRESSION
Checking
A
Use MEL1063 – Engine Compression Kit to do the
following procedure.
The engine must be at operating temperature.
The compression must be at least 75% of 337–448 PSI
(2324–3089 kPa) with no more than 50 PSI (345 kPa)
difference between the cylinders.
Remove the nut and the glow plug wire [A].
CD–08635
Remove the glow plug [B].

B

CD–08636
Install the compression adapter in the glow plug hole[C].

C
CD–08637
Connect the compression gauge to the adapter [D].

D
Turn the engine with the starter and check the gauge
pressure.
CD–08638

FUEL SYSTEM
A
Fuel Filters
See the Service Schedule (See Page 1–1) for the correct
service interval for water drainage.
To remove the water from thefuel filter element, open the
drain valve (Item 1) at the bottom of the fuel filter element
[A].
When fuel, free of water emerges from the drain valve, 1
close the drain valve.
CD–13231
Fuel Filter Assembly

Remove the fuel lines (Item 1) [B] from the fuel filter
B
housing.
2
Plug the fuel lines. 1
1
Remove the two mounting bolts (Item 2)[B] from the filter
housing.

Remove the filter housing assembly.
3
CD–13230
In–Line Fuel Filter (if equipped)

Remove the hose clamps (Item 1)[C] from the in–line fuel
C
filter. 1
Plug the fuel lines.

Loosen the bolt (Item 2) [C] and remove the in–line fuel
filter.
2
1
CD–13232
Removing Air From the Fuel System

Loosen the filter bleed screw (Item 3) [B] on the filter D
housing.
1
Pump the priming ball (Item 1) [D] until fuel, free of air
bubbles emerges from the bleed screw.
Tighten the bleed screw.
N–11963

Revised Feb.
27694
FUEL SHUT–OFF SOLENOID
Adjustment
A 2
Stop the engine. 1 0.05 in.

(1,2 mm)
Loosen the jam nut (Item 1) [A] and rotate the solenoid
shaft to adjustment the linkage for a maximum distance
of .05 inch (1,2 mm) between the lever (Item 2) [A] and
the stop when the solenoid plunger is seated.
B–13704

Disconnect the wire from the solenoid [B].
B

N–12387
Remove the nuts from the ball joint [C].

C
N–12388
Remove the nuts from the shut–off mounting nuts [D].

D
Remove the shut–down.
Add fuel shut–off timer module.
N–12389

FUEL INJECTION PUMP
A
Checking the Injection Pump
The injection pump contains parts which have a very
close tolerance and its operation has a directeffect on the
performance of the engine.
Do not attempt to maintain or adjust unless

you are trained and have the correct CD–09523
equipment.
I–2028–0289
B
The tools listed will be needed to do the following
procedure:
MEL1237–Adapter Fuel Line
MEL1173–1–Pressure Gauge
To check the discharge pressure at the fuel injection
pump, use the following procedure:

Disconnect the clamp from the fuel line [A].
Disconnect the high pressure fuel line at the pump [B]/

CD–09524
Disconnect the other end of the same high pressure line C

[C].
CD–09525
Connect the adapter fuel line (Item 1) to the fitting [D].

D
Connect the pressure gauge (Item 2) [D].
Crank the engine, with the starter , to increase the
pressure to 2133 PSI (14707 kPa). Align the plunger at
T.D.C.
The pressure should hold at 2133 PSI (14707 kPa), at 1
least 5 seconds. If not, repair or replace the injection
pump.
B–08235

FUEL INJECTION PUMP (Cont’d)
A
Clean the area around the fuel injection pump. Remove
the high pressure fuel lines.
Disconnect the throttle linkage cable from the injection
pump [A].
N–12390
Loosen the jam nuts from the bracket to remove

throttle cable [B].
the B

N–12391
Disconnect the fuel inlet hose (Item 1) [C] and return

hose (Item 2) [C]. C
Remove the four injection pump mounting nuts (Item 1)
[C]. 1 2 1
Installation: Tighten the nuts to 17–20 ft.–lbs. (23–27
Nm) torque.
N–12392
Align the pin (Item 1) [D] in the control rack with the slot
in the engine block. D
Remove the injection pump.
Installation: When the injection pump is installed, make
sure the pin (Item 1) [D] on the control rack is correctly
installed on the fork lever. If the slot is not installed
correctly, the engine will run over maximum speed and
serious damage can result.
1
NOTE: Make sure the same number shims are
installed under the injection pump. The
shims are used for engine timing.
B–13709

FUEL INJECTION PUMP (Cont’d)
Timing the Injection Pump
A
NOTE: The engine timing marks are located on the
engine flywheel. Remove the left rear motor
mount [A].
N–12393
NOTE: Check the delivery valve nuts (Item 1) [B].

tighten to 29–30 ft.–lbs. (40–41 Nm) torque. B
Timing the fuel injection pump is done by changing the 1
number of shims (Item 2) [B] between the injection pump
and engine block. 2
Each shim will change the timing 1.5 degrees. Thetiming
of the pump will be later when a shim is added, and earlier
when a shim is removed.

Use the following procedure to time the injection pump:
1. Remove the number 1 cylinder high pressure line
from the injection pump.
B–13710
2. Install a short pipe in the number 1 outlet of the pump.
Point the pipe up (vertical).
3. With fuel supply to the injection pump, rotate the
C
engine counterclockwise direction (viewed from the
flywheel end of the engine). Fuel must flow from the
pipe as the mark on the flywheel and the pointer are
in alignment [C].
4. The correct timing for the engine is 23–25 degrees
B.T.D.C. Add or subtract shims(s) as needed to
adjust the delivery time of the fuel injection pump.
5. Repeat Step 3 several times for correct timing mark
alignment before adding or removing shim(s).
N–12394

FUEL INJECTOR NOZZLES
A
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 orwood
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. CD–09524
W–2072–0496
Some problems caused by faulty injector nozzles:

B
• The engine is hard to start or will not start.
• Rough engine operation at idle.
• The engine will not have full power.
• The engine exhaust smoke is black, white or blue.

CD–09526
Do not bend the high pressure fuel injection C

tubes when removing or installing them.
I–2029–0289

procedure:
MEL1181–Nozzle Socket
Disconnect the high pressure fuel lines from the fuel
injectors and the injection pump. Remove the high
pressure fuel lines [A].
CD–09527
Disconnect the return fuel hoses [B].
Remove the banjo fitting from the fuel injector [C]. D

Use the special socket and loosen the injector nozzle.
Installation: Tighten the injector nozzle to 29–36 ft.–lbs.
(39–49 Nm) torque.
Remove the injector nozzle from the cylinder head [D].
CD–09528

FUEL INJECTOR NOZZLES (Cont’d)
A
Checking the Injector Nozzle
3
Do not disassemble or test the fuel injector

nozzles unless you have the correct service
and testing tools. 2
I–2027–0284 1
B–04103
procedure:
MEL10018–Injector Nozzle Tester B
You can adjust the release pressure of the injector nozzle
by adding or removing spacer(s) (Item 1)[A] from the top
of the nozzle spring (Item 2) [A].
Each spacer is 0.004 inch (0,10 mm) thick and will change
the release pressure by about 142 PSI (980 kPa). The
release pressure should be 1920–2133 PSI

(13238–14707 kPa).
Connect the injector nozzle to the tester with the nozzle

down [B].
Operate the hand lever slowly and note the opening A–02513
pressure. If the pressure is not correct, disassemble the
injector nozzle and add or remove spacer(s) (Item 1) [A]
as needed. C Spring
Assemble the nozzle and check the pressure again. CORRECT WRONG
Pressure
Tighten the nozzle body (Item 3) [A] to 43–58 ft.–lbs. Pin Holder
(59–79 Nm) torque [A].
Nozzle
NOTE: Do not over–tighten, or slow action of the Body
valve will occur.
Needle
Check for internal leakage. Operate the hand lever until Valve
the pressure is almost enough to open the injectorvalve.
Record the pressure. Release the hand lever. check the A–02621
pressure drop for 10 seconds. If the pressure drop more
is
than 740 PSI (5102 kPa), the nozzle is damaged.
Check that the spray pattern is correct [C]:

• Fuel does not come out the side of the nozzle.
• Drops of fuel are not present at the nozzle. Diesel fuel or hydraulic fluid under pressure
can penetrate skin or eyes causing serious
• The nozzle has an even flow coming from the nozzle. injury. Fluid leaks under pressure may not be
visible. Use a piece of cardboard or wood to
find leaks. Do not use your bare hand. W ear
safety goggles. If fluid enters skin or eyes, get
immediate medical attention.
W–2074–1285

GLOW PLUGS
A
Remove the high pressure fuel lines from the injector
nozzles and injection pump.
Do not bend the high pressure fuel injection

tubes when removing or installing them.
I–2029–0289 CD–08635
Disconnect the glow plug wires [A]. B

Remove the glow plugs from the cylinder head [B].

CD–08636
Checking the Glow Plug

C
Connect a voltmeter to the terminal end of the glow plug,
touch the other lead from the voltmeter to the heating end
of the glow plug [C].
The reading must be approximately 1.5 OHMS. If the
resistance is zero OHMS, the glow plug has a short
circuit. If the resistance is infinite, the coil ofthe glow plug
is broken.
B–11571

RADIATOR
A
Drain the cooling system.
Disconnect the top radiator hose [A].
Disconnect the lower radiator hose and engine block
drain hose.
N–12395
Remove the two lower radiator mountingbolts and rubber

mounts [B]. B

N–12397
Remove the three mounting bolts from each [C].

Move the shroud away from the radiator.
C
Remove the lower radiator hose.
N–12398
Remove the overflow hose.

D
Remove the radiator drain valve hoses [D].
N–12399

RADIATOR (Cont’d)
A
Remove the four bolts from below the radiator mount[A].
Move the mount away from the engine for radiator
removal clearance.
N–12400
Remove the fan mounting bolts [B]. B

Remove the pulley.
Remove the shroud.

N–12401
Remove the top bolt from the right engine cover latch
bracket [C]. C
N–12402
Move the latch bracket to the left for radiator clearance

[D]. D
N–12403

RADIATOR (Cont’d)
A
Remove the radiator [A].
NOTE: Use care not to damage radiator fins.
N–12404
Remove the upper rubber mounts and washers [B].

B

N–12405

AIR CLEANER
A
Loosen the hose clamps on the air intake hose [A].
Remove the hose.
CD–09536
Remove the bolt from the air cleaner clamp [B].

B

CD–09537
Remove the clamp from the air cleaner intake hose [C]. C
CD–09538
Remove the air cleaner [D].

D
CD–09539

MUFFLER
A
Remove the bolt from the exhaust pipe flange [A].
N–12406
Loosen the bolt from the muffler clamp [B].

B

N–12407
Remove the muffler clamp bolt [C]. C
N–12408
Remove the muffler [D].

D
N–12409

HEATER
231ServiceManual#6722178S/N508912000&Above–EngineServiceSectionPart1of2
A
Open the drain valve (Item 1) [A] and drain the coolant
into a container.
N–12399
Remove the screws from the heater cover [B]. B

N–12410
Disconnect the wires from the switch [C].

Pull the wire harness from the heater housing.
C
N–12411
Mark the heater hoses (Item 1) [D] for installation.

D
Remove the heater hoses from the heater core. 2
Remove the four heater housing mounting bolts (Item 2)
[D]. 1
Remove the heater.
2
N–09543

ENGINE
A
Remove the engine cover. (See Page 5–1.)
Remove the radiator. (See Page 7–12.)
Remove the air cleaner. (See Page 7–15.)
Remove the seat and swing motor cover. (See Page 5–1
and 5–3.)
Disconnect the battery cables from the battery.
Disconnect the engine harness [A].
N–08669
Remove the motor mount bolts [B]. B

Remove the hydraulic pumps mounting bolts.
Remove the hydraulic pump.
Remove the heater hoses from the engine.
Remove the throttle cable from the fuel injection pump.
(See Page 7–7.)

Disconnect the shut–off wires.
Remove the tool box. (See Page 5–4.)
N–12393
Remove the fuel hose from the injection pump.

C
Remove the fuel return hose from the injection pump.
Connect a chain to the lift eyes on the engine and remove
the engine using a chain hoist [C].
N–12412

ENGINE FLYWHEEL
A
NOTE: The flywheel can be removed with the engine

installed in the machine.
If the engine is not removed; disconnect the two inlet

hoses (Item 1) [A] from the hydraulic pump. 1
2
Drain the hydraulic fluid into a container.
If the engine is not removed, disconnect the three high
pressure hoses (Item 2) [A] from the hydraulic pump.
N–10596
Remove the two mounting bolts (Item 1) [B] from the

hydraulic pump. B
Remove the hydraulic pump from the flywheel bell
housing.
NOTE: The following photos show flywheel removal

with engine removed from the machine. 1

N–10597
Remove the bolts from the flywheel housing [C].

C
N–08673
Remove the two top bolts from the muffler bracket [D].
D
Remove the muffler bracket.
N–08674

ENGINE FLYWHEEL (Cont’d)
A
Remove the cover from the flywheel housing [A].
N–08676
Remove the bolts from the hydraulic pump coupler [B].

B

Remove the hydraulic pump coupler [C].
Remove the bolts from the flywheel [D].

N–08677
Nm) torque.
Remove the flywheel.
C
Flywheel Ring Gear

• Flying debris or loose material is present. N–08678
W–2019–1285 D
The ring gear on the flywheel is an interference fit. Heat
the ring gear enough to expand it and hit with
it a hammer,
evenly to remove it.
Clean the outer surface of the flywheel to give a smooth
fit.
Clean the new ring gear and heat it to a temperature of
450–500°F (232–260°C).
Fit the ring gear over the flywheel. Make sure the gear is
seated correctly.
N–08679

CYLINDER HEAD
A
Removal
Remove the nuts from the valve cover and remove the
valve cover [A].
C–02559
Disconnect the injector tubelines and bleed–off banjo

fittings. B
Remove the injector nozzles and the copper gasket [B].
Remove the intake manifold.
Remove the belt shield and remove the alternator.

B–04091
Remove the rocker arms [C]. C

Remove the push rods.
Remove the water return pipe.
Remove the cylinder head bolts.
A–02764
Remove the cylinder head [D].

D
Remove the cylinder head gasket and the O–rings.
B–04120

CYLINDER HEAD (Cont’d)
Disassembly
A
6
NOTE: There may be a shim under the head gasket.
Use the shim over again or replace it with the 5
same size shim.
4 3 2
1
Remove the valve cap (Item 1) [A] and the valve spring
collet (Item 2) [A].
Remove the valve spring retainer (Item 4) [A].
Valve
Remove the spring (Item 5) [A]. Spring Retainer Seal Collets Cap
Remove the seal (Item 3) [A] and the valve (Item 6) [A]. B–04122
Remove the thermostat [B].

B

B–03643
Servicing the Cylinder Head

Use the tool listed for the following procedure:
C 1
MEL1098 – Valve Lapper

Clean the surface of the cylinder head.
Put a straight edge (Item 1) [C] on the cylinder head.
NOTE: Do not put the straight edge across the

combustion chamber.
2
Put a feeler gauge (Item 2)[C] between the straight edge
and the surface of the cylinder head.
A–02735
The maximum distortion of the cylinder headsurface is ±
0.002 inch (± 0,05 mm).
If the measurement is more than the specifications, the D
cylinder head must be planed.
NOTE: Place a soft brass rod through the injector

hole and tap the combustion chamber out
before planing the head. Plane the same
amount from the bottom side of the
combustion chamber before installing it
back in the head.
Clean the valve surface.
Measure the width of the valve seat [D].
B–03632

A Valve Contacting
Servicing the Cylinder Head (Cont’d) C Width
A
The correct width of the valve seat is 0.0827 inch (2,1 B
mm) and the seat angle is 45°.
Grind the valve seats as follows:
A. Use a 45° cutter to grind the surface of the valve seat
[A]. Uncorrected Surface Corrected Surface
of Valve Seat of Valve Seat
B. Use a 15° cutter to grind the front surface of the valve
seat [A]. A–45° Cutter
B–15° Cutter
C. Use a 65° or 75° cutter to grind the rear surface of the C–65° or 70° Cutter
valve seat to finish the seat to a 0.0827 inch (2,1 mm) A–02729
width [A].
D. Grind the valve surface to a 45° angle. B
Install the valve in the seat and check the depth [B].
The specifications of the depth of the valve is
0.043–0.051 inch (1,1–1,3 mm).
If the measurement is more than the specification, add
the correct thickness of the washer under the valve spring

to keep the correct tension on the spring.
Clean the valve guide.
Install the valve in the cylinder head.
Install the dial indicator. B–03634
Measure the clearance of the valve guide and the valve

[C].
C
The measurement must be 0.0016–0.0023 inch
(0,040–0,06 mm).
If the measurement exceeds the limit, replace the valve
guide.
Ream the new guide to the correct dimensions.
Measure the valve spring. The length of the spring must
be 1.6417–1.6614 inches (41,7–42,2 mm).
Replace the valve spring if it does not meet these
specifications. B–03698
Check the valve spring with a combination square to

make sure it stands straight.
D
Replace if not straight [D].
B–03680

A
Servicing the Cylinder Head (Cont’d)
Put the valve spring in a tester [A].
Push down on the spring 1.384 inches (35,15 mm). The
compression load must be 22.5–26.5 lbs. (10,21–12,03
kg).
Replace the valve spring if it does not meet these
specifications.
A–02759
Measure the inside diameter of the rocker arm bushing

(Item 1) [B] and the shaft diameter (Item 2) [B].
B
The inside of the rocker bushing is 0.551–0.553 inch
(14,002–14,043 mm). 2
1
If the measurements are not within the specifications
replace the needed parts.

Assembly
Install the valves.
B–03697
Put oil in the valve seal and install the seal on the valve.
Install the valve spring and the retainer. C
Install the spring collet and the valve cap.
Install the thermostat.
NOTE: If a new cylinder head is installed be sure to

install the screw plugs which are shipped
with the new cylinder head.
Installation
Install a new gasket and O–ring. Install a shim if there was
one removed.
Install the cylinder head on the engine block. B–03624
Put oil on the bolts and nuts and tighten to correct torque,
as follows:
D
Bolts with washers 58–61 ft.–lbs. (78–82 Nm).
Flange head bolts 65–58 ft.–lbs. (88–92 Nm).
Use the tightening sequence as shown [C].
Lower the piston which is to be measured for the

clearance, between the cylinder head and the piston.
Put a piece of solder in the injector port.
Make sure the solder does not touch the valves [D].
B–04068

A 0.006’’–0.007’’
Installation (Cont’d)
(0,15–0,18 mm)
Turn the engine manually.
Remove the solder and measure it. The thickness must
be 0.028–0.035 inch (0,7–0,9 mm).
If the measurement is not in the specifications, remove
the cylinder head and add the correct shim between the
cylinder head and the engine block.
Install the cylinder head and tighten the bolts and nuts as
shown on Page 7–24.
NOTE: Be sure to torque the bolts and nuts again A–02730
after the engine has been operated for 30
minutes.
Install the push rods.

B
Install the water return pipe.
Install the rocker arms.
Install the alternator, belt and shield.

Install the intake manifold.
Install the injector nozzle with a new copper gasket.
tighten to 22–36 ft.–lbs. (30–49 mm) torque.
Install the injector tubelines.
B–11493
Adjust the valve clearance. Make sure the piston is at
T.D.C. when making the adjustment [A].
C
ENGINE REPAIR
Remove the cylinder head. (See Page 7–21.)
Remove the push rods.
Remove the starter.
Remove the injector pump. (See Page 7–7.)
Removing the Gearcase

Remove the governor spring from the governor fork [B] B–03676
& [C].

ENGINE REPAIR (Cont’d)
A
Removing the Gearcase (Cont’d)
1
Remove the plate (Item 1) [A] for speed control and the
governor spring (Item 2) [A].
2
B–03647
Remove the start spring from the gearcase [B] & [C].
Straighten the washer on the crankshaft sheave.Remove
B
the nut and washer.
Installation: Tighten the nut to 101–110 ft.–lbs. (137–149
Nm) torque.
After installation, bend the washer on the sheave.

B–12949
B–03678

Removing the Gearcase (Cont’d)
A
The tool listed will be needed for the following procedure:
MEL1234 – Crankshaft Nut socket
Use a puller and remove the engine crankshaft sheave
[A].
Remove the key.
Remove the bolts from the gearcase.
B–03694
Remove the gearcase [B].

B

B–04095

A
Removing the Timing Gear, Camshaft and Oil Pump
Remove the crankshaft collar (Item 1) [A], O–ring, oil
slinger and the gear collar.
Remove the snap ring on the idler gear.
1
B–03637
Remove the idler gear (Item 1) [B]. B

Remove the idler gear collar from the shaft [B]. 1
Straighten the washer on the bolt for the camshaft stop.

Remove the bolt for the camshaft stop.

2
B–03699
Remove the camshaft [C]. C

Remove the three bolts that hold the fork lever on the fuel
camshaft.
Remove the stop for the fuel camshaft.
B–03655
Remove the fuel camshaft and the fork lever at the same
time [D]. D
B–03694

A
Removing the Timing Gear, Camshaft and Oil Pump
(Cont’d)
Remove the crankshaft gear with a puller [A].
Remove the key.
Straighten the washer on the gear of the oil pump.
Remove the bolt on the gear of the oil pump.
B–03686
Remove the gear pump (Item 1) [B]. B

Remove the oil pump bolt.
1
Remove the oil pump (Item 2) [B].

2
B–03658
Removing the Pistons and Crankshaft C

Remove the oil pan.
Remove the screen [C].
NOTE: Do not damage the O–ring.

Straighten the washer on the connecting rod bolts.
Remove the connecting rod bolts.
B–04124
Remove the cap and the bearing from the connectingrod

[D]. D
NOTE: Be sure to mark the piston and the
connecting rod so they will be assembled
correctly [D].
NOTE: Face the marks toward the injection pump

side of the block.
B–03688

A
Removing the Pistons and Crankshaft (Cont’d)
Remove the piston from the engine block [A].
NOTE: Be sure the pistons are marked so they will
be
returned to the same cylinder.
Straighten the washer on the flywheel bolts.

Remove the bolts from the flywheel.
Use a puller to remove the flywheel.
Straighten the washer on the bolts that hold the main
B–03625
bearing in position.
Remove the main bearing case bolts from the engine

block [B].
B
Nm) torque.

B–03644
Straighten the washer on the bolts that hold the main

bearings in position. C
Remove the bolts.
Install two bolts in the rear cover and pull the cover out
[C].
B–03648
Remove the crankshaft from the rear of the engine [D].

D
NOTE: Do not damage the crankshaft when
removing it from the engine block.
Straighten the washer on the bolts of the main bearings.
B–04129

A
Removing the Pistons and Crankshaft (Cont’d)
Remove the bolts from the bearing cap halves [A].
Remove the halves of the main bearings.
NOTE: When installing the bearing cap halves, make

sure the holes in the bearing caps align with
the holes in the engine block. Thrust washers
must be installed with oil grooves facing
outward.
Nm) torque.
B–04092
Servicing the Timing Gear and Camshaft

Measure the camshaft bearing in the engine block [B].
B
The specification is 1.5748–1.5758 inches (40–40,041
mm) The wear limit is 0.002–0.0036 inches (0,05–0,09
mm).

B–03620
Measure the camshaft journal [C]. C

The specification is 1.5722–1.5728 inches (39,934–
39,950 mm). The wear limit is 0.002–0.0036 inch
(0,05–0,09 mm).
If the measurements are not within the specifications
replace the needed parts.
Put the camshaft on V–blocks.
Put a dial indicator on the journals.
Turn the camshaft at a slow rate.
A–02761
The wear limit is 0.0008 inch (0,02 mm) [D]. D

If the camshaft measurements are not within the
specifications replace the needed parts.
A–02760

A
Servicing the Timing Gear and Camshaft (Cont’d)
Measure the highest point on each camshaft lobe [A].
The specification is 1.3134 inch (33,36 mm).
The wear limit is 1.3115 inch (33,31 mm).
B–05001
NOTE: After the crankshaft is installed, check the

clearance for the camshaft gear. B
Install a dial gauge.
Hold one gear while turning the other gear [B].
The specification is 0.006–0.0045 inch (152–1 14 mm).

B–03672
Servicing the Connecting Rods and Pistons

C
Remove the piston rings (Item 1) [C].
Remove the piston pin (Item 2) [C].
2 1
B–03621
NOTE: Be sure to mark the piston and the

connecting rod so they will be assembled D
correctly [D].
1. Align the marks
with each other.
2. Face the marks

toward the injection
pump side of the
block.
A–02903

Servicing the Timing Gear and Camshaft (Cont’d)
A
Measure the piston pin hole [A].
the specifications are 0.9055–0.9060 inch (23–23,013
mm). The wear limit is 0.9076 inch (23,053 mm).
A–02733
Measure the piston pin (Item 1) [B].

Measure the connecting rod bushing (Item 2) [B].
B
the specifications are 0.0006–0.0015 inch (0,152–0,039
mm). The wear limit is 0.0059 inch (0,015 mm).
NOTE: Replacement bushing specifications are

0.0006–0.0026 inch (0,015–0,066 mm).

When replacing bushings use the connecting rod hole
(Item 3) [B] as a guide, drill a hole through the 2
replacement bushing and deburr the hole.
3
1
B–03633
Put the piston ring on the bottom of the cylinder. C

Check the clearance of the ring gap [C].
The specification is 0.018–0.0177 inch (0,046–0,45 mm)
for the first and second rings. The wear limit is 0.0492 inch
(1,25 mm).
The specification for oil 0.0098–0.0177 inch
(0,249–0,450 mm).
Install the connecting rod on the tool for checking
connecting rod alignment.
B–03622
Check the clearance at the piston pin area [D]. D

The specification is 0.0008 inch (0,02 mm).
NOTE: Be sure the bushing diameter of the
connecting rod is within specification.
B–04067

A
Servicing the Crankshaft
NOTE: If a new crankshaft is used, besure the plugs
that come with the crankshaft are installed in
the crankshaft or engine damage will occur .
Put the crankshaft on V–blocks.

Put a dial indicator on the center journal and turn the
crankshaft slowly [A].
The specifications are 0.0008 inch (0,02 mm).
A–02763
Check the inside diameter of the crankshaft bearing in the

engine block [B].
B
The specification is 2.0565–2.0499 inches
(51,980–52,039 mm). The wear limit is 0.0079 inch (0,2
mm).

B–03631
Check the outside diameter of the #1 crankshaft journal

C
[C].
The specifications is 2.0441–2.0449 inches
(51,921–51,940 mm). the wear limit is 0.0079 inch (0,2
mm).
B–03618
D
Check the connecting rod bearings [D].
The specifications are 1.7327–1.7343 inches
mm).
120°
A–02727

A
Servicing the Crankshaft (Cont’d)
Check the connecting rod journals [A].
The specifications 1.7307–1.7313 inches (43,959–
43,975 mm). The wear limit is 0.0079 inch (0,2 mm).
A–02716
A
If the connecting rod journals are not within specifications
grind the journals as follows [B]:
B
a. Crankshaft corner radius must be 0.1378 ± 0.0079
inch (3,5R ± 0,2 mm) R.
b. The oil hole must be chamfered to 0.0394–0.0591
inch R (1–1,5 mm) R.
B

A
A–02716
Install the crankshaft and check the endplay [C]. C

Normal end play is 0.0059–0.0122 inch (0,15–0,31 mm).
Replace the thrust bearings on the main bearing if end
play exceeds 0.020 inch (0,5 mm).
B–09565
Servicing the Cylinder Liners

D
Check the inside diameter of the cylinder liner [D].
The tools listed will be used for the following procedure:
MEL1060–Ridge Reamer
MEL1180–Dry Liner Puller
B–04066

A
Servicing the Cylinder Liners (Cont’d)
To find the maximum wear check the inside diameter in
three different locations [A].
the specifications are 3.2283–3.2292 inches (82–82,021
mm). The wear limit is + 0.0059 inch (+ 0,15 mm).
When the cylinder liner has more wear than
specifications, bore and hone the cylinder to
3.2480–3.2489 inches (82,499–82,522 mm).
NOTE: Make sure you use the correct oversize
pistons and rings.
A–02717
If the cylinder liner is not within the specifications, replace

the cylinder liner. These are dry liners. B I J
Remove the cylinder liners. K
L
Clean and rub oil in the bores of the engine block.
M
Clean and put oil on the outside of the cylinder liners. N
H G
Install the cylinder liners into the engine block with the

inside and outside diameter chamfered end down.
the top of the liner must be even with the top of the engine
block machined surface.
F
After installation, bore and hone the cylinder liner to
3.2283–3.2291 inches (82–82,019 mm). B
C E
D
Lubrication System O
The lubrication system consists of a trochiode rotor–type
driven oil pump, oil filter cartridge, oil pressure regulating A
valve, oil switch, and oil filter [B].
Oil is drawn by the oil pump (B) from the oil pan (O) (A) Oil Screen . . . . . . . . . . . . . .(I)Rocker Arm Shaft
through the oil screen (A), where the oil is kept at 42–64 (B) Oil Pump . . . . . . . . . . . . . . .(J)Rocker Arm
PSI (294–441 kPa) by an oil pressure regulating valve (C) (C) Pressure Regulating Valve (K)Push Rod
installed in the gear case. Then oil flows towards thefilter (D) By–Pass Valve . . . . . . . . . . (L)Tappet
cartridge where it will be further filtered. T o insure the (E) Filter Element . . . . . . . . . . . (M)Oil Pressure Switch
supply of lubricating oil, a bypass valve (D) is provided, (F) Crankshaft . . . . . . . . . . . . . . . . .(N)Camshaft
the valve opens when the filter element (E) is restricted (G) Piston . . . . . . . . . . . . . . . . . . . . (O)Oil
. Pan
from the filter cartridge, the pressurized oil is then (H) Idle Gear
distributed into two areas; some will be fed through
crankshaft passage to the crank pin bearing and the rest B–09194
to the rocker arm shaft (I) through the frame. Oil then
returns to the oil pan by gravity.
The oil pressure switch (M) will indicate when oil pressure
drops below 7 PSI (50 kPa). The oil pressure switch is
connected to the oil pressure gauge in the dash panel. If
the pressure reads low or zero while the engine is in
normal operation, stop the engine immediately andcheck
the oil level. (Refer to Operation& Maintenance Manual.)

Oil Pump Service
A
Check the clearance between the inner and outer rotor
[A].
The clearance for the inner rotor is 0.0039–0.0063 inch
mm).
B–03616
Check the clearance between the outer rotor and the

B
body of the oil pump [B].
The clearance for the outer rotor is 0.0043–0.0075 inch
(0,11–0,19 mm).
At rated engine speed, the normal oil pressure is 42–56
PSI (289,5–3861,1 kPa) and minimum of 35 PSI (241,2
kPa).

A–02732
Water Pump Service C

Remove the water pump from the gearcase [C].
B–05318
Put the water pump in a vise and remove the nut [D]. D
Remove the pulley using a puller.
Remove the key.
Remove the snap ring.
B–05324

Water Pump Service (Cont’d)
A
Drive the shaft out of the impeller side [A].
B–05325
Install the new seals [B]. B

Install the shaft.
Put the water pump in a vise and tighten the nut to 50–57
ft.–lbs. (68,8–78,4 Nm) torque.
Install the water pump assembly on the gearcase with a
new gasket.

A–02783

ENGINE ASSEMBLY
A
Installing the Crankshaft
Install the main bearing case on the crankshaft journals. Main
Bearing
Tighten the bolts to 21–25 ft.–lbs. (29,4–34,3 Nm)torque. Case
Install the thrust bearing with the oil grooves to the
outside.
Install the crankshaft in the engine block.
Each main bearing is numbered for correct location.
Case
Be sure the holes in the main bearings align with the holes Bolts
in the engine block [A]. A–02736
Install the main bearing case bolts and tighten to 47–50

ft.–lbs. (63,7–20,7 Nm) torque. B
Install new seals in the crankshaft rear cover.
Install the rear cover and tighten the bolts to 13–15 ft.–lbs.
(17,7–20,7 Nm) torque.
Installing the Pistons

The tools listed will be needed for the following procedure.
MEL1063–Ring Compressor
MEL1064–Piston Ring Expander Alignment
Marks
Assemble the connecting rod to the piston. B–03614
NOTE: Be sure the marks on the piston and the

connecting rod are in the same direction. C
Install the rings on the piston [B].
Position the top ring so the gap is not lined up with the
piston pin. Position the other rings sothere is a gap every
90°.
Use a ring compressor to install the pistons in theengine
block with the marks away from the camshaft.
Align the bearing cap on the connecting rod [C].
Put oil on the bolts, install them in the bearing caps and
tighten the bolts with 13 mm heads to 26–30 ft.–lbs.
(36,3–41,2 Nm) torque. A–02731
Tighten the bolts with 12 mm heads to 32–36 ft.–lbs.

(43–49 Nm) torque. D
Install the oil pump tube and screen.
Install a new oil pan gasket and install the oil pan.
Installing the Camshaft and Timing Gears
Install the oil pump and tighten the bolts to 60–72 in.–lbs.
(6,78–8,13 Nm) torque [D].
Install the gear and tighten the nut.
Install the key and the gear on the crankshaft.
B–03658

ENGINE ASSEMBLY (Cont’d)
A
Installing the Camshaft and Timing Gears (Cont’d)
Install the fuel camshaft and the lever at the same time
[A].
Install the stop bolt on the fork lever . Tighten the bolt to
60–72 in.–lbs. (678–813 Nm) torque.
Install the bolts and tighten to 13–15 ft.–lbs. (17,7–20,6
Nm) torque.
B–03649
Install the camshaft and tighten the bolts to 13–15 ft.–lbs.

(17,7–20,6 Nm) torque [B].
B

B–03655
Install the idler gear [C]. C
B–03699
Be sure the timing marks are in correct alignment [D].

D Gear Marks
Install the snap ring on the idler gear shaft.
Cam Gear
Injection Pump Idle Gear
Gear
Oil Pump Crank Gear

Drive Gear
A–02771

A
Installing the Camshaft and Timing Gears (Cont’d)
Install the oil slinger (Item 1)[A]. Put oil on the O–ring and
install the O–ring (Item 2) [A] and the collar (Item 3) [A]. 1 3
2
B–04098
Installing the Gearcase
Install the O–ring and the oil seal in the gearcase cover
[B]/
B
NOTE: Put oil on the oil seal.
Install the gearcase cover and bolts.

O–rings
Tighten the bolts to 13–15 ft.–lbs. (17,7–20,6 Nm)torque.

Install the crankshaft sheave and tighten the nut to
101–116 ft.–lbs. (137–157 Nm) torque. Oil Seal
B–03617
Install the start spring [C].

C
B–03678
Install the speed control plate and governor spring [D].

D
NOTE: Do not drop the governor spring into the gear
case.
B–03647

231ServiceManual#6722178S/N508912000&Above–EngineServiceSectionPart2of2
A
Installing the Gearcase (Cont’d)
Connect the governor spring [A].
Install the injector pump. (See Page 7–7.)
Install the cylinder head. (See Page 7–21.)
Install the engine. (See Page 7–17.)
B–03676

TECHNICAL DATA
Page
Number
ENGINE SPECIFICATIONS
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4 ....
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–5 ....
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–5
....
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 ....
Engine Oil Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5 ...
Engine Bolt Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–6 ...
Fuel Injection Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4 ...
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4 ...
Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–5....
Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–5
....
Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–5....
Re–Grinding the Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–7 ..
Rocker Arms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 ....
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–4
....
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4 ....
FUEL, COOLANT AND LUBRICANTS
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–8
....
HYDRAULIC EXCAVATOR SPECIFICATIONS

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–3
....
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–3 ....
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–2
....
Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–3 ...
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–2 ...
Lifting Capacity with Blade off Ground . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 ..
Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–1 ...
Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....
Performance & Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2 ...
Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....
Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–3
....
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3 ....
OIL SPECIFICATIONS TECHNICAL
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8–8
.... DATA


HYDRAULIC EXCAVATOR SPECIFICATIONS • All dimensions are shown in inches. Respective metric dimensions are given in
millimeters enclosed by parentheses.
Machine Dimensions • Where applicable, specifications conform to SAE standards. Specifications are
subject to change without notice.
16.8
(426)
27.9
(710)
MC–1581
190.2
(4831)
137.6
(3495)

53.8
(1368) 94
(2388)
21.9
(558)
60.8
.98 (1545) 14.8
(25) (377)
61.3
(1557)
78.2
(1987)
MC–1583 12.6 MC–1582
(320)
60.7
(1542)
C
D
G With 32.2 (820)
Arm
A Max. digging depth 124.7 (3168)
B Max. vertical wall depth 82.5 (2097)
E
H C Max. digging reach 195.4 (4963)
D Max. digging reach at ground level 190.5 (4840)
F
I
E Max. digging height 182 (4725)
F Max. dumping height 126 (3200)
G Max. work equip, radius (w/ boom
J B at max. height & arm retracted) 82 (2088)
A H Max. height of Min. swing radius 140 (3561)
I Max. lift above ground (blade) 14 (357)
MC–1580 J Max. drop below ground (blade) 11 (280)

Revised Feb. 94
HYDRAULIC EXCAVATOR SPECIFICATIONS (Cont’d)
Lifting Capacity With Blade Off Ground (Model 231 with Canopy)
Lifting Capacity With Blade Off Ground (Model 231 with Cab)

Performance & Operation
Operating Weight W/Cab & Standard Bucket
W/Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7465. . . lbs. (3393 kg)
W/Steel Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7623
. lbs. (3465 kg)
Operating Weight W/Canopy & Standard Bucket
W/Rubber Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7134. . . lbs. (3235 kg)
W/Steel Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7292
. lbs. (3307 kg)
Travel Speed
Low Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5 MPH (2,5 km/hr.)
High Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9 MPH (4,7 km/hr.)
Controls:
Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Two
. . Hand or optional foot levers control speed and direction
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Foot
. . . . lever controls 2 speed drive motors
Right and Left joysticks control boom, bucket, arm and swing
Left foot pedal controls auxiliary hydraulic.
Right foot pedal controls boom swing. Separate hand lever controls blade.

Revised Feb. 94340
1.
Engine
Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kubota
..
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V–1902
.
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Diesel
..
Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 . . HP
. . . (25.4 kW) @ 2500 RPM
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 . . . cu. in. (1902 cu. cm.)
Maximum Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.5 . . . . ft.lbs. (111.8 Nm) @ 1800 RPM
Maximum Governed RPM – Full Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2500 . . . . .RPM
No Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2600 . . . . .RPM
Low Idle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000 . RPM
Number of Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Four
Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35/3.23 (85/82)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid .
Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure ..... System with Filter
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cartridge Type – Full Flow
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Volt, (1.4 kW)
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volt, 50 Amp.
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . . Volt, 425 Cold Crank Amps.
Hydraulic System
Pump Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three
.
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Triple Section Gear Pumps
Capacity (Implement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(3) . . .9.1
. GPM (34,5 L/min.)
System Relief Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2500 . . . . PSI (17235 kPa)
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Three
. . . Spool & Six Spool
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two Axial Piston

Swing Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Orbit
. Piston
Swing System
Swing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axial
. . . . .Piston Motor Planetary Drive
Swing Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Single
.. Row Shear Type Ball Bearings W/Internal Gears
Built Into Swing Circle
Swing Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.5 RPM
Boom Swing (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 degrees
(Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 degrees
Hydraulic Cylinders
Bore Dia. Rod Dia. Stroke
Boom (Cushion Boom Up) . . . . . . . . . . . . . . . . . . . 3.25 . (83) . . . . . . . . . . . .1.75 (44) . . . . . . . . . . . . . 25.31 (643)
Arm (Cushion Retract & Extend) . . . . . . . . . . . . . . .3.00 (76) . . . . . . . . . . . .1.75 (44) . . . . . . . . . . . . . 23.62 (600)
Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25
. . . (83) . . . . . . . . . . . .2.00 (50) . . . . . . . . . . . . . 19.69 (500)
Boom Swing (Cushion Left & Right) . . . . . . . . . . . .3.00 (76) . . . . . . . . . . . .1.50 (38) . . . . . . . . . . . . . 20.67 (525)
Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
. . . (89) . . . . . . . . . . . .1.75 (44) . . . . . . . . . . . . . 4.92 (125)
Drive System
Final Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Each
. . . . Track is driven by an Axial Piston Motor
Type of Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2. Stage
. . . Planetary Gear Reduction
Maximum Drawbar Pull . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7100 . . . . lbs. (3550 kg.)
Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 degrees
Brakes
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Lock in Motor
Swing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic
.... Lock on Motor & Pin Lock
Undercarriage
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crawler–Tractor
... Design Undercarriage. Sealed Track Rollers
W/Box–Section Track Roller Frame
Track
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rubber
. . . . (Standard) . . . . . . . Steel (Optional)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12.6
. . . .(320) . . . . . . . . . . . . . 12.6 (320)
Number of Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 . . . . . . . . . . . . . . . . . . . . . 41
Number of Track Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4. each .. side . . . . . . . . . . . 4 each side
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.63 . . . PSI (32 kPa) . . . . . . 4.7 PSI (32,6 kPa)

Capacities
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Gals. (45,4 L)
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Qts. (6 L)
Engine Oil & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.0 Qts. (8,5 L)
Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 . Gals. (45,4 L)
Final Drive Case (Each) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.55 . . . . Qts. (0,5 L)
Miscellaneous
Arm Digging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3600
. . lbs. (1633 kg)
Bucket Digging Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5170
. . . . lbs. (2350 kg)
Maximum Loading Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 . (2925)
Fuel Injection Nozzles

Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1990–2130
.... PSI (13726–14691 kPa)
Fuel Tightness Nozzle Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry
. . . .Nozzle at 1848–1990 PSI
(12742–13721 kPa)
Fuel Injection Pump

Fuel Tightness of Plunger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. .sec.: . initial pressure from 2133 PSI
(14707 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 seconds or less
Fuel Tightness of Delivery Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 . . sec.: initial pressure from 1422–71 PSI
(9804,7–489,5 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 seconds or less
Injection Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25–26
. . . . . degrees before TDC
Cylinder Head

Cylinder Head Surface Distortion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0002”
. . . . (0,05 mm)
Thickness of Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0512–0.0630”
... (1,300–1,600 mm)
Thickness of Gasket Shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0078”
. . . . . (0,20 mm)
Top Clearance (Piston to Head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0276–0.0354”
.... (0,7–0,9 mm)
Head Bolt Torque (Flanged Head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65–68 . . . ft.lbs. (88–92 Nm)
(Bolt and Washer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58–61
. . . . ft.lbs. (78–82 Nm)
Maximum Milling Allowed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.004”
. . . . . (0,1 mm)
Valves
Valve Seat Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0827” (2,1 mm)
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 degrees
O.D. of Valve Stems (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3134–0.3140” .. (7,960–7,975 mm)
I.D. of Valve Guides (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.3156–0.3161” .. (8,015–8,030 mm)
Clearance Between Valve Stem And Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0028” ... (0,04–0,07 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0039” (0,1 mm)
Depth of Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0433–0.0512”
..... (1,1–1,3 mm)
Valve Clearance (Old) (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0071–0.0087” ... (0,18–0,22 mm)
Valve Springs
Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6417–1.6614”
..... (41,7–42,2 mm)
Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3839” (35,15 mm)
Load to Compressed to Fitted Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26.5 . . . . lbs. (12,03 kg)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.5 lbs. (10,22 kg)
Rocker Arms
O.D. of Rocker Arm Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.5501–0.5506”
... (13,973–13,984 mm)
I.D. of Rocker Arm Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.5513–0.5529”
... (14,002–14,043 mm)
Clearance Between Rocker Arm and Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0004–0.0028” .. (0,01–0,07 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0059” (0,15 mm)
Camshaft
O.D. of Camshaft Bearing Journal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5722–1.5728”
.. (39,934–39,950 mm)
I.D. of Camshaft Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5748–1.5758”
.... (40–40,025 mm)
Clearance Between Camshaft Journal and Bearing . . . . . . . . . . . . . . . . . . . . . . . . . .0.002–0.0036” .. (0,50–0,091 mm)
Alignment of Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0008” . . . . . (0,02 mm)
Cam Lobe Height (Intake and Exhaust) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3134” .... (33,36 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3114” (33,31 mm)
Gear Clearance (Backlash) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0016–0.0045”
... (0,0415–0,1154 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118” (0,3 mm)
Revised Feb. 94
Cylinder
I.D. of Cylinder Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3465–3.3473”
.... (85–85,022 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.0059
... ” (+0,150 mm)
Oversize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.366–3.3670”
.... (85,5–85,5522 mm)
Piston Rings
Ring Gap (Top and 2nd Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0118–0.0177”
.... (0,30–0,45 mm)
Ring Gap (Oil Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0098–0.0177”
.... (0,25–0,45 mm)
Side Clearance of Ring Groove
Top Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0 Clearance
Second Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0037–0.0047”
.... (0,093–0,120 mm)
Oil Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0008–0.0020”
.... (0,020–0,052 mm)
Pistons
O.D. of Piston (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.342” . . . . . (84,88 mm)
O.D. of Piston (Oversize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.362” . . . . . (85,39 mm)
I.D. of Piston Bosses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9055–0.9060”
.... (23–23,013 mm)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.9076”
. (23,053 mm)
O.D. of Piston Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.9056–0.9059”
... (23,002–23,011 mm)
I.D. of Connect Rod Bushing (Small End, Fitted) . . . . . . . . . . . . . . . . . . . . . . . .0.9065–0.9071” . (23,025–23,030 mm)
Clearance Between Piston Pin
And Bushing (New) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0006–0.0015”
... (0,014–0,028 mm)
(Service Replacement Part) . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0006–0.0026” . (0,015–0,066 mm)
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0008” . . . . . (0,02 mm)

Crankshaft
I.D. of Crankshaft Main Bearing (No. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0465–2.0488”.. (51,98–52,039 mm)
I.D. of Crankshaft Main Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.0465–2.0482”
... (51,98–52,025 mm)
Clearance Between Crankshaft And Journal and Bearing . . . . . . . . . . . . . . . . . . . . .0.0016–0.0046” . (0,04–0,118 mm)
O.D. of Connecting Rod Journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7307–1.7313”.. (43,959–43,975 mm)
I.D. of Connecting Rod Bearings (Std.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7327–1.7343”.. (44,010–44,052 mm)
I.D. of Connecting Rod (Undersize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.7228–1.7234”
.. (43,759–43,775 mm)
1.7149–1.7156” (43,559–43,575 mm)
Clearance Between Connecting Rod Journal and Bearing . . . . . . . . . . . . . . . . . . .0.0014–0.0037” (0,035–0,093 mm)
End Play of Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0059–0.0122”
.... (0,15–0,21 mm)
Oil Pump
Oil Pressure @ rated RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42–64 . . . . PSI (289,6–441,3 kPa)
Limit Permitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 PSI (248,2 kPa)
Rotor Lobe Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .0.0016–0.0051”
.... (0,04–0,13 mm)
Clearance Between Outer Rotor And Pump Body . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0043–0.0075” .. (0,11–0,19 mm)
Engine Oil Specifications
Check oil level every 8 hours of operation (Check oil every 4 hours on new engine during the first 50 hours of operation).
Oil level must be between the add and full marks on the dipstick. Use a good quality detergent motor oil that meets the
correct API service classification (See Chart on Page 8–8).
Use oil of the correct SAE viscosity for expected temperature conditions.

ENGINE BOLT TORQUE

ft. lbs. Nm
*Cylinder head Bolts & Nuts (Flanged Head) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65–68 ... . . . . . . . . . . . .73–78
(Bolts and Washers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58–61 . . . . . . . . . . . . . . . . .78–82
*Main Bearing Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21–25 . . . . . . . . . . . . . . . . .29–34
*Main Bearing Case Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47–50 . . . . . . . . . . . .. . . . 63–68
*Flywheel Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72–79 . . . . . . . . . . . . . . 91–108
*Connecting Rod Bolts (12 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33–36 . . . . . . . . . . . . . . . .45–50
(13 mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26–30 . . . . . . . . . . . . . . . .36–41
*Rocker Arm Bracket Studs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12–15 . . . . . . . . . . . . .. . . 17–21
*Idler Gear Shaft Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8 . . . . . . . . . . . . . . . . .9–11
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15–18
. . . . . . . . . . . . .20–25
Drain Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30–36 . . . . . . . . . . . .39–49
Nozzle Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21–36
.. . . . . . . . . . . . .29–49
Oil Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–15 . . . . . . . . . . . .15–20
Fuel Injection Tubeline Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–19 . . . . . . . . . . . . . . . .13–26
Crankshaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101–116
..... . . . . . . . . . 137–157
Injection Pump Vent Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10–13 . . . . . . . . . . . . .. . . 14–18
*Lightly Oiled Threads

PUNCHED NUMBER BOLT MATERIAL GRADE
None Standard Bolts SS41, S20C
7 Special Bolts S43C, 248C (Refined)
9 Special Bolts SCM3, SCR3 (Refined)
BOLT TORQUES
MATERIAL GRADE STANDARD BOLT SPECIAL BOLT SPECIAL BOLT
NOMINAL DIAMETER SS42, S20C S43C, S48C (Refined) SCR3, SCM3 (Refined)
M6 6 to 7 ft. lbs. 7 to 8 ft. lbs. 9 to 11 ft. lbs.
(8 to 9 Nm) (9 to 11 Nm) (12 to 15 Nm)
(18 to 20 Nm) (23 to 27 Nm) (30–34 Nm)
(39 to 45 Nm) (47 to 56 Nm) (61 to 71 Nm)
(62 to 73 Nm) (77 to 91 Nm) (103 to 118 Nm)
(108 to 126 Nm) (123 to 148 Nm) (167 to 197 Nm)
(167 to 191 Nm) (197 to 225 Nm) (260 to 304 Nm)
M18 181 to 210 ft.–lbs 203 to 235 ft. lbs. 253 to 297 ft. lbs.
(245 to 285 Nm) (275 to 319 Nm) (343 to 403 Nm)
M20 246 to 289 ft.–lbs 271 to 318 ft. lbs. 362 to 420 ft. lbs.
(334 to 392 Nm) (367 to 431 Nm) (491 to 578 Nm)

ENGINE SPECIFICATIONS (Cont’d)
1.
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed
by parentheses.
Re–Grinding The Crankshaft

If the standard size bearing cannot be used due to excessive wear of the crank pin and
crankshaft journals, use undersize or oversize bearings.
D
C
2
3
2
A B
1
2 B–5928
1

REF. SIZE CODE NUMBER DESCRIPTION DIMENSION MARK
0.008” 15221–2391–1 Crankshaft 2.0363–2.0370” 020US

(0,2 mm) U/S Bearing #1 (51,721–51,740 mm)
A
0.016 ” 15221–2392–1 Crankshaft 2.0284–2.0291” 040US
(0,4 mm) U/S Bearing #1 (51,521–51,540 mm)
0.008 ” 15221–2393–1 Crankshaft 2.0363–2.0370” 020US

(0,2 mm) U/S Bearing #2 (51,721–51,740 mm)
B
0.016 ” 15221–2394–1 Crankshaft 2.0284–2.0291” 040US
(0,4 mm) U/S Bearing #2 (51,521–51,540 mm)
0.008” 15471–2297–1 Crankpin 1.7228–1.7234” 020US

(0,2 mm) U/S Bearing (43,759–43,775 mm)
C
0.016” 15471–2298–1 Crankpin 1.7149–1.7156” 040US
(0,4 mm) U/S Bearing (43,559–43,575 mm)
0.008 ” 15221–2397–1 Crankshaft 0.0315–0.0335” 0.20 OS

(0,2 mm) O/S 15221–2395–1 Thrust Bearing (26,20–26,25 mm)
D
0.016” 15221–2398–1 Crankshaft 1.0394–1.0413” 0.40 OS
(0,4 mm) O/S 15221–2396–1 Thrust Bearing (26,40–26,45 mm)
1 Radius – 0.0079–0.1181” (0,2–3,0 mm)
2 Radius – 0.0076–0.1378” (0,2–3,5 mm)
3 IMPORTANT: Oil holes must have a 0.0394–0.0591” (1–1,5 mm) chamfer.

Use on oil stone to chamfer the oil hole.

FUEL, COOLANT AND LUBRICANTS
231ServiceManual#6722178S/N508912000&Above–TechnicalDataSection
Use this chart for correct selection of Fuel, Coolant and Lubricants.
AMBIENT TEMPERATURE CAPACITY

F° –30 –20 –10 0 +10 +20+30 +40 +50 +60 +70 +80 +90 +100
RESERVOIR KIND OF FLUID C° –34 –29 –23 –18–13 –7 –1 +4 +10 +15 +21 +27 +32 +38 Refill
Engine oil pan Use SAE SAE 10W–30
4.5 qts.
Viscosity (4,3 L)
Number as
Listed With API SAE 15W–40
Classification
CC, CD or CE SAE 5W–30
SAE 30
SAE 20W/20
SAE 10W
Fuel Tank Diesel Fuel No. 1 6.5 gals

(24,6 L)
No. 2

Cooling System 50/50 Water & 50/50 Water & Anti–Freeze 6.0 qts.
Anti–Freeze (5,7 L)
Hydraulic Tank Bobcat Fluid Tank Cap.
6563328* 3.65 gals.
(13,8 L)
System Cap.
7.15 gals.
(27,1 L)
Final Drive Case 90W Gear 0.3 qts.
(each) (0,3 L)
* If Bobcat fluid (P/N 6563328) is not available. Use Engine Oil SAE 10W–30/10W–40, Class SE
OIL SPECIFICATIONS
Description
When fuel sulphur content is less than 0.5% change the
engine oil and filter as shown in the Service Schedule.
(See Page 1–1.)
Change engine oil and filter according to the following
chart if fuel sulphur content is above 0.5%.
Fuel Sulphur Change Interval Of
Content Engine Oil & Filter
0.5 to 1.0% 1/2 of Regular Interval
Above 1.0% 1/4 of Regular Interval

Revised Feb. 94340
231–1
® Revision Number
16 June 1992
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
Product BOBCAT EXCAVATOR X
SERVICE MANAGER
Model 231 (S/N 12001 & Above) SALES MANAGER
Manual No. 6722178 (3–92)
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
The following pages are a revision to the 231 Excavator Service Manual P/N 6722178 (3–92).

Take out and put in the pages as follows:
TAKE OUT PUT IN

Section 5 – Content Page Section 5 – Content Page (Revised June 92)
5–13, 5–14 5–13, 5–14 (Revised June 92)
5–15 (Added June 92)
325 of 340 Printed in U.S.A.

326 of 340
231–2
® Revision Number
11 August 1992
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SERVICE MANAGER
Manual No. 6722178 (3–92)

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Section 3 – Content Page Section 3 – Content Page (Revised Aug. 92)
3–19 thru 3–49 (Added Aug. 92)
327 of 340
328 of 340
231–3
® Revision Number
12 January 1994
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SERVICE MANAGER
Manual No. 6722178 (3–92)

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Section 4 – Content Page Section 4 – Content Page (Revised Jan. 94)
4–3 thru 4–11 4–3 thru 4–11 (Revised Jan. 94)
4–12 thru 4–33 (Added Jan. 94)
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FOREWORD FOREWORD (Revised Feb. 94)
SAFETY SAFETY (Revised Feb. 94)
v, vi v, vi (Revised Feb. 94)
SECTION 1
1–1, 1–2 1–1, 1–2 (Revised Feb. 94)
1–5 thru 1–8 1–5 thru 1–8 (Revised Feb. 94)
SECTION 2
CONTENT PAGE CONTENT PAGE (Revised Feb. 94)
231 HYDRAULIC SCHEMATIC (STANDARD) 231 HYDRAULIC SCHEMATIC (STANDARD)
(S/N 12000 & Above) (Printed March 1992) (S/N 12000 –12380) (Printed February 1994)
231 HYDRAULIC SCHEMATIC (ISO) 231 HYDRAULIC SCHEMATIC (ISO)
(S/N 12000 & Above) (Printed March 1992) (S/N 12000 –12380) (Printed February 1994)
HYDRAULIC SYSTEM OPERATION HYDRAULIC SYSTEM OPERATION
231 Excavator (S/N 12000 & Above) (ISO & STANDARD)
Chart #6722146 (Printed March 1992) 231 Excavator (S/N 12000 –12380)
Chart #6722146 (Printed February 1994)
231 HYDRAULIC SCHEMATIC (STANDARD)
(S/N 12381 & Above) (Printed February 1994)
231 HYDRAULIC SCHEMATIC (ISO)
(S/N 12381 & Above) (Printed February 1994)
HYDRAULIC SYSTEM OPERATION
(ISO & STANDARD)
231 Excavator (S/N 12381 & Above)
Chart #6722608 (Printed February 1994)
331 of 340
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SECTION 2
2–30 thru 2–63 (Added Feb. 94)
SECTION 5
CONTENT PAGE CONTENT PAGE (Revised Feb. 94)
SECTION 7
7–3, 7–4 7–3, 7–4 (Revised Feb. 94)
SECTION 8
8–7, 8–8 8–7, 8–8 (Revised Feb. 94)
332 of 340
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Section 5 – Content Page Section 5 – Content Page (Revised Feb. 95)
5–13 5–13 thru 5–13g (Added Feb. 95)
5–14a thru 5–14g (Added Feb. 95)
333 of 340
334 of 340
231–6
® Revision Number
8 March 1995
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6722178 (3–92)

TAKE OUT PUT IN

5–14a 5–14, 5–14a
335 of 340
336 of 340
231–7
® Revision Number
10 July 1997
SERVICE MANUAL Date
REVISION ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER
SERVICE MANAGER
Manual No. 6722178 (3–92)
The following page is a revision to the 231 Excavator Service Manual P/N 6722178 (3–92) Revised (7–96).

Put in the added page as follows:
TAKE OUT PUT IN

Section 2 Section 2
DO NOT remove the charts in Section 2
Section 4 Section 4
Section 6 Section 6
DO NOT remove the charts in Section 6
337 of 340
338 of 340
ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: 231-8

Date: 15 June 2012
Product: Bobcat Excavator
Model: 231
Manual No: 6722178 (3-92)

The following Sections are a revision to the above Service Manual.
COVER
339 of 340 SMR-1

340 of 340
SMR-2

231 6722178 enUS SM

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X 231

Dealer Copy -- Not for Resale

Doosan purchased Bobcat Company from Ingersoll-Rand Company in

6722178 (6-12) Printed in U.S.A. © Melroe Company 1992

Dealer Copy -- Not for Resale

231 (S/N 508912001 & Above) Excavator

231 (S/N 508912001 & Above) Excavator

2. Check that ROPS mounting 10. Check for correct function of

Dealer Copy -- Not for Resale

5. Machine signs must be legible 13. Lubricate the hydraulic

6. Steering levers, control levers 14. Check the condition of the

8. Check the electrical charging Recommend to the owner that all

231 (S/N 508912001 & Above) Excavator

231 (S/N 508912001 & Above) Excavator

MACHINE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v. . .

Dealer Copy -- Not for Resale

231 (S/N 508912001 & Above) Excavator

231 (S/N 508912001 & Above) Excavator

Dealer Copy -- Not for Resale

Warnings on the machine and in the This notice identifies procedures

231 (S/N 508912001 & Above) Excavator

Dealer Copy -- Not for Resale

231 (S/N 508912001 & Above) Excavator

HYDRAULIC EXCAVATOR SERIAL NUMBER

The excavator serial number is on the front of the

ENGINE SERIAL NUMBER

Dealer Copy -- Not for Resale

All Delivery Report items must be explained to the

231 (S/N 508912001 & Above) Excavator

Dealer Copy -- Not for Resale

231 (S/N 508912001 & Above) Excavator

Dealer Copy -- Not for Resale

231 (S/N 508912001 & Above) Excavator

6537457 (U.S.) 6537588 (I.S.O.)

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231 (S/N 508912001 & Above) Excavator

ENGINE LUBRICATION SYSTEM

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LUBRICATION OF THE HYDRAULIC EXCAVATOR

USING A BOOSTER BATTERY (JUMP STARTING)

231 (S/N 508912001 & Above) Excavator

231 (S/N 508912001 & Above) Excavator

ITEM SERVICE REQUIRED 8–10 50 100 250 500 1000

Dealer Copy -- Not for Resale

*After the first 50 hours of machine operation do the following:

231 (S/N 508912001 & Above) Excavator

AVOID INJURY OR DEATH

Open the engine cover to service the engine. Pull on the

AIR CLEANER SERVICE

Dealer Copy -- Not for Resale

Service the air cleaner as follows:

Remove the wing nut (Item 1) [D].

231 (S/N 508912001 & Above) Excavator

Push the button on the condition indicator (Item 1)[B] so

Dealer Copy -- Not for Resale

231 (S/N 508912001 & Above) Excavator

Stop and cool the engine before adding fuel.

Fuel System Service

Dealer Copy -- Not for Resale

Remove and inspect the fill neck screen [C].

To remove the water and sediment from the fuel tank, 1

231 (S/N 508912001 & Above) Excavator

See the Service Schedule (Page 1–1) for the correct