S 650

2 of 896
Dealer Copy -- Not for Resale

MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 NA1204 NA1193

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG

NA1192 NA1205 NA1206
Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
NA1200 NA1191 B-6589

Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW35-0409
3 of 896 1-1 S650 Service Manual


CONTENTS
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01


FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Spark Arrestor Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Loader Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16


SAFETY &
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc. HYDRAULIC
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including side screens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 11. Bob-Tach wedges and

correctly installed, functional linkages must function
and in good condition. correctly and be in good

condition.
4. The seat bar must be 12. Safety treads must be in good

correctly adjusted, clean and condition.
lubricated. ENGINE
5. Check lift arm support device, 13. Check for correct function of
replace if damaged. indicator lamps.
6. Machine signs (decals) must 14. Check hydraulic fluid level,

be legible and in the correct engine oil level and fuel
location. supply.
7. Steering levers, hand controls 15. Inspect for fuel, oil or

and foot pedals must return to hydraulic fluid leaks.
neutral (as applicable).
8. Check for correct function of 16. Lubricate the loader.

the work lights.
FW SSL-1008 SM

17. Check the condition of the 23. Operate the machine and
battery and cables. check all functions.
18. Inspect the air cleaner for 24. Check for correct function of
damage or leaks. Check the the Bobcat Interlock Control
condition of the element. System (BICS™) before the
machine is returned to the
customer.
19. Check the electrical charging 25. Check for proper function of
system. front horn and back-up alarm
(if equipped).
20. Check tires for wear and 26. Check function or condition of
pressure. Check tracks for all equipped options and

wear and tension. Use only accessories (examples: fire
approved tires or tracks. extinguisher, rotating beacon,
lift kits, etc.).
21. Inspect for loose or broken 27. Recommend to the owner
parts or connections. that all necessary corrections
be made before the machine
is returned to service.
22. Check for any field

modification not completed.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
FW SSL-1008 SM

FW SSL-1008 SM

SAFETY INSTRUCTIONS The following publications provide information on the safe
use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903

operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
• The Skid-Steer Loader Operator Training Course is
DANGER available through your local dealer or at

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

your Bobcat dealer or at www.training.bobcat.com
The signal word WARNING on the machine and in the or www.bobcat.com.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI SSL-1008 SM

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

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

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

Dial 811 (USA Only)

1-888-258-0808 (USA & Canada)
When you call, you will be directed to a location in your
state / province, or city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.).
SI SSL-1008 SM

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

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

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

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard. Stop the engine and let it cool before adding fuel. No
smoking! Do not refuel a machine near open flames or
The operator’s area, engine compartment and engine sparks. Fill the fuel tank outdoors.

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating. Starting
All fuels, most lubricants and some coolants mixtures are Do not use ether or starting fluids on any engine that has
flammable. Flammable fluids that are leaking or spilled glow plugs or air intake heater. These starting aids can
onto hot surfaces or onto electrical components can cause explosion and injure you or bystanders.
cause a fire.
Use the procedure in the Operation & Maintenance
Operation Manual for connecting the battery and for jump starting.
Do not use the machine where exhaust, arcs, sparks or

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

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

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI SSL-1008 SM

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

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

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

hoods, fenders or covers can be flammable or explosive.
Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers

Know where fire extinguishers and first aid kits are
located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Obey the recommendations on the instructions plate.
SI SSL-1008 SM

SERIAL NUMBER LOCATIONS Engine Serial Number
Always use the serial number of the loader when Figure 3

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1
1 P-90466
The engine serial number is located on the side of the

engine (Item 1) [Figure 3] behind the alternator.

P-90537
The loader serial number plate (Item 1) [Figure 1] is

located on the outside of the loader frame.
Figure 2
Module 2 - Production
Sequence (Series)
Module 1 - Model / Engine

Combination P-90175
Explanation of loader Serial Number [Figure 2]:
1. The four digit Model / Engine Combination Module

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

the order which the loader is produced.

DELIVERY REPORT
Figure 4
B-16315
The delivery report [Figure 4] must be completed by the

dealer and signed by the owner or operator when the
Bobcat loader is delivered. An explanation of the form
must be given to the owner.

LOADER IDENTIFICATION
FRONT OPERATION &

LIGHTS MAINTENANCE
MANUAL AND
OPERATOR’S
GRAB HANDBOOK
HANDLES
OPERATOR SEAT [1] REAR AUXILIARY
with SEAT BELT QUICK COUPLERS
AND SEAT BAR
TILT
CYLINDERS
FRONT AUXILIARY
QUICK COUPLERS
[2] BUCKET

STEP
BUCKET
STEPS
[3] OPERATOR CAB

LIFT (ROPS AND FOPS)
CYLINDER LIFT ARM
SUPPORT DEVICE
REAR
GRILLE
LIFT ARM
BACK-UP
ALARM
REAR
LIGHT
REAR
TAIL LIGHT [4] TIRES NA1667
DOOR NA1668
[1] Optional or Field Accessory. (Not Standard Equipment).

[2] BUCKETS - Several different buckets and other attachments are available for the Bobcat loader.
[3] ROPS, FOPS - Roll Over Protective Structure, per ISO 3471, and Falling Object Protective Structure per ISO
3449, Level I. Level II is available. The Bobcat loader is base-equipped with a standard operator cab as shown.
Extra insulated cab is available as an option (Reduced noise level).
[4] TIRES - Standard tires are shown. Several different tire styles and sizes are available for the Bobcat loader.

SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Removing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Special Applications Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Special Applications Kit Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
TRANSPORTING LOADER ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

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

TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
REMOTE START TOOL KIT-MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-2
Service Tool Harness Communicator - MEL1566 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-3
REMOTE START TOOL (SERVICE TOOL) KIT - 7003031 . . . . . . . . . . . . . . . . . . . . . . 10-61-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
Remote Start Tool (Service Tool) - 7003030 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-2
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-3
Computer Service Tool Harness - 6689746 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-4
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-5
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Biodiesel Blend Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1

Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-2
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Charge Filter . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-7
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-141-1

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1

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

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-200-1

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

EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
External Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
Front Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-210-1
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-220-1



LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
Figure 10-10-1
P-85985
Lift the front of the loader and put jack stands under the
B-7023A axle tubes [Figure 10-10-2].
NOTE: Make sure the jackstands do not touch the

tires. Make sure tires clear floor or any
obstacles.
WARNING

Figure 10-10-3
AVOID INJURY OR DEATH
Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Operator’s
Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
service. Untrained operators and failure to follow
instructions can cause injury or death.
W-2003-0807
Always park the loader on a level surface.

P-90556
P-85425
WARNING Lift the rear of the loader and install jack stands [Figure
10-10-3].
Put jackstands under the front axles and rear corners
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
23 of 896 10-10-1 S650 Service Manual


LIFT ARM SUPPORT DEVICE Figure 10-20-1
Installing
1
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
Service lift arm support device if damaged or if parts

are missing. Using a damaged lift arm support or P-85463A P-90566
with missing parts can cause lift arms to drop

causing injury or death. Put jackstands under the rear corners of the loader frame
W-2572-0407
(Inset) [Figure 10-20-1].
Remove the lift arm support device (Item 1) [Figure 10-

20-1] from the storage position.
DANGER

The operator must stay in the operator seat with the seat
belt fastened and the seat bar lowered until the lift arm
support device is installed.
Start the engine and raise the lift arms all the way up.
Figure 10-20-2
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part failure
can cause lift arms to drop.
• Keep out of this area when lift arms are raised
unless supported by an approved lift arm
support. Replace if damaged.
D-1009-0409
Remove attachment from the loader. (See Removal And

Installation on Page 50-40-1.) OR (See Removal And P-90567
Installation on Page 50-41-1.)
Have a second person install the lift arm support device
over the rod of one of the lift cylinders [Figure 10-20-2].
The lift arm support device must be tight against the

cylinder rod.

LIFT ARM SUPPORT DEVICE (CONT’D) Removing
Installing (Cont’d) The operator must be in the operator’s seat, with the seat
belt fastened and seat bar lowered, until the lift arm
Figure 10-20-3 support device is removed and the lift arms are lowered
all the way.
Start the engine and raise the lift arms all the way up.
Have a second person remove the lift arm support

device.
Lower the lift arms all the way and stop the engine.
P100005A
Return the lift arm support device to the storage position
and secure with clamping knobs.
Remove the jackstands.
P100005
Lower the lift arms slowly until the lift arm support device
is held between the lift arms and the lift cylinder [Figure

10-20-3]. The tabs of the lift arm support device must go
past the end of the cylinder (Inset) [Figure 10-20-3].

OPERATOR CAB
Description
The Bobcat loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. The seat belt must be
worn for rollover protection.
Check the ROPS / FOPS cab, mounting and hardware for

damage. Never modify the ROPS / FOPS cab. Replace
the cab and hardware if damaged. See your Bobcat
dealer for parts.
ROPS / FOPS - Roll Over Protective Structure per ISO

3471, and Falling Object Protective Structure per ISO
3449, Level I. Level II is available.
Level I
Protection from falling bricks, small concrete blocks,

and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction sites.

Level II
Protection from falling trees, rocks: for machines

involved in site clearing, overhead demolition or
forestry.
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat Company. Changes to
the cab can cause loss of operator protection from
rollover and falling objects, and result in injury or
death.
W-2069-0200

OPERATOR CAB (CONT'D)
Raising
WARNING
Always stop the engine before raising or lowering the
operator cab. UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
Stop the loader on a level surface. Lower the lift arms. If CONTROLS CAN CAUSE SERIOUS
the lift arms must be up while raising the operator cab, INJURY OR DEATH
install the lift arm support device. (See LIFT ARM
SUPPORT DEVICE on Page 10-20-1.) • STOP ENGINE before raising or lowering cab.
W-2758-0908
Figure 10-30-1
NOTE: On some machines, the operator cab frame
could contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.
Figure 10-30-3

P-85463A
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
Figure 10-30-2
Hardware Installed Hardware Removed

P-90564A
Lift on the grab handles and bottom of the operator cab

[Figure 10-30-3] slowly until the operator cab is all the
way up and the latching mechanism engages.
P-90512A P-90511A
Remove the nuts and washers [Figure 10-30-2] (both

sides) at the front corners of the operator cab.

OPERATOR CAB (CONT'D) Support the operator cab and release the latching
mechanism (Inset) [Figure 10-30-4]. Remove your hand
Lowering from the latch mechanism when the operator cab is past
the latch stop. Use both hands to lower the operator cab
Always stop the engine before raising or lowering the all the way down.
operator cab.
NOTE: Always use the grab handles to lower the

operator cab.
WARNING
Figure 10-30-4
PINCH POINT CAN CAUSE INJURY
Remove your hand from the latching mechanism
when the cab is past the latch stop.
W-2469-0803
Figure 10-30-5
Hardware Removed Hardware Installed

N-20120 P-90565A
Pull down on the bottom of the operator cab until it stops

at the latching mechanism [Figure 10-30-4].
NOTE: The weight of the operator cab increases

when equipped with options and accessories P-90511A P-90512A
such as cab door, heater, air conditioning,
etc. In these cases, the operator cab may need
to be raised slightly from the latch to be able Install the washers and nuts (both sides) [Figure 10-30-
to release the latch. 5].
Tighten the nuts to 54 - 61 N•m (40 - 45 ft-lb) torque.
WARNING
UNEXPECTED LOADER, LIFT ARM OR ATTACHMENT
MOVEMENT CAUSED BY CAB CONTACT WITH
CONTROLS CAN CAUSE SERIOUS
INJURY OR DEATH
• STOP ENGINE before raising or lowering cab.
W-2758-0908
NOTE: On some machines, the operator cab frame

could contact the steering levers while raising
or lowering the operator cab. The engine
MUST be stopped before raising or lowering
the operator cab.

OPERATOR CAB (CONT’D) Special Applications Kit
Cab Door Sensor
This machine may be equipped with a Cab Door Sensor.

WARNING
Figure 10-30-6
Some attachment applications can cause flying
debris or objects to enter front, top or rear cab
3 openings. Install the Special Applications Kit to
provide added operator protection in these
applications.
S3999A
W-2737-0508
Figure 10-30-8
1
2
P-68116
P-68115

The cab door has a sensor (Item 1) [Figure 10-30-6]
installed which deactivates the lift and tilt valves when the
door is open.
A decal is located on the latch mechanism (Item 2) NA1026

[Figure 10-30-6].
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] Available for special applications to restrict material from
will be OFF when the door is closed, the key switch is entering cab openings. Kit includes 1/2 inch thick
turned to RUN or the RUN button is pressed, the seat bar polycarbonate front door and polycarbonate rear window
is lowered and the PRESS TO OPERATE LOADER [Figure 10-30-8].
button is pressed.
Polycarbonate top window (standard item) must be
Figure 10-30-7 installed for special applications to restrict material from
entering cab openings.
See your Bobcat dealer for availability.
Special Applications Kit Inspection And Maintenance
• Inspect for cracks or damage. Replace if required.

• Pre-rinse with water to remove gritty materials.
• Wash with a mild household detergent and warm
water.
• Use a sponge or soft cloth. Rinse well with water and
dry with a clean soft cloth or rubber squeegee.
• Do not use abrasive or highly alkaline cleaners.
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] • Do not clean with metal blades or scrapers.
will be ON when the door is open, the key switch is
turned to RUN or the RUN button is pressed, the seat bar
is lowered and the PRESS TO OPERATE LOADER
button is pressed.
[DOOR] will appear in the data display [Figure 10-30-7].

TRANSPORTING LOADER ON A TRAILER Fastening
Loading And Unloading Figure 10-40-2

Rear Tie Down Front Tie Down
WARNING
AVOID SERIOUS INJURY OR DEATH
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury. P-85615A P-85616A
W-2058-0807
Be sure the transport and towing vehicles are of

adequate size and capacity for weight of loader. (See
Performance on Page SPEC-10-2.)
Figure 10-40-1

P-90561A
Alternate Rear Tie Down Alternate Front Tie Down
P-90560A
P-85466
P-85717A P-85599A
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10-
40-1]. Use the following procedure to fasten the Bobcat loader
to the transport vehicle to prevent the loader from moving
The rear of the trailer must be blocked or supported (Item during sudden stops or when going up or down slopes
1) [Figure 10-40-1] when loading or unloading the loader [Figure 10-40-2].
to prevent the front end of the trailer from raising up.
1. Lower the bucket or attachment to the floor.
2. Stop the engine.
3. Engage the parking brake.
4. Install chains at the front and rear loader tie down

positions [Figure 10-40-2]. (Lift arms shown raised
for clarity.)
5. Fasten each end of the chain to the transport vehicle.
6. Use chain binders to tighten the chains.


TOWING THE LOADER
Procedure
Because of the design of the loader, there is not a

recommended towing procedure.
• The loader can be lifted onto a transport vehicle.
• The loader can be skidded a short distance to move

for service (EXAMPLE: Move onto a transport
vehicle.) without damage to the hydrostatic system.
(The tires will not turn.) There might be slight wear to
the tires when the loader is skidded.
The towing chain (or cable) must be rated at 1.5 times the
weight of the loader. (See Performance on Page SPEC-
10-2.)


REMOTE START TOOL KIT-MEL1563 Figure 10-60-2
Remote Start Tool - MEL1563
Tools that will be needed to complete the following steps

are:
2
MEL1563 - Remote Start Tool 3
MEL1565 - Service Tool Harness Control 1
MEL1566 - Service Tool Harness Communicator
(Computer Interface)
Figure 10-60-1
P16117
1
The traction lock switch (Item 1) [Figure 10-60-2] is used

to turn traction lock ON or OFF. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
able to turn.

The maximum flow / variable flow switch (Item 2) [Figure
10-60-2] is used to activate the auxiliary hydraulics.
Pressing the switch will activate variable flow. The switch
P16114 will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
when checking pressures and flow rate.
The remote start tool (Item 1) [Figure 10-60-1] is
required when the service technician is checking the NOTE: With the engine running; pushing and holding
hydraulic / hydrostatic system, adjusting the steering the pressure release switch (Item 3) [Figure
linkage, and electrical diagnostics. 10-60-2] will cause the engine to stop.

REMOTE START TOOL-MEL1563 (CONT'D) Figure 10-60-5
Service Tool Harness Control - MEL1565
Figure 10-60-3
2
2
1
1
P-85728
Loaders equipped with an attachment harness (Item 1)

P16114 must disconnect the attachment harness from the loader
harness (Item 2) [Figure 10-60-5].
The service tool harness control (Item 1) is used to Connect the service tool harness to the ACD connector
connect the remote start tool (Item 2) [Figure 10-60-3] to and the loader harness connector.

the electrical system on the loader.
NOTE: To monitor, diagnose or load new software
Figure 10-60-4 the Service PC must be connected to the
Remote Start Tool.
P-85729
Remove the cap (Item 1) [Figure 10-60-4] from the

loader harness connector.
Connect the service tool harness control to the loader

harness connector.

REMOTE START TOOL-MEL1563 (CONT'D) Remote Start Procedure
Service Tool Harness Communicator - MEL1566 The tool listed will be needed to do the following
procedure:
Figure 10-60-6
MEL1563: Remote Start Tool Kit
2
Figure 10-60-7
1
1
P16119
The service tool harness communicator (Item 1) is P16115

required to connect remote start tool to the Service PC

(Item 2) [Figure 10-60-6].
The remote start tool (Item 1) [Figure 10-60-7] is
required when the operator cab is in the raised position
for service and the service technician needs to turn the
key switch on or start the engine. Example: adjusting the
steering linkage.
Lift and block the loader.
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device.
Raise the operator cab (if required by the procedure).
Open the rear door of the loader.

REMOTE START TOOL KIT-MEL1563 (CONT’D) Figure 10-60-10
Remote Start Procedure (Cont'd)
Figure 10-60-8
1
1
P-85728
Figure 10-60-11
P-85729
Figure 10-60-9
1

2
P-85726
Connect the remote start tool to the engine harness

P-85728
connector (Item 1) [Figure 10-60-10].
OR
Remove the cap (Item 1) [Figure 10-60-8].
Connect the remote start tool to the engine harness
OR connector (Item 1) and to the attachment control harness
(Item 2) [Figure 10-60-11] (If equipped).
Disconnect the attachment control harness (Item 1)
[Figure 10-60-9] (If equipped). NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Tool Kit will not operate.

REMOTE START TOOL KIT-MEL1563 (CONT'D) Figure 10-60-13
WARNING 2
3 1
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the P16118
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899 The traction lock switch (Item 1) [Figure 10-60-13] is
used to turn traction lock ON or OFF. Push the switch to
the override position. The switch will illuminate to indicate
Figure 10-60-12
traction lock OVERRIDE, in this position the wheels are
able to turn.

The maximum flow / variable flow switch (Item 2) [Figure
10-60-13] is used to activate the auxiliary hydraulics.
Pressing the switch will activate variable flow. The switch
will illuminate to indicate the flow rate is active. Pressing
the switch again will turn the flow OFF. The switch is used
1
when checking pressures and flow rate.
NOTE: With the engine running; pushing and holding

the pressure release switch (Item 3) [Figure
10-60-13] will cause the engine to stop.
P16116
WARNING
The remote start tool (Item 1) [Figure 10-60-12] has
three rocker switches. AVOID INJURY OR DEATH
• Use traction lock override switch for service work
with seat bar raised.
• Traction lock is engaged when light is OFF.
• Lift and block the loader. Check that wheels are
clear.
• Traction lock is disengaged when light is ON.
• See Service Manual for more instruction.
W-2785-0209

REMOTE START TOOL KIT-MEL1563 (CONT'D)
Figure 10-60-14
P-85311
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front

auxiliary pressure [Figure 10-60-14].

REMOTE START TOOL (SERVICE TOOL) KIT -
7003031
Description
The Remote Start Tool (Service Tool) Kit is a

replacement tool for MEL 1563 Remote Start Tool and
MEL 1400B - BOSS® Diagnostic Tool.
The Remote Start Tool (Service Tool) Kit, P/N 7003031,

can be used to service newer loaders using the supplied
harness P/N 6689747.
A computer can be connected to the Remote Start Tool

(Service Tool) for diagnostics and software updates using
the computer harness P/N 6689746 in conjunction with
the loader harness.

REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-2
7003031 (CONT'D)
2
Remote Start Tool (Service Tool) - 7003030
Tools that will be needed to complete the following steps

5 3
are:
Order from Bobcat Parts P/N: 7003031 - Remote Start 6 4

Tool (Service Tool) Kit
Kit Includes:
1
7003030 - Remote Start Tool (Service Tool)
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
P-76439
6689745 - BOSS® Service Tool Harness
Figure 10-61-1
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-2] has five buttons.
The STOP button (Item 2) [Figure 10-61-2] is used to

stop the Remote Start Tool (Service Tool) from
communicating and stop the loader engine.

The RUN button (Item 3) [Figure 10-61-2] is used to turn
the Remote Start Tool (Service Tool) on and activates the
loader ignition power. The button will illuminate to
1
indicate the service tool is active.
The START button (Item 4) [Figure 10-61-2] is used to

start the loader engine.
P-76678
The traction lock button (Item 5) [Figure 10-61-2] is used
to turn traction lock ON or OFF. Push the button and the
The remote start tool (Item 1) [Figure 10-61-1] is button will illuminate indicating the traction lock is
required when the service technician is checking the disabled in which the wheels or tracks are able to turn.
hydraulic / hydrostatic system, adjusting the steering
linkage, and electrical diagnostics. The auxiliary button (Item 6) [Figure 10-61-2] is used to
activate the auxiliary hydraulics. The button will illuminate
to indicate the auxiliary hydraulics are active. Pressing
the button a second time will turn the flow OFF. The
button is used when checking pressures and flow rate.

7003031 (CONT'D)
2
Loader Service Tool Harness - 6689747
Figure 10-61-3
1
1
P-85725
2
Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
P-76678 disconnected from the loader harness (Item 2) [Figure
10-61-5].
The loader service tool harness (Item 1) [Figure 10-61-3] When the remote start procedure is completed, replace

is used to connect the remote start tool (service tool) the loader connector cap (Item 1) [Figure 10-61-4] or
(Item 2) [Figure 10-61-3] to the electrical system on the reconnect the attachment control harness to the loader
loader. harness [Figure 10-61-5].
Figure 10-61-4
P-85729
Loaders without an attachment control harness, remove

the loader harness cap (Item 1) [Figure 10-61-4] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).

REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
7003031 (CONT'D)
Figure 10-61-7
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-6
2 1
1
2
P-76450
P-85726 The computer service tool harness (Item 1) [Figure 10-

61-7] is required to connect remote start tool (service
tool) to the Service PC (Item 2) [Figure 10-61-7].
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item

1) and (Item 3). The main connector (Item 1)
[Figure 10-61-6] is always used for connection
to the loader harness.
The second connector (Item 3) [Figure 10-61-

6] is used for attachment ACD upgrades or
attachment operational diagnostics only. This
connector has a cap attached to it to prevent
damage or corrosion when not in use.
Connect the Remote Start Tool (Service Tool) connector

(Item 1) to the loader harness connector (Item 2) and the
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-6].
NOTE: The key switch must be in the off position or

the Remote Start Tool (Service Tool) will not
operate.
WARNING
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

7003031 (CONT'D)
Remote Start Procedure
WARNING
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the P-85729
operator panel key switch from the start circuit. If the
service technician will be working the engine area it
is important to remove the operator panel keys. Loaders without an attachment control harness, remove
W-2357-0899 the loader harness cap (Item 1) [Figure 10-61-9] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).
The tool listed will be needed to do the following
procedure:
NOTE: When using a Remote Start Tool (Service tool)

harness on loaders not equipped with an
7003031: Remote Start Tool (Service Tool) Kit
attachment control device, the Remote Start
Tool (Service Tool) harness attachment
Figure 10-61-8
control device connector must be capped.
Figure 10-61-10
2
1
P-76450
The Remote Start Tool (Service Tool) (Item 1) [Figure 10- P-85725
61-8] is required when the operator cab is in the raised
position for service and the service technician needs to
turn on the loader or start the engine. Example: adjusting Loaders with an attachment control harness (7 pin or 14
the steering linkage. pin), the attachment harness (Item 1) must be
disconnected from the loader harness (Item 2) [Figure
Lift and block the loader. 10-61-10].
Raise the lift arms (if required by the procedure) and When the remote start procedure is completed, replace
install an approved lift arm support device. the loader connector cap (Item 1) [Figure 10-61-10] or
reconnect the attachment control harness to the loader
Raise the operator cab (if required by the procedure). harness.

7003031 (CONT'D)
2
Figure 10-61-11
5 3
2
1 6 4
P-76439
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-

61-12] has five buttons.
P-85726
The STOP button (Item 2) [Figure 10-61-12] is used to
stop the Remote Start Tool (Service Tool) from
NOTE: The Remote Start Tool (Service Tool) communicating and stop the loader engine.
connection harness has two connectors (Item

1) and (Item 3). The main connector (Item 1) The RUN button (Item 3) [Figure 10-61-12] is used to
[Figure 10-61-11] is always used for turn the Remote Start Tool (Service Tool) on and
connection to the loader harness. activates the loader ignition power. The button will
illuminate to indicate the service tool is active.
The second connector (Item 3) [Figure 10-61-
11] is used for attachment ACD upgrades or The START button (Item 4) [Figure 10-61-12] is used to
attachment operational diagnostics only. This start the loader engine.
connector has a cap attached to it to prevent
damage or corrosion when not in use. The traction lock button (Item 5) [Figure 10-61-12] is
used to turn traction lock ON or OFF. Push the button and
Connect the Remote Start Tool (Service Tool) connector the button will illuminate indicating the traction lock is
(Item 1) to the loader harness connector (Item 2) and the disabled in which the wheels or tracks are able to turn.
other Remote Start Tool (Service Tool) connector to the
ACD harness connector (Item 3) [Figure 10-61-11]. The auxiliary button (Item 6) [Figure 10-61-12] is used to
activate the auxiliary hydraulics. The button will illuminate
NOTE: The key switch must be in the off position or to indicate the auxiliary hydraulics are active. Pressing
the Remote Start Tool (Service Tool) will not the button a second time will turn the flow OFF. The
operate. button is used when checking pressures and flow rate.
WARNING
• Lift and block the machine.
• Check that wheels or tracks are clear.
• Cab ignition must be in the “STOP” position to
start the engine with the Service Tool (if
applicable).
• See machine Service Manual for more
instructions.
W-2792-0409

7003031 (CONT'D)
Figure 10-61-13
1 2
P-85311
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
P-76441 auxiliary pressure [Figure 10-61-14].
The gear icon with the left facing arrows (Item 1) [Figure
10-61-13] will illuminate and blink when the RUN key is

pressed and the loader is communicating with the service
tool.
The computer icon with the right facing arrows (Item 2)

[Figure 10-61-13] will illuminate and blink when the
Remote Start Tool (Service Tool) is transmitting data to
and from the computer.
NOTE: To relieve the pressure at the rear or

secondary front auxiliary, (if equipped) press
the RUN button on the remote start tool. Then
press the auxiliary (AUX) hydraulics button on
the remote start tool and move the AUXILIARY
Hydraulic Switch to the right and left several
times.


SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
signs (decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
SERVICE SCHEDULE HOURS

[5] [5] [5]
ITEM SERVICE REQUIRED
8-10 50 100 250 500 1000
Engine Oil Check the oil level and add as needed. Do not overfill.
Engine Air Filter and Air System Check display panel. Service only when required. Check for leaks and
damaged components.
Engine Cooling System Clean debris from oil cooler, radiator and grille. Check coolant level COLD and
add premixed coolant as needed.
Fuel Filter Remove the trapped water.
Lift Arms, Lift Links, Cylinders, Lubricate with multi-purpose lithium based grease.
Bob-Tach, Pivot Pins, Wedges
Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM
pressure shown on the sidewall of the tire.
Seat Bar, Control Interlocks, Seat Check the condition of seat belt. Clean or replace seat belt retractors as

Belt, Seat Belt Retractors needed. Check the seat bar and control interlocks for correct operation. Clean
dirt and debris from moving parts.
Bobcat Interlock Control Systems Check for correct function. Lift and Tilt functions MUST NOT operate with seat
(BICS) bar raised. See details in this Manual.
Front Horn / Back-up Alarm Check for proper function.
Safety Signs and Safety Treads Check for damaged signs (decals) and safety treads. Replace any signs or
safety treads that are damaged or worn.
Operator Cab Check the fastening bolts, washers and nuts. Check the condition of the cab.
Indicators and Lights Check for correct operation of all indicators and lights.
Heater and A/C Filters Clean or replace filters as needed.
(If Equipped)
Hydraulic Fluid Check fluid level and add as needed.
Hydraulic Hoses and Tubelines Check for damage and leaks. Repair or replace as needed.
Final Drive Trans. (Chaincase), Check fluid level and add as needed.
Parking Brake, Foot Pedals, Check for correct operation. Repair or adjust as needed.
Hand Controls and Steering
Levers or Joysticks
Wheel Nuts Check for loose wheel nuts and tighten to correct torque. (See TIRE [1]
MAINTENANCE in this manual.)
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. [2]
Drive Belts (Alternator, air Check condition. Replace as needed.
conditioning, water pump)
Bobcat Interlock Control System Check the function of the lift arm bypass control.
(BICS)
Engine Oil and Filter Replace oil and filter. [2] [3]
Hydraulic / Hydrostatic Filter, Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir
Charge Filter, Reservoir Breather breather.
Final Drive Trans. (Chaincase) Replace the fluid.
Hydraulic Reservoir Replace the fluid.
Engine Valves Adjust the engine valves. [4]
Coolant Replace the coolant Every 2 years
[1] Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
[2] Perform at first 50 hours, then as scheduled.
[3] Change oil and filter every 100 hours when operating under severe conditions.
[4] Perform at first 500 hours, then as scheduled.
[5] Or every 12 months.


AIR CLEANER SERVICE Outer Filter
Replacing Filter Elements Figure 10-80-2
Figure 10-80-1
3 1 2
P-76460G
P100072
It is important to change the air filter element only when

necessary. The service indicator (Item 1) will FLASH. Open the latches (Item 1) and remove the dust cover
Press the information button (Item 3) until the display (Item 2) [Figure 10-80-2].
screen (Item 2) shows the service codes. Service code
[M0117] (Air Filter Plugged) will show in the display Figure 10-80-3

screen (Item 2) [Figure 10-80-1] when air filter change is
necessary.
Replace the inner filter every third time the outer filter is
replaced or as indicated.
P-90523A
Pull the outer filter element (Item 1) [Figure 10-80-3] out

and discard.
NOTE: Make sure all sealing surfaces are free of dirt

and debris. DO NOT use compressed air.
Install new filter element. Push all the way in until it

contacts the base of the housing.
Install the dust cover and secure the latches [Figure 10-
80-2].

AIR CLEANER SERVICE (CONT’D) Figure 10-80-5
Replacing Filter Elements (Cont’d)
Inner Filter
Only replace the inner filter element under the following

conditions:
• Replace the inner filter element every third time the 1 2

outer filter is replaced.
• After the outer element has been replaced, start the

engine and run at full RPM. If service code [M0117]
(Air Filter Plugged) is still displayed in the data
display, replace the inner filter element. P100072
Remove the dust cover [Figure 10-80-2] and the outer

filter element [Figure 10-80-3]. Install the dust cover (Item 2) and secure the latches
(Item 1) [Figure 10-80-5].
Figure 10-80-4

1
P-90524A
Remove the inner filter element (Item 1) [Figure 10-80-

4].
NOTE: Make sure all sealing surfaces are free of dirt

and debris. DO NOT use compressed air.
Install new inner filter element. Push all the way in until it
contacts the base of the housing.
Install the outer filter element [Figure 10-80-3].

ENGINE COOLING SYSTEM Loaders With Air Conditioning
Check the cooling system every day to prevent over- Figure 10-90-2
heating, loss of performance or engine damage.
Maintenance Platform 1
Figure 10-90-1
2 2
1
P100180
Use low air pressure or water pressure to clean the top of

the air conditioning condenser (Item 1) [Figure 10-90-2].
P100040A
The area between the air conditioning condenser and the

oil cooler will require occasional cleaning. Remove the
A maintenance platform (Item 1) [Figure 10-90-1] is bolts (Item 2) and the brackets (Item 3) [Figure 10-90-2].
available from your Bobcat dealer to facilitate access
when cleaning the engine cooling system. Figure 10-90-3
WARNING 1

Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
2
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
P100056A
Cleaning
Open the rear door. (See REAR DOOR (TAILGATE) on NOTE: Be careful when raising and lowering the air
Page 50-70-1.) conditioning condenser so that the air
conditioning condenser does not fall on the
Remove the rear grille. (See REAR GRILLE on Page 50- oil cooler and damage the fins.
60-1.)
Raise the air conditioning condenser (Item 1) and use
low air pressure or water pressure to clean the top of the
oil cooler (Item 2) [Figure 10-90-3].
Lower the air conditioning condenser (Item 1) [Figure

10-90-3]. Install the brackets (Item 3) [Figure 10-90-2]
and the bolts (Item 2) [Figure 10-90-2].

ENGINE COOLING SYSTEM (CONT’D) All Loaders
Cleaning (Cont’d) Unhook the two rubber straps (Item 2) [Figure 10-90-4].
Loaders Without Air Conditioning Figure 10-90-5
Figure 10-90-4
1 1
2
3
2
P100179
P100181
Raise the oil cooler (Item 1) until the bar (Item 2) drops
into place to support the oil cooler. Use low air pressure

Use low air pressure or water pressure to clean the top of or water pressure to clean the top of the radiator (Item 3)
the oil cooler (Item 1) [Figure 10-90-4]. [Figure 10-90-5].
Raise the bar (Item 2) [Figure 10-90-5] slightly and lower

the oil cooler. Fasten the two rubber straps.
Check the cooling system for leaks.
Install the rear grille and close the rear door.

ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant
Checking Level For the service interval for replacing the engine
coolant (See SERVICE SCHEDULE on Page 10-70-1.)
Open the rear door and raise the rear grille.
Open the rear door and remove the rear grille.
Figure 10-90-6
Remove the coolant fill cap (Item 1) [Figure 10-90-6].
Figure 10-90-7
1
1
2
P-90529A

Check coolant level using the level markers (Item 2) P-85606
[Figure 10-90-6] on the tank. Coolant must be at the
bottom marker when the engine is cold; top marker when
hot. Disconnect the coolant hose (Item 1) [Figure 10-90-7]
from the oil filter assembly. Drain the coolant into a
Lower the rear grille and close the rear door. container. Connect the coolant hose to the oil filter
assembly. Recycle or dispose of coolant in an
environmentally safe manner.
Mix new coolant in a separate container. (See Capacities

IMPORTANT on Page SPEC-10-4.)
The correct mixture of coolant to provide a -37°C (-34°F)

AVOID ENGINE DAMAGE freeze protection is 5 L propylene glycol mixed with 4,4 L
Always use the correct ratio of water to antifreeze. of water OR 1 U.S. gal propylene glycol mixed with 3.5 qt
of water.
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine NOTE: The loader is factory filled with propylene
damage. glycol coolant (purple color). DO NOT mix
propylene glycol with ethylene glycol.
Too little antifreeze reduces the additives which
protect the internal engine components; reduces the Add premixed coolant, 47% water and 53% propylene
boiling point and freeze protection of the system. glycol to the coolant tank until the coolant level reaches
the lower marker on the tank [Figure 10-90-6].
Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature Use a refractometer to check the condition of propylene
engine damage. glycol in your cooling system and install coolant fill cap.
I-2124-0497
NOTE: When installing the coolant fill cap, the cap
must be tightened until it clicks.
Run the engine until it is at operating temperature. Stop

the engine. Check the coolant level when cool. Add
coolant as needed.
Install the rear grille and close the rear door.


FUEL SYSTEM Biodiesel Blend Fuel
Fuel Specifications Biodiesel blend fuel has unique qualities that should be
considered before using in this machine:
Use only clean, high quality diesel fuel, Grade No. 2 or
Grade No. 1. • Cold weather conditions can lead to plugged fuel
system components and hard starting.
The following is one suggested blending guideline which
should prevent fuel gelling during cold temperatures: • Biodiesel blend fuel is an excellent medium for
microbial growth and contamination which can cause
TEMPERATURE NO. 2 NO. 1 corrosion and plugging of fuel system components.
-9°C (+15°F) 100% 0% • Use of biodiesel blend fuel may result in premature
Down to -29°C (-20°F) 50% 50% failure of fuel system components, such as plugged
Below -29°C (-20°F) 0% 100% fuel filters and deteriorated fuel lines.
• Shorter maintenance intervals may be required, such

At a minimum, Low Sulfur (500 ppm sulfur) Diesel Fuel
as cleaning the fuel system and replacing fuel filters
must be used in this machine:
and fuel lines.
The following fuels may also be used in this machine:
• Using biodiesel blended fuels containing more than
five percent biodiesel can affect engine life and cause
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.
deterioration of hoses, tubelines, injectors, injector
pump and seals.

• Biodiesel Blend Fuel - Must contain no more than five
percent biodiesel mixed with low sulfur or ultra low
Apply the following guidelines if biodiesel blend fuel is
sulfur petroleum based diesel. This is commonly
used:
marketed as B5 blended diesel fuel. B5 blended
diesel fuel must meet ASTM D975 (US Standard) or
• Ensure the fuel tank is as full as possible at all times
EN590 (EU Standard) specifications.
to prevent moisture from collecting in the fuel tank.
• Ensure that the fuel tank cap is securely tightened.
• Biodiesel blend fuel can damage painted surfaces,

remove all spilled fuel from painted surfaces
immediately.
• Drain all water from the fuel filter daily before

operating the machine.
• Do not exceed engine oil change interval. Extended

oil change intervals can cause engine damage.
• Before vehicle storage; drain the fuel tank, refill with

100% petroleum diesel fuel, add fuel stabilizer and
run the engine for at least 30 minutes.
NOTE: Biodiesel blend fuel does not have long term

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

FUEL SYSTEM (CONT’D) Figure 10-100-2
Filling The Fuel Tank WRONG
WARNING
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an
explosion or fire.
W-2063-0807
Open the rear door. NA1684
Figure 10-100-1
Use a clean, approved safety container to add fuel of the
correct specification. Add fuel only in an area that has
free movement of air and no open flames or sparks NO
1 SMOKING [Figure 10-100-2].
Install and tighten the fuel cap (Item 1) [Figure 10-100-

1].
Close the rear door.
WARNING
P-85367 AVOID INJURY OR DEATH
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Remove the fill cap (Item 1) [Figure 10-100-1]. Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508

FUEL SYSTEM (CONT’D) Removing Air From The Fuel System
Fuel Filter After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
For the service interval for removing water from, or system before starting the engine.
replacing the fuel filter (See SERVICE SCHEDULE on
Page 10-70-1.)
Removing Water
WARNING
Figure 10-100-3
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
2 W-2072-0807
Figure 10-100-4

1
P-85508
Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter element to remove water from the 1 2
filter.
Replacing Element
Remove the filter element (Item 2) [Figure 10-100-3].
Clean the area around the filter housing. Put clean oil on
the seal of the new filter element. Install the fuel filter, and P-85507
hand tighten.
Open the vent (Item 2) [Figure 10-100-4] on the fuel filter
Remove air from the fuel system. (See Removing Air
housing.
From The Fuel System on Page 10-100-3.)
Squeeze the hand pump (priming bulb) (Item 1) [Figure
10-100-4] until fuel flows from the vent with no air
WARNING bubbles.
Close the vent (Item 2) [Figure 10-100-4].

Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508


ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-110-2
Check the engine oil level every day before starting the ENGINE OIL
engine for the work shift. RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
Figure 10-110-1 CRANKCASE)
P-85506

Park the machine on level ground. Open the rear door TEMPERATURE RANGE ANTICIPATED BEFORE
and remove the dipstick (Item 1) [Figure 10-110-1]. NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CI-4 OR BETTER)
Keep the oil level between the marks on the dipstick. Do [1] Synthetic Oil - Use recommendation from Synthetic
not overfill. Oil Manufacturer.
Use good quality engine oil that meets API Service

Classification of CI-4 or better [Figure 10-110-2].
WARNING
explosion or fire.
W-2103-0508

ENGINE LUBRICATION SYSTEM (CONT’D) Install and tighten the oil drain cap [Figure 10-110-4].
Removing And Replacing Oil And Filter Install the cover and the cover mounting bolts [Figure
10-110-3]. Tighten all bolts.
For the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-70-1.) Figure 10-110-5
Run the engine until it is at operating temperature. Stop

the engine.
Figure 10-110-3 2
P-85506
2
Open the rear door, remove the oil filter (Item 3) [Figure

10-110-5] and clean the filter housing surface.
3 P-90497A
P-90499A
Use genuine Bobcat filter only.
The oil drain hose is located behind a cover under the Put oil on the new filter gasket, install the filter and hand
right rear corner of the loader (Inset) [Figure 10-110-3]. tighten.
Remove two cover mounting bolts (Item 1) [Figure 10- Remove the oil fill cap (Item 1) [Figure 10-110-5].
110-3].
Put oil in the engine. For the correct quantity (See
Loosen one cover mounting bolt (Item 2) and slide the Capacities on Page SPEC-10-4.) Do not overfill.
cover (Item 3) [Figure 10-110-3] to the rear of the loader.
Start the engine and let it run for several minutes. Stop
Figure 10-110-4 the engine and check for leaks at the filter.
Remove the dipstick (Item 2) [Figure 10-110-5] and

check the oil level.
Add oil as needed if it is not at the top mark on the

dipstick. Install the dipstick and close the rear door.
WARNING
1 AVOID INJURY OR DEATH
P-90498A
explosion or fire.
Remove the oil drain cap (Item 1) [Figure 10-110-4] from W-2103-0508
the oil drain hose and drain the oil into a container.
Recycle or dispose of used oil in an environmentally safe
manner.

HYDRAULIC/HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-120-3

HYDRAULIC / HYDROSTATIC FLUID
Check the hydraulic / hydrostatic fluid level every day RECOMMENDED ISO VISCOSITY GRADE (VG)
before starting the work shift. AND VISCOSITY INDEX (VI)
Park the loader on a level surface, lower the lift arms and
place the attachment flat on the ground or tilt the Bob-
Tach fully back if no attachment is installed.
Stop the engine.
Figure 10-120-1
TEMPERATURE RANGE ANTICIPATED

DURING MACHINE USE
[1] VG 100; Minimum VI 130
1 [3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid
[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable

based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
P-90538A temperatures.)
Use only recommended fluid in the hydraulic system

Check the fluid level in the sight gauge (Item 1) [Figure [Figure 10-120-3]. (See Hydraulic System on Page
10-120-1]. Keep the fluid level within the operating range. SPEC-10-3.)
Remove the rear grille. (See REAR GRILLE on Page 50-

60-1.)
Figure 10-120-2
WARNING
1 Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
P100055
Remove the fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level within the operating

range in the sight gauge (Item 1) [Figure 10-120-1].
Install the fill cap (Item 1) [Figure 10-120-2] and install

the rear grille.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-5
Removing And Replacing Hydraulic Fluid
For the correct service interval (See SERVICE

SCHEDULE on Page 10-70-1.)
Replace the fluid if it becomes contaminated or after 1

major repair.
2
Always replace the hydraulic / hydrostatic filter and the
hydraulic charge filter whenever the hydraulic fluid is
replaced. (See Removing And Replacing Hydraulic /
Hydrostatic Filter on Page 10-120-4.)
Remove the rear grille. (See REAR GRILLE on Page 50- P100179
60-1.)
Figure 10-120-4 Raise the oil cooler (Item 1) until the bar (Item 2) [Figure
10-120-5] drops into place to support the oil cooler. This
will aid in draining the hydraulic fluid.
Figure 10-120-6

1 1
P100055
P100007
Remove the right side access cover bolts (Item 1)

[Figure 10-120-6] and remove the cover. (Lift arms
shown raised for visual clarity.)
P100181
Remove the hydraulic fill cap (Item 1) and unhook the

two rubber straps (Item 2) [Figure 10-120-4].

Removing And Replacing Hydraulic Fluid (Cont’d)
Figure 10-120-7
1
P-90506
Remove and clean the hydraulic fill screen (Item 1)

P-85721 [Figure 10-120-8]. Use low air pressure to dry the
screen.
Pinch off and disconnect the hose (Item 1) [Figure 10- Install hydraulic fill screen and add the correct fluid to the
120-7] from the cooling fan motor. Route the hose out the reservoir until the fluid level is within the operating range

side of the loader and drain the fluid into a container. of the sight gauge. (See Capacities on Page SPEC-10-
4.) and (See Checking And Adding Fluid on Page 10-
Connect the hose to the cooling fan motor when the fluid 120-1.)
stops draining.
Install the hydraulic fill cap.
Recycle or dispose of used fluid in an environmentally
safe manner. Install the rear grille.
Start the engine and operate the loader hydraulic

controls.
WARNING
Stop the engine and check for leaks.
Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-120-1.)
explosion or fire.
W-2103-0508
Install the side access cover.
Raise the bar supporting the oil cooler and lower the oil
cooler. Fasten the two rubber straps.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Earlier Models
Removing And Replacing Hydraulic / Hydrostatic Figure 10-120-10

Filter
For the correct service interval. (See SERVICE


60-1.)
The filter housing is located behind the hydraulic fluid

reservoir.
1
Clean the top of the filter housing.
Figure 10-120-9
Earlier Model Later Model P-90500
Remove the filter (Item 1) [Figure 10-120-10] using a

socket wrench.
Figure 10-120-11

P-90500A P100047A
Two types of filters are used on this model loader [Figure

10-120-9]. Select the correct procedure for your
machine.
P-85478
Discard the entire filter (Item 1) [Figure 10-120-11].
Clean the surface of the filter housing where the filter seal
contacts the housing.
Install new filter and tighten to 61 N•m (45 ft-lb) torque.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) All Models
Removing And Replacing Hydraulic / Hydrostatic

Filter (Cont’d)
Later Models
WARNING
Figure 10-120-12 AVOID INJURY OR DEATH
explosion or fire.
W-2103-0508
Install the rear grille.

controls.
1
P100047
WARNING

Remove the filter cap (Item 1) [Figure 10-120-12].
Figure 10-120-13
1 from a physician familiar with this injury.
W-2072-0807
Stop the engine and check for leaks at the filter.

2 P100044 P100046
Remove the filter element (Item 1) [Figure 10-120-13]

and discard.
Remove the O-ring (Item 2) [Figure 10-120-13] and

discard.
Install new O-ring and lubricate with clean oil.
Install new filter element ensuring that element is fully

seated in the housing.
Install the filter cap and tighten to 25 N•m (18 ft-lb)

torque.

Removing And Replacing Hydraulic Charge Filter
The hydraulic charge filter is located under the operator

cab. For the correct service interval (See SERVICE
1
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 10-120-14
1
P-85489A
2 Remove and discard the filter element (Item 1) [Figure

10-120-16].
Clean the surface of the filter housing and the filter base
where they contact the filter element seal.

Put clean oil on the seal of the new filter element. Install
P-85470 the element on the filter base. Install and tighten the filter
housing to 47 - 54 N•m (35 - 40 ft-lb) torque.
Unhook the rubber straps (Item 1) and remove the lower

fan duct (Item 2) [Figure 10-120-14].
Figure 10-120-15
WARNING
explosion or fire.
W-2103-0508
1
Install the lower fan duct [Figure 10-120-14].
NOTE: Failure to install the lower fan duct correctly

may result in decreased cooling.
Lower the operator cab. (See Lowering on Page 10-30-

P-85489 3.)

Place a suitable container below the filter housing and controls.
remove the filter housing (Item 1) [Figure 10-120-15]
using a socket wrench.

safe manner.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Breather Cap
Removing And Replacing Hydraulic Charge Filter See the SERVICE SCHEDULE for the correct
(Cont’d) replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)

WARNING 60-1.)
Figure 10-120-17
not use your bare hand. Wear safety goggles. If fluid 1
W-2072-0807
Stop the engine and check for leaks at the filter.


P100055
Remove the breather cap (Item 1) [Figure 10-120-17]

and discard.
Install new breather cap.
Install the rear grille.


FINAL DRIVE TRANSMISSION (CHAINCASE) Removing And Replacing Oil
Checking And Adding Oil Figure 10-130-2
The chaincase contains the final drive sprockets and

chains and uses the same type of oil as the hydraulic /
hydrostatic system. (See Hydraulic System on Page
SPEC-10-3.)
1
Stop the loader on a level surface and stop the engine.
Figure 10-130-1
P-85745
1
Remove the check plug (Item 1) [Figure 10-130-2] from

the front of the chaincase housing.
Figure 10-130-3

P-85744
Remove the check plug (Item 1) [Figure 10-130-1] from

the front of the chaincase housing. (Lift arms shown
raised for clarity.)
If oil can be reached with the tip of your finger through the
hole, the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole.
P-85742
Install and tighten the plug.

Pump the oil out of the chaincase [Figure 10-130-3].
Recycle or dispose of the used oil in an environmentally

safe manner.
Add oil through the check plug hole until the oil flows from
the hole.
WARNING
explosion or fire.
W-2103-0508


BOB-TACH (HAND LEVER) The spring loaded wedges (Item 1) must contact the
lower edge of the holes in the attachment mounting
Inspection And Maintenance frame (Item 2) [Figure 10-140-2].
Figure 10-140-1 If the wedges do not contact the lower edge of the holes
[Figure 10-140-2], the attachment will be loose and can
come off the Bob-Tach.
Figure 10-140-3
P-85513A
Move the Bob-Tach levers down to engage the wedges

[Figure 10-140-1].

The levers and wedges must move freely.
WARNING
The Bob-Tach wedges must extend through the holes
in the attachment mounting frame. Levers must be
fully down and locked. Failure to secure wedges can
allow attachment to come off.
W-2715-0208
Figure 10-140-2
B-17460
2
Inspect the mounting frame on the attachment and Bob-
Tach, linkages and wedges for excessive wear or
Wedge must contact lower damage [Figure 10-140-3]. Replace any parts that are
edge of hole in the damaged, bent or missing. Keep all fasteners tight.
attachment mounting
frame. Look for cracked welds. Contact your Bobcat dealer for
repair or replacement parts.
P-31233A P-31233
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) (See LUBRICATING THE LOADER on
The wedges (Item 1) [Figure 10-140-2] must extend Page 10-150-1.)
through the holes in the attachment mounting frame.


BOB-TACH (POWER) The wedges (Item 1) [Figure 10-141-2] must extend
through the holes in the attachment mounting frame.
This machine may be equipped with a Power Bob-Tach.
The spring loaded wedges (Item 1) must contact the
Inspection And Maintenance lower edge of the holes in the attachment mounting
frame (Item 2) [Figure 10-141-2].
Figure 10-141-1
If the wedges do not contact the lower edge of the holes
[Figure 10-141-2], the attachment will be loose and can
come off the Bob-Tach.
1
Figure 10-141-3
P-85320A

Push and hold the BOB-TACH “WEDGES UP” switch
(Item 1) until wedges are fully raised. Push and hold the
BOB-TACH “WEDGES DOWN” switch (Item 2) [Figure
10-141-1] until the wedges are fully down.
The levers and wedges must move freely.
WARNING
Bob-Tach wedges must extend through the holes in
attachment. Lever(s) must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0497
Figure 10-141-2
1 B-17460
Inspect the mounting frame on the attachment and Bob-

2 Tach, linkages and wedges for excessive wear or
damage [Figure 10-141-3]. Replace any parts that are
damaged, bent or missing. Keep all fasteners tight.
Wedge must contact lower Look for cracked welds. Contact your Bobcat dealer for
edge of hole in the repair or replacement parts.
attachment mounting
frame. Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1.) and (See LUBRICATING THE LOADER
P-31233A P-31233 on Page 10-150-1.)


LUBRICATING THE LOADER Figure 10-150-3
Lubrication Locations
Lubricate the loader as specified for the best
performance of the loader. (See SERVICE SCHEDULE
on Page 10-70-1.)
3
Record the operating hours each time you lubricate the
Bobcat loader.
Always use a good quality lithium based multi-purpose
grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Remove attachment from the loader.
Tilt the Bob-Tach forward until it contacts the ground.
P-90543A
Stop the engine.
Lubricate the following: 3. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-150-3].
Figure 10-150-1
Figure 10-150-4

4
1
P-90540
P-90542A
1. Rod End Lift Cylinder (Both Sides) (2) [Figure 10-

150-1]. 4. Lift Arm Link Pivot (Both Sides) (2) [Figure 10-150-4].
Figure 10-150-2
P-90572A
2. Base End Lift Cylinder (Both Sides) (2) [Figure 10-

150-2].

LUBRICATING THE LOADER (CONT’D) Figure 10-150-7
Lubrication Locations (Cont’d)
Figure 10-150-5
5
7
P-85719
7. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-150-

P-85484 7].
Figure 10-150-8
5. Base End Tilt Cylinder (Both Sides) (2) [Figure 10-
150-5].

Figure 10-150-6
P-85487
8. Bob-Tach Wedge (Both Sides) (2) [Figure 10-150-8].

P-85720
6. Rod End Tilt Cylinder (Both Sides) (2) [Figure 10-

150-6].

LUBRICATING THE LOADER (CONT’D)
Lubrication Locations (Cont’d)
Figure 10-150-9
P-90570A
9. Rear Control Link (Both Sides) (2) [Figure 10-150-9].

Figure 10-150-10
10
P-90544A
10. Front Control Link (Both Sides) (2) [Figure 10-150-

10].


TIRE MAINTENANCE It is important to keep the same size tires on each side of
the loader. If different sizes are used, each tire will be
Wheel Nuts turning at a different rate and cause excessive wear. The
tread bars of all the tires must face the same direction.
Figure 10-160-1
Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
capability. Check for correct pressure before operating
the loader.
Mounting
Tires are to be repaired only by an authorized person

using the proper procedures and safe equipment.
Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust.

P-85479
The tire bead and rim flange must be lubricated with a
rubber lubricant before mounting the tire.
See your SERVICE SCHEDULE for the correct interval to
check the wheel nuts [Figure 10-160-1]. (See SERVICE Avoid excessive pressure which can rupture the tire and

SCHEDULE on Page 10-70-1.) cause serious injury or death.
When installing wheel nuts, tighten to 217 N•m (160 ft-lb) During inflation of the tire, check the tire pressure
torque. frequently to avoid over inflation.
When checking wheel nut torque, set the torque wrench
to 190 N•m (140 ft-lb) to prevent over-tightening.
Rotating WARNING
Check the tires regularly for wear, damage and pressure.
Do not inflate tires above specified pressure. Failure
Figure 10-160-2
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1007
IMPORTANT
Inflate tires to the MAXIMUM pressure shown on the
sidewall of the tire. DO NOT mix brands of tires used
on the same loader.
I-2057-0794
NA1023A
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-160-2].


SPARK ARRESTOR MUFFLER
Cleaning Procedure
See the SERVICE SCHEDULE for service interval for
WARNING
cleaning the spark arrestor muffler. (See SERVICE
SCHEDULE on Page 10-70-1.) When the engine is running during service, the
driving and steering controls must be in neutral and
Do not operate the loader with a defective exhaust
the parking brake engaged. Failure to do so can
system.
cause injury or death.
W-2006-1209
IMPORTANT Start the engine and run for about 10 seconds while a
second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.
This machine is factory equipped with a U.S.D.A.
Forestry Service approved spark arrestor exhaust This will force contaminants out through the cleanout
system. hole.
Stop the engine.
The spark arrestor muffler, if equipped, must be
cleaned to keep it in working condition. The spark Install and tighten the plug. Close the rear door.
arrestor muffler must be serviced by dumping the
spark chamber every 100 hours of operation.
On some models, the turbocharger functions as the WARNING

spark arrestor and must operate correctly for proper
spark arrestor function. AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
If this machine is operated on flammable forest, air must be added to avoid concentration of exhaust
brush, or grass covered land, it must be equipped fumes. If the engine is stationary, vent the exhaust
with a spark arrestor attached to the exhaust system outside. Exhaust fumes contain odorless, invisible
and maintained in working order. Failure to do so will gases which can kill without warning.
be in violation of California State Law, Section 4442. W-2050-0807
PRC. Refer to local laws and regulations for spark
arrestor requirements.
I-2284-0409
Stop the engine and open the rear door. WARNING

Figure 10-170-1
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
WARNING
1
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
flammable material. Failure to obey warnings can
cause injury or death.
P-85509 W-2068-1285
Remove the plug (Item 1) [Figure 10-170-1] from the

bottom of the muffler.


PIVOT PINS
Inspection And Maintenance
Figure 10-180-1
P-90536A
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure

10-180-1].
Check that the lock nuts are tightened to 48 - 54 N•m (35

- 40 ft-lb) torque.


LOADER STORAGE AND RETURN TO SERVICE Return To Service
Storage After the Bobcat loader has been in storage, it is

necessary to follow a list of items to return the loader to
Sometimes it may be necessary to store your Bobcat service.
loader for an extend period of time. Below is a list of items
to perform before storage. • Check the engine and hydraulic oil levels; check
coolant level.
• Thoroughly clean the loader including the engine
compartment. • Install a fully charged battery.
• Lubricate the loader. • Remove grease from exposed cylinder rods.
• Replace worn or damaged parts. • Check all belt tensions.
• Park the loader in a dry protected shelter. • Be sure all shields and guards are in place.
• Lower the lift arms all the way and put the bucket flat • Lubricate the loader.
on the ground.
• Check tire inflation and remove blocks from under
• Put blocks under the frame to remove weight from the frame.
tires.
• Remove cover from exhaust pipe opening.
• Put grease on any exposed cylinder rods.

• Start the engine and let run for a few minutes while
• Put fuel stabilizer in the fuel tank and run the engine observing the instrument panels and systems for
a few minutes to circulate the stabilizer to the pump correct operation.
and fuel injectors.
• Operate machine, check for correct function.
If biodiesel blend fuel has been used, perform the
following: • Stop the engine and check for leaks. Repair as
needed.
Drain the fuel tank, refill with 100% petroleum diesel
fuel, add fuel stabilizer and run the engine for at least
30 minutes.
• Drain and flush the cooling system. Refill with

premixed coolant.
• Replace all fluids and filters (engine, hydraulic /

hydrostatic).
• Replace air cleaner, heater and air conditioning filters.
• Put all controls in neutral position.
• Remove the battery. Be sure the electrolyte level is

correct then charge the battery. Store it in a cool dry
place above freezing temperatures and charge it
periodically during storage.
• Cover the exhaust pipe opening.
• Tag the machine to indicate that it is in storage

condition.


STOPPING THE ENGINE AND LEAVING THE LOADER Remove the key from the switch (Standard Key Panel) to
prevent operation of the loader by unauthorized
Procedure personnel.
Stop the loader on level ground. NOTE: Activating the Password Lockout Feature on
machines with the Keyless Start Panel or the
Fully lower the lift arms and put the attachment flat on the Deluxe Instrumentation Panel allows
ground. operation of the loader without using a
password. (See Password Lockout Feature on
Figure 10-200-1 Page 60-190-2.) or (See Password Lockout
Feature on Page 60-191-1.)
Figure 10-200-3

P-90525A P-85737A P-85735A
Push the engine speed control fully down [Figure 10- Exit the loader using grab handles, safety tread and
200-1] to decrease the engine speed. steps (maintaining a 3-point contact) [Figure 10-200-3].
Engage the parking brake.
Figure 10-200-2
WARNING
1
Before you leave the operator’s seat:
• Lower the lift arms and put the attachment flat on
the ground.
2 • Stop the engine.
• Engage the parking brake.
• Raise the seat bar.
• Move all controls to the NEUTRAL / LOCKED
position to make sure the lift, tilt and traction
P-90688A P-90214A drive functions are deactivated.
Turn the key switch to the STOP position (Item 1) or The seat bar system must deactivate these functions
press the STOP button (Item 2) [Figure 10-200-2]. when the seat bar is up. Service the system if
controls do not deactivate.
NOTE: If the loader lights are ON, they will remain ON W-2463-0610
for approximately 90 seconds after turning
the loader OFF.
Raise the seat bar and make sure the lift and tilt functions
are deactivated.
Unbuckle the seat belt.


EMERGENCY EXIT Figure 10-210-3
The front opening on the operator cab and rear window

provide exits.
External Access
Figure 10-210-1
P-90563A
Exit through the rear of the operator cab [Figure 10-210-

3].
Front Door
P-85724
This machine may be equipped with a front door.

The rear window can be removed from outside the loader NOTE: Use this procedure to remove the front door
using a T40 TORX® driver. Turn both screws (Item 1) only under emergency conditions. Damage to
[Figure 10-210-1] in until the latches disengage from the machine may occur.
window frame. Pull the top of the window away from the
cab and lift up to remove. Figure 10-210-4
Rear Window
NOTE: Use this procedure to remove the rear window

only under emergency conditions. Damage to
machine may occur.
1
Figure 10-210-2
P-90725
Turn both latches (Item 1) [Figure 10-210-4] down until

they disengage from the door frame.
Push the door out of the operator cab door frame.
P-85309A Exit through the opening.
Turn both latches (Item 1) [Figure 10-210-2] in until they

disengage from the window frame.
Push the rear window out of the rear of the operator cab.

EMERGENCY EXIT (CONT’D) Figure 10-210-7
Front Door (Cont’d)
Front Door Reassembly

2
Figure 10-210-5
P-90685
2
Orient the latches as shown (Item 1) and install the door
hinges (Item 2) [Figure 10-210-7] on the door. (Bottom
hinge shown)
P-85781A
Figure 10-210-8

Disconnect electrical connector (Item 2) and washer fluid
hose (Item 1) [Figure 10-210-5].
1
Figure 10-210-6
2
3
P-90686A
1
Install cast washers (Item 2) on door hinges taking care

to match rectangular surfaces. Hold cast washer firmly
P-85588A P-85589A against door and rotate latch (Item 1) [Figure 10-210-8]
up to lock cast washer into place. (Bottom hinge shown)
(Plastic cap shown removed for clarity)
Rotate and pull the clip (Item 1) out of the gas spring
socket. Pull the gas spring socket (Item 3) straight off the Install door on loader.
ball stud fitting (Item 2) [Figure 10-210-6].
Install the gas spring socket on the ball stud fitting. Install
Remove the door hinges from the loader. the clip into the hole in the gas spring socket. Rotate the
clip to lock into place [Figure 10-210-6].
Connect electrical connector (Item 2) and washer fluid


SEAT BELT Figure 10-220-1
Inspection And Maintenance 1
WARNING 3
Failure to properly inspect and maintain the seat belt

can cause lack of operator restraint resulting in
serious injury or death.
W-2466-0703
2 4
Check the seat belt daily for correct function.
Inspect the seat belt system thoroughly at least once

each year or more often if the machine is exposed to
severe environmental conditions or applications.
Any seat belt system that shows cuts, fraying, extreme or

unusual wear, significant discolorations due to ultraviolet
UV exposure, dusty / dirty conditions, abrasion to the
seat belt webbing, or damage to the buckle, latch plate,

retractor (if equipped), hardware or any other obvious
problem should be replaced immediately. B-22283
The items below are referenced in [Figure 10-220-1].
1. Check the webbing. If the system is equipped with a

retractor, pull the webbing completely out and inspect
the full length of the webbing. Look for cuts, wear,
fraying, dirt and stiffness.
2. Check the buckle and latch for correct operation.

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

by extending webbing to determine if it looks correct
and that it spools out and retracts webbing correctly.
4. Check webbing in areas exposed to ultraviolet (UV)

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

parts for your machine.


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

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-8
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
Base End Pivot Pin Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-4
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-8

CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-5
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-2
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-4

HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . . . . . . . . . . 20-40-8
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . . 20-40-9
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-40-10
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-40-10
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-11
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31

Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-34
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Actuator Removal And Installation (In Loader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-5
Actuator Removal And Installation (Out Of Loader) . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-7
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-10
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-11
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-11
Load Check Valve Removal And Installation (Tilt & Auxiliary) . . . . . . . . . . . . . . . . 20-41-12
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End) . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Base End) . . . . . 20-41-14
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod End) . . . . . 20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-16
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Lift Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-17
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-22
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-24
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-26
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-28
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-29
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-30

LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
HYDRAULIC PUMP (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2

Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7
High Flow Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-8
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-9
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-10
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-11
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-12
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-13
HYDRAULIC / HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2

REAR AUXILIARY DIVERTER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-3
BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

HYDRAULIC/HYDROSTATIC SCHEMATIC
WITH NO OPTIONS
S650 (S/N A3NV11001 AND ABOVE)
(S/N A3NW11001 AND ABOVE)
Printable Version Click Here
(PRINTED JUNE 2009)

V-1348legend
LEGEND
1 RESERVOIR: 16 FILTER - BICS CONTROL VALVE
(SCREEN) 33 CHARGE PUMP -
Capacity at sight gauge . . 10.7 Qts. (10,2 L)
13.5 GPM (51,1 L/min) at High Engine Idle
System Capacity . . . . . . . 10.5 Gal. (39,7 L) 17 CHECK VALVE - With 14.5 PSI (1,0 bar)
Spring 34 HYDRAULIC PUMP . . . . . . . Gear Type
2 SIGHT GUAGE
18 RESTRICTION . . . . . . . 0.079 in. (2,0 mm) 23.0 GPM (87,1 L/min.) at High Engine Idle
3 DIFFERENTIAL PRESSURE SWITCH:
19 35 VARIABLE CAPACITY DISPLACEMENT
15 PSI (1,07 bar) PULL BUTTON ACTIVATED
DIRECTIONAL CONTROL VALVE - LIFT BIDIRECTIONAL HYDROSTATIC PUMP
Normally Closed
ARM BY-PASS
4 FILTER - HYDRAULIC (CANISTER) 36 RELIEF/REPLENISHING VALVE - HIGH
20 LIFT CYLINDER SPOOL - MADE TO PRESSURE: 5294 PSI (365 bar)
5 SPRING LOADED FILTER BY-PASS RESTRICT FLOW DURING BOOM
DOWN BUT NOT DURING BOOM UP 37
RELIEF VALVE - CHARGE INLET:
VALVE: 25 PSI (1,7 bar)
21 ANTICAVITATION VALVE 465 PSI (32, bar)
6 DIAGNOSTIC COUPLER at High Engine Idle
22 PROPORTIONAL RELIEF VALVE – Dealer Copy -- Not forWith 140 degrees F. (60 degrees C.) Fluid
Resale
7 RELIEF VALVE - MAIN: (Fan Speed Regulator):
3500 PSI (241 bar) 1566 - 1784 PSI (108 - 123 bar) 38 CHECK VALVE – COLD WEATHER BY-PASS
at Front Quick Couplers 23 SPRING LOADED FILTER BY-PASS With 50 PSI (3,45 bar) Spring
8 RELIEF/ANTICAVITATION VALVE - VALVE: 75 - 83 PSI (5,2 - 5,7 bar)

PORT 4000 PSI (276 bar) 24 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR
9 RELIEF/ANTICAVITATION VALVE - 25 FILTER - HYDRAULIC (CANISTER)
PORT (OPTIONAL) 4000 PSI (276 bar)
26 SENSOR – CHARGE PRESSURE –
10 SOLENOID ACTIVATED DIRECTIONAL
Fan Filter
CONTROL VALVE - AUXILIARY
27 ANTICAVITATION VALVE
11 LOAD CHECK VALVE
28 SENSOR – HYD. TEMPERATURE
12 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE 29 RESTRICTION - 0.06 inch (1,5 mm)
13 PILOTED ACTIVATED DIRECTIONAL 30 CHECK VALVE - With 200 PSI (13,8 bar)
CONTROL VALVE - TILT CONTROL
Spring
14 PILOTED ACTIVATED DIRECTIONAL
31 DRIVE MOTOR SHUTTLE VALVE
CONTROL VALVE - LIFT CONTROL
15 SOLENOID ACTIVATED DIRECTIONAL 32 FIXED CAPACITY DISPLACEMENT

BIDIRECTIONAL HYDROSTATIC
CONTROL VALVE - BICS CONTROL
MOTOR
NOTE: Unless otherwise specified

springs have NO significant
pressure value.
Printed in U.S.A. V-1348legend (6-8-09)
99 of 896
INTEGRATED COUPLER BLOCK
12
Male
DRIVE MOTOR
OUT
Male
L HYDRAULIC CONTROL VALVE
31 29
30 12
Female
9
10
10
Auxiliary Spool
32
TILT
CYLINDERS
A B
8
11
BICS CONTROL VALVE

HYDROSTATIC PUMP
Tilt Spool
35
38 8 13
27
11
M4 M
3
14
D C
Lift Spool
36 36
Charge
Inlet
Dealer 8Copy -- Not for Resale
LIFT
CYLINDERS
37 36 20 18
11 16 16
B A 17 15 ?
IN 2
M M1 7
2 6
36
1
T 19
35
VARIABLE SPEED HYDRAULIC
Oil Cooler 3 RESERVOIR (VENTED)
FAN MOTOR W/ INTEGRATED FILTER 2
34 5
1
33 25 23
4
26 PUMP
SUPPLY
WORKING
B A CIRCUIT
HYDRAULIC FILTER
PILOT
PRESSURE
24 21 DRAIN /
32 RETURN
P DR 22
28
30 WITH NO OPTIONS
29 31
S650 (S/N A3NV11001 & ABOVE)
L
(S/N A3NW11001 & ABOVE)
DRIVE MOTOR Printable Version Click Here
DRAIN / RETURN MANIFOLD
(PRINTED JUNE 2009)
100 of 896 7170812

PRINTED IN U.S.A.
WITH ALL OPTIONS
(PRINTED JUNE 2009)
V-1349legend Printable Version Click Here
LEGEND
1 RESERVOIR: 19 PULL BUTTON ACTIVATED RELIEF VALVE - 1200 PSI (83 bar) 57 HIGH PRESSURE SHUTTLE
36
Capacity at sight gauge . . 10.7 Qts. (10,2 L) DIRECTIONAL CONTROL VALVE - LIFT
System Capacity . . . . . . . 10.5 Gal. (39,7 L) ARM BY-PASS 37 CHECK VALVE - With 80 PSI (5,5 bar) Spring 58 FIXED CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC
2 SIGHT GUAGE 20 LIFT CYLINDER SPOOL - MADE TO
38 RELIEF VALVE - 2000 PSI (137 bar) MOTOR – 2 SPEED
RESTRICT FLOW DURING BOOM
3 DIFFERENTIAL PRESSURE SWITCH: 59 FIXED CAPACITY DISPLACEMENT
DOWN BUT NOT DURING BOOM UP 39 CHECK VALVE - With 300 PSI (20,7 bar)
15 PSI (1,07 bar) 21 ANTICAVITATION VALVE BIDIRECTIONAL HYDROSTATIC
Spring And With 0.016 inch (0,40 mm) Orifice
Normally Closed MOTOR
4 FILTER - HYDRAULIC (CANISTER) 22 PROPORTIONAL RELIEF VALVE – 40 RESTRICTION - 0.025 inch (0,6 mm) 60 HYDRAULIC BRAKE – SPRING APPLIED –
(Fan Speed Regulator): 41 SENSOR – HYD. TEMPERATURE PRESSURE RELEASE (SAPR)
5 SPRING LOADED FILTER BY-PASS 1566 - 1784 PSI (108 - 123 bar)
VALVE: 25 PSI (1,7 bar) HYDRAULIC PUMP . . . . . . . Gear Type 61 SOLENOID ACTIVATED DIRECECTIONAL
23 SPRING LOADED FILTER BY-PASS 42
23.0 GPM (87,1 L/min.) at High Engine Idle CONTROL VALVE – 2 SPEED
6 DIAGNOSTIC COUPLER VALVE: 75 - 83 PSI (5,2 - 5,7 bar)
43 CHARGE PUMP - 62 CHECK VALVE
24 FIXED CAPACITY DISPLACEMENT 13.5 GPM (51,1 L/min) at High Engine Idle
7 RELIEF VALVE - MAIN: Dealer Copy -- Not for Resale
HYDRAULIC MOTOR 63 SOLENOID ACTIVATED DIRECECTIONAL
3500 PSI (241 bar) 44 PILOT ACTIVATED DIRECTIONAL
25 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE – MAKE-UP
at Front Quick Couplers CONTROL VALVE - REAR AUXILIARY
8 26 SENSOR – CHARGE PRESSURE – 45 RELIEF VALVE: 3300 PSI (228 bar) 64 FILTER - BRAKE
RELIEF/ANTICAVITATION VALVE -
PORT 4000 PSI (276 bar) Fan Filter 46 SOLENOID ACTIVATED DIRECTIONAL 65 SOLENOID ACTIVATED DIRECECTIONAL
27 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - TWO COIL CONTROL VALVE – BRAKE
9 RELIEF/ANTICAVITATION VALVE -
CONTROL VALVE - BUCKET POSITION 47 RESTRICTOR - 0.031 inch (0,8 mm)
PORT (OPTIONAL) 4000 PSI (276 bar) 66 HIGH FLOW HYDRAULIC PUMP Gear Type
VALVE (ON/OFF)
10 SOLENOID ACTIVATED DIRECTIONAL FLOW DIVIDER ADJUSTMENT VALVE 48 LOAD SHUTTLE VALVE - BLEED OFF 7.5 GPM (28,4 L/min.) at High Engine Idle
28
CONTROL VALVE - AUXILIARY 67 RELIEF VALVE - 3500 PSI (241 bar)
29 PILOTED ACTIVATED DIRECTIONAL 49 SOLENOID ACTIVATED DIRECTIONAL
11 LOAD CHECK VALVE CONTROL VALVE - BASE 68
CONTROL VALVE - FLOW CONTROL DUMP VALVE – ON / OFF
12 FRONT AUXILIARY MANUAL PRESSURE SPOOL 50 SOLENOID ACTIVATED DIRECTIONAL CHECK VALVE - With 5.0 PSI (0,34 bar)
69
BLEED-OFF VALVE 30 CHECK VALVE - BUCKET POSITION CONTROL VALVE - ROD Spring
13 PILOTED ACTIVATED DIRECTIONAL VALVE 51 VARIABLE CAPACITY DISPLACEMENT 70 ANTICAVITATION VALVE
CONTROL VALVE - TILT CONTROL 31 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP
14 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING 52 RELIEF/REPLENISHING VALVE - HIGH 71 RIDE CONTROL VALVE
CONTROL VALVE - LIFT CONTROL SPOOL PRESSURE: 5294 PSI (365 bar)
72 HIGH PRESSURE CHAMBER
15 SOLENOID ACTIVATED DIRECTIONAL 32 PILOT ACTIVATED DIRECTIONAL 53 RELIEF VALVE - CHARGE INLET:
CONTROL VALVE - BICS CONTROL CONTROL VALVE - HYDRAULIC 465 PSI (32, bar) 73 LOW PRESSURE CHAMBER
16 FILTER - BICS CONTROL VALVE POWERED BOB-TACH at High Engine Idle
With 140 degrees F. (60 degrees C.) Fluid 74 FILTER – BOB-TACH VALVE
(SCREEN) 33 FILTER - BOB-TACH VALVE
17 CHECK VALVE - With 14.5 PSI (1,0 bar) 54 RESTRICTION - 0.06 inch (1,5 mm) 75 CHECK VALVE – COLD WEATHER BY-PASS
Spring 34 RESTRICTION - 0.089 inch (2,26 mm) With 50 PSI (3,45 bar) Spring
55 CHECK VALVE - With 200 PSI (13,8 bar)
18 RESTRICTION . . . . . . . 0.079 in. (2,0 mm) 35 SOLENOID ACTIVATED DIRECTIONAL Spring NOTE: Unless otherwise specified
CONTROL VALVE (TWO COIL) springs have NO significant
56 DRIVE MOTOR SHUTTLE VALVE
pressure value.
101 of 896
12
Male
TWO SPEED DRIVE MOTOR (OPTIONAL)
56 54 Male
12
55
Female
HIGH FLOW VALVE (OPTIONAL)
BUCKET POSITIONING VALVE (OPTIONAL)
68 OUT D
HYDRAULIC CONTROL VALVE 29 30
69
X 31
67 28
?
57
W
REAR AUXILIARY COUPLERS (OPTIONAL)
9
C
A
58 59 10
FEMALE MALE 27
60 10 ?
Auxiliary Spool
Z
Base
? Rod ?
6
A B
48
B TILT
50 CYLINDERS
8
49 11
HYDROSTATIC PUMP
46
? ? BICS CONTROL VALVE
51 Tilt Spool
75
47
8 13
70
M4
45 11
M
3
LIFT
D C CYLINDERS
44 14
P - in P - out T
REAR AUXILIARY
52
52
VALVE (OPTIONAL)
Dealer CopyLift--SpoolNot for Resale
Charge
Inlet BOB-TACH CYLINDER 8
(OPTIONAL) RIDE CONTROL
53 18 (OPTIONAL)
20
BOBTACH VALVE 11 16 16
B A 74 17 15
(OPTIONAL) ?
37 IN
M M1 74 38 7
2
2 36 6
71
DUAL STAGE
ACCUMULATOR
52 52 1
39
19
51 35
? ?
73 72
34 40 PP
DR Oil Cooler RESERVOIR (VENTED)
T 3 2
5
P1 P2 1
42 33 32 4
43 VARIABLE SPEED HYDRAULIC

FAN MOTOR W/ INTEGRATED FILTER
2-SPEED & SAPR BRAKE HYDRAULIC FILTER
64 VALVE (OPTIONAL)
B1 66
65 25 23
B PUMP
64 60 26 SUPPLY
WORKING
B A CIRCUIT
63 PILOT
Z PRESSURE
62 C DRAIN /
P 24 21 RETURN
D 58 59
W
P DR 22
62 61
?
57
A X
A1 HYDRAULIC/HYDROSTATIC SCHEMATIC
T WITH ALL OPTIONS
41
S650 (S/N A3NV11001 & ABOVE)
55 (S/N A3NW11001 & ABOVE)
54 56
L DRAIN / RETURN MANIFOLD (PRINTED JUNE 2009)
7170812
102 of 896
PRINTED IN U.S.A.
SJC WITH NO OPTIONS
(PRINTED JUNE 2009)
V-1350legend Printable Version Click Here
LEGEND
1 RESERVOIR: 14 LIFT CYLINDER SPOOL - MADE TO 28 SENSOR – CHARGE PRESSURE –
Capacity at sight gauge . . 10.7 Qts. (10,2 L) RESTRICT FLOW DURING BOOM Fan Filter
System Capacity . . . . . . . 10.5 Gal. (39,7 L) DOWN BUT NOT DURING BOOM UP
29 HYDRAULIC PUMP . . . . . . . Gear Type
2 SIGHT GUAGE 15 PILOTED ACTIVATED DIRECTIONAL 23.0 GPM (87,1 L/min.) at High Engine Idle
CONTROL VALVE - TILT CONTROL
30 CHARGE PUMP -
3 DIFFERENTIAL PRESSURE SWITCH: 13.5 GPM (51,1 L/min) at High Engine Idle
16 PILOTED ACTIVATED DIRECTIONAL
15 PSI (1,07 bar)
CONTROL VALVE - LIFT CONTROL 31 VARIABLE CAPACITY DISPLACEMENT
Normally Closed
17 BIDIRECTIONAL HYDROSTATIC PUMP
4 FILTER - HYDRAULIC (CANISTER) SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BICS CONTROL 32 RELIEF/REPLENISHING VALVE - HIGH
5 SPRING LOADED FILTER BY-PASS 18 FILTER - BICS CONTROL VALVE PRESSURE: 5294 PSI (365 bar)
VALVE: 25 PSI (1,7 bar) (SCREEN) 33 RELIEF VALVE - CHARGE INLET:
385 PSI (26,5 bar) at High Engine Idle
19 CHECK VALVE - With 14.5 PSI (1,0 bar) Dealer Copy -- Not for Resale
6 DIAGNOSTIC COUPLER
Spring With 140 degrees F. (60 degrees C.) Fluid
7 RELIEF VALVE - MAIN: 20 RESTRICTION . . . . . . . 0.079 in. (2,0 mm) 34 SERVO PISTON – Swash Plate
3500 PSI (241 bar)
at Front Quick Couplers 21 PULL BUTTON ACTIVATED 35 SOLENOID ACTIVATED DIRECTIONAL
DIRECTIONAL CONTROL VALVE - LIFT CONTROL VALVE – FORWARD/REVERSE
ARM BY-PASS 36 FILTER
PORT 4000 PSI (276 bar)
22 SENSOR – HYD. TEMPERATURE
9 RELIEF/ANTICAVITATION VALVE - 37 CHECK VALVE – COLD WEATHER BY-PASS
23 ANTICAVITATION VALVE With 50 PSI (3,45 bar) Spring
PORT (OPTIONAL) 4000 PSI (276 bar)
38 RESTRICTION - 0.06 inch (1,5 mm)
10 SOLENOID ACTIVATED DIRECTIONAL 24 PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator):
CONTROL VALVE - AUXILIARY 39 CHECK VALVE - With 200 PSI (13,8 bar)
1566 - 1784 PSI (108 - 123 bar)
Spring
11 LOAD CHECK VALVE
25 SPRING LOADED FILTER BY-PASS 40 DRIVE MOTOR SHUTTLE VALVE
VALVE: 75 - 83 PSI (5,2 - 5,7 bar)
12 FRONT AUXILIARY MANUAL PRESSURE
BLEED-OFF VALVE 26 FIXED CAPACITY DISPLACEMENT 41 FIXED CAPACITY DISPLACEMENT
HYDRAULIC MOTOR BIDIRECTIONAL HYDROSTATIC
13 ANTICAVITATION VALVE MOTOR
27 FILTER - HYDRAULIC (CANISTER)
NOTE: Unless otherwise specified

springs have NO significant
pressure value.

103 of 896
Male
TWO SPEED DRIVE MOTOR (OPTIONAL) 12
39 L OUT Male
40 38 HYDRAULIC CONTROL VALVE (SPOOL

VALVE)
12
Female
10
41 10
A B
6
8 TILT CYLINDERS
31 37 11
R BICS CONTROL VALVE

TANDEM
T
HYDROSTATIC
DRIVE PUMP
36 35
X
34 15
8
X
11
16 LIFT CYLINDERS
13
M 36
M
A B
M
32 32
Charge
Dealer Copy
8 -- Not for Resale
33 G Inlet
20
A B
M 14 19
M 36 11 18 18 17 ?
IN 2
32 ?
7 6
32
X
VARIABLE SPEED HYDRAULIC
34 FAN MOTOR W/ INTEGRATED FILTER
1
X ?
36
35 27
25 RESERVOIR (VENTED)
T OIL COOLER 2 21
31 28
R
1
29 5 3
4
23
30 26 PUMP
SUPPLY
P WORKING
DR 24 HYDRAULIC FILTER CIRCUIT
PILOT
PRESSURE
B A DRAIN /
RETURN
41
SJC WITH NO OPTION
22
38
40 S650 (S/N A3NV11001 & ABOVE)
39
DRAIN/RETURN
(S/N A3NW11001 & ABOVE)
L
MANIFOLD
DRIVE MOTOR (PRINTED JUNE 2009)
104 of 896
7170813
PRINTED IN U.S.A.
SJC WITH ALL OPTIONS
(PRINTED JUNE 2009) Printable Version Click Here
V-1351legend
LEGEND
60 CHECK VALVE – COLD WEATHER BY-PASS
1 RESERVOIR: 20 RESTRICTION . . . . . . . 0.079 in. (2,0 mm) 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring
With 50 PSI (3,45 bar) Spring
Capacity at sight gauge . . 10.7 Qts. (10,2 L)
System Capacity . . . . . . . 10.5 Gal. (39,7 L) 21 PULL BUTTON ACTIVATED 40 FILTER – BOB-TACH VALVE
DIRECTIONAL CONTROL VALVE - LIFT 61 RESTRICTION - 0.06 inch (1,5 mm)
2 SIGHT GUAGE 41 RELIEF VALVE - 2000 PSI (137 bar)
ARM BY-PASS 62 CHECK VALVE - With 200 PSI (13,8 bar)
3 DIFFERENTIAL PRESSURE SWITCH: 22 RIDE CONTROL VALVE 42 CHECK VALVE - With 300 PSI (20,7 bar) Spring
15 PSI (1,07 bar) Spring And With 0.016 inch (0,40 mm) Orifice 63 DRIVE MOTOR SHUTTLE VALVE
23 ANTICAVITATION VALVE
Normally Closed
43 RESTRICTION - 0.025 inch (0,6 mm) 64 HIGH PRESSURE SHUTTLE
4 FILTER - HYDRAULIC (CANISTER) 24 PROPORTIONAL RELIEF VALVE –
(Fan Speed Regulator): 44 SENSOR – HYD. TEMPERATURE 65 FIXED CAPACITY DISPLACEMENT
5 SPRING LOADED FILTER BY-PASS 1566 - 1784 PSI (108 - 123 bar) BIDIRECTIONAL HYDROSTATIC
VALVE: 25 PSI (1,7 bar) 45 HYDRAULIC PUMP . . . . . . . Gear Type
MOTOR – 2 SPEED
25 SPRING LOADED FILTER BY-PASS 23.0 GPM (87,1 L/min.) at High Engine Idle
6 DIAGNOSTIC COUPLER 66 FIXED CAPACITY DISPLACEMENT
VALVE: 75 - 83 PSI (5,2 - 5,7 bar)
46 CHARGE PUMP - BIDIRECTIONAL HYDROSTATIC
7 RELIEF VALVE - MAIN: 26 FIXED CAPACITY DISPLACEMENT 13.5 GPM (51,1 L/min) at High Engine Idle MOTOR
3500 PSI (241 bar) HYDRAULIC MOTOR Dealer Copy --47NotPILOT
for Resale
ACTIVATED DIRECTIONAL 67 HYDRAULIC BRAKE – SPRING APPLIED –
at Front Quick Couplers 27 FILTER - HYDRAULIC (CANISTER) CONTROL VALVE - REAR AUXILIARY PRESSURE RELEASE (SAPR)
28 SENSOR – CHARGE PRESSURE – 48 RELIEF VALVE: 3300 PSI (228 bar) 68 SOLENOID ACTIVATED DIRECECTIONAL
PORT 4000 PSI (276 bar) CONTROL VALVE – 2 SPEED
Fan Filter
9 RELIEF/ANTICAVITATION VALVE - 49 SOLENOID ACTIVATED DIRECTIONAL
29 SOLENOID ACTIVATED DIRECTIONAL 69 CHECK VALVE
PORT (OPTIONAL) 4000 PSI (276 bar) CONTROL VALVE - BUCKET POSITION CONTROL VALVE - TWO COIL
10 SOLENOID ACTIVATED DIRECTIONAL 50 RESTRICTOR - 0.031 inch (0,8 mm) 70 SOLENOID ACTIVATED DIRECECTIONAL
VALVE (ON/OFF)
CONTROL VALVE - AUXILIARY CONTROL VALVE – MAKE-UP
30 FLOW DIVIDER ADJUSTMENT VALVE 71
11 LOAD CHECK VALVE 51 LOAD SHUTTLE VALVE - BLEED OFF FILTER - BRAKE
31 PILOTED ACTIVATED DIRECTIONAL SOLENOID ACTIVATED DIRECTIONAL 72 SOLENOID ACTIVATED DIRECECTIONAL
12 FRONT AUXILIARY MANUAL PRESSURE CONTROL VALVE - FLOW CONTROL 52
CONTROL VALVE - BASE CONTROL VALVE – BRAKE
BLEED-OFF VALVE SPOOL
SOLENOID ACTIVATED DIRECTIONAL 73 HIGH FLOW HYDRAULIC PUMP Gear Type
13 ANTICAVITATION VALVE 32 CHECK VALVE - BUCKET POSITION 53
CONTROL VALVE - ROD 7.5 GPM (28,4 L/min.) at High Engine Idle
VALVE
14 LIFT CYLINDER SPOOL - MADE TO 74 RELIEF VALVE - 3500 PSI (241 bar)
33 PILOTED ACTIVATED DIRECTIONAL 54 VARIABLE CAPACITY DISPLACEMENT
RESTRICT FLOW DURING BOOM
CONTROL VALVE - UNLOADING BIDIRECTIONAL HYDROSTATIC PUMP 75 DUMP VALVE – ON / OFF
DOWN BUT NOT DURING BOOM UP
SPOOL 55 RELIEF/REPLENISHING VALVE - HIGH
15 PILOTED ACTIVATED DIRECTIONAL 76 CHECK VALVE - With 5.0 PSI (0,34 bar)
PRESSURE: 5294 PSI (365 bar)
CONTROL VALVE - TILT CONTROL 34 PILOT ACTIVATED DIRECTIONAL Spring
CONTROL VALVE - HYDRAULIC 56 RELIEF VALVE - CHARGE INLET:
16 PILOTED ACTIVATED DIRECTIONAL 77
POWERED BOB-TACH 385 PSI (26,5 bar) at High Engine Idle HIGH PRESSURE CHAMBER
CONTROL VALVE - LIFT CONTROL
With 140 degrees F. (60 degrees C.) Fluid LOW PRESSURE CHAMBER
17 SOLENOID ACTIVATED DIRECTIONAL 35 FILTER - BOB-TACH VALVE 78
57 SERVO PISTON – Swash Plate
CONTROL VALVE - BICS CONTROL RESTRICTION - 0.089 inch (2,26 mm)
36
18 FILTER - BICS CONTROL VALVE 58 SOLENOID ACTIVATED DIRECTIONAL
(SCREEN) 37 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE – FORWARD/REVERSE NOTE: Unless otherwise specified
19 CHECK VALVE - With 14.5 PSI (1,0 bar) CONTROL VALVE (TWO COIL) 59 FILTER springs have NO significant
Spring 38 RELIEF VALVE - 1200 PSI (83 bar) pressure value.

105 of 896
Male
12
62 L
Male
63 61
12
Female
HIGH FLOW VALVE (OPTIONAL)
74
BUCKET POSITIONING VALVE
75 OUT (OPTIONAL) D
31 32
HYDRAULIC CONTROL VALVE (SPOOL
X VALVE) 33
30
?
65 64
W
76 9
C
A
66 REAR QUICK COUPLERS
10
67 10 ?
FEMALE MALE
Z
A B
?
51
?
6
29
B
8 TILT CYLINDERS
53
54 60 11
52
R
49
TANDEM
? ?
BICS CONTROL VALVE
T
HYDROSTATIC
59 58
X
50
57 15
8
X
48 11
16 LIFT CYLINDERS
47 13
M 59 P in P out T
M REAR AUXILIARY
A B VALVE (OPTIONAL)
M Dealer Copy -- Not for Resale
55 55
Charge 8
56 G Inlet
BOBTACH CYLINDER (OPTIONAL)
20
A B 22
M 14 19
40 POWER BOBTACH
M 59 11 18
VALVE (OPTIONAL) 18 17 ?
39 IN 2
55 38 40 41 7
? 6
55
X
57
1
X ?
42
59 37 ? ?
58
36 43 PP
DR
OIL COOLER RESERVOIR (VENTED) 21
T 2
54 78 77
R P1 P2
1
45 35 34 5 3
4
46 VARIABLE SPEED HYDRAULIC

FAN MOTOR W/ INTEGRATED FILTER
2-SPEED & SAPR HYDRAULIC FILTER
71 BRAKE VALVE
B1
73
72 27
B
25 PUMP
67 SUPPLY
71 28 WORKING
CIRCUIT
B A PILOT
69 70 PRESSURE
Z DRAIN /
RETURN
C
P 23
D 66 26
W
68 P DR 24
69 ?
64 65
A X
DRAIN/RETURN MANIFOLD
A1 HYDRAULIC/HYDROSTATIC SCHEMATIC
T
SJC WITH ALL OPTION
44 S650 (S/N A3NV11001 & ABOVE)
63
62
61 (S/N A3NW11001 & ABOVE)
L
TWO SPEED DRIVE MOTOR (OPTIONAL) (PRINTED JUNE 2009)
106 of 896 7170813

PRINTED IN U.S.A.
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols

SYMBOL DESCRIPTION SYMBOL DESCRIPTION
FLOW LINES and CONNECTIONS BASIC and MISCELLANEOUS SYMBOLS
WORKING CIRCUITS - Continuous, RESTRICTION - Line with Fixed

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

TEMPERATURE INDICATOR -
Drain Line (drain or bleed line - line
(temperature measurement -
conducting fluid from a component
thermometer).
housing to the reservoir.

FILTER (strainer or screen) - For fluid
conditioning.
COMPONENTS - Long Chain Line -
Enclosure outline for several
components assembled in one unit. VENTED AND FILTERED
RESERVOIR (reservoir open to
atmosphere).
MECHANICAL CONNECTIONS -
Double Line (Shaft, Lever, Piston
Rod). PRESSURIZED, VENTED AND
FiLTERED RESERVOIR (Reservoir
uses a pressured cap).
CONNECTED JUNCTION OF OIL
LINES (Flow Line Connection). OIL COOLER (heat exchanger) - The
arrows in the diamond indicate the
extraction of heat (heat dissipation).
OIL LINES CROSSING (NOT PRESSURE SENSOR - Varies

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

activates when pressure reaches
specified level.
MUFFLER (silencer) - Reduces

noise.

HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)

CYLINDER: Equipment to convert hydraulic energy into CONTROL MECHANISMS

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

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

LEVER (manual).
PUMP: To convert mechanical energy into hydraulic

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

mechanical energy. PROPORTIONAL ELECTRICAL
SOLENOID (electrical).
FIXED CAPACITY DISPLACEMENT CONTROL VALVE ACTIVATED BY

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


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

OUT IN - Used as Replenishing Valve, Lock PATHS
Check Valve or Anticavitation Valve -
Opens if the Inlet pressure is higher
than the Outlet pressure. Often SOLENOID ACTIVATED
contains internal spring which has NO DIRECTIONAL CONTROL VALVE
significant pressure value. (Two Position) - controlled by an
electric solenoid (with return spring).
SPRING LOADED VALVE (bypass
OUT IN Valve) - Opens if the Inlet pressure is PILOT ACTIVATED DIRECTIONAL
greater than the Outlet pressure plus CONTROL VALVE (Two Position) -
the spring pressure. controlled by pressure (with return
spring).
PILOT CONTROLLED NON-

RETURN VALVE- It is possible to MANUALLY ACTIVATED DIRECTION
open the valve by pilot pressure. CONTROL VALVE (Variable Position)
T
OUT IN
Joystick Controlled, variable pressure
P
to shift the pilot activated directional
control valve spool.
SHUTTLE VALVE - The Inlet port
IN IN connected to the higher pressure is
OUT
automatically connected to the Outlet MANUALLY ACTIVATED FLOW
port while the other Inlet port is CONTROL VALVE (Two Position)
closed. allows for changing pilot flow to
ST
O
IS
D
FRON T
BACK
control switching joystick functions for
STD / ISO Control (Excavators Only).
STEERING CONTROL VALVE

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


PRESSURE CONTROL VALVE: Valve ensuring the MISCELLANEOUS

control of pressure.
ACCUMULATOR - Supplies
RELIEF VALVE - When the Inlet temporary reserve pressure to the
pressure overcomes the opposing hydraulic system when the engine
IN OUT
force of the spring, the valve opens has been stopped.
permitting flow from the Outlet port.
RELIEF/REPLENISHING VALVE or
RELIEF/ANTICAVITATION VALVE -
When the Inlet pressure overcomes
IN OUT
the opposing force of the spring, the
valve opens permitting flow from the
Outlet port - Allows free flow in the
opposite direction.
DUAL PRESSURE RELIEF VALVE -

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

applied to open the valve to allow the
hydraulic cylinder to move.
FLOW CONTROL VALVE: Valve controlling the flow in

one or both directions.
ONE WAY RESTRICTOR VALVE

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

position.
LOAD SENSE BLEED VALVE -

Regulates small amount of fluid flow
(leakage).

HYDRAULIC SYSTEM INFORMATION (CONT'D)
Troubleshooting WARNING
The following troubleshooting chart is provided for
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
If a service code appears in the left instrument panel.

(See DIAGNOSTIC SERVICE CODES on Page 60-90-
1.)
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
Slow hydraulic system action. 1, 3, 4, 6, 8
Hydraulic action is not smooth. 1, 4, 5, 6, 7
Lift arms go up slowly at full engine RPM 1, 3, 4, 5, 6, 7, 8, 9
The lift arms or Bob-Tach will move when the pedal is in neutral position 4
The lift arms come down when the pedal is in neutral position 4, 9, 10, 11
Lift arm bypass control valve stuck 12

Lift arm bypass control valve stem bent or broken 13
KEY TO CORRECT CAUSE
1. The fluid level is not correct.

2. The pedal linkage is disconnected.
3. The hydraulic pump has damage.
4. The pedal linkage is not adjusted correctly.
5. Relief valve is not at the correct pressure.
6. Suction leak on the inlet side of the hydraulic pump.
7. Fluid is cold. Wrong viscosity fluid.
(See HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-40-1.)
8. Exceeding the loaders rated operating capacity.
9. Internal leak in the lift cylinder(s).
10. External leak from the cylinder(s).
11. Damaged lift spool.
12. Rotate shaft.
13. Replace lift arm bypass control valve assembly.


CYLINDER (LIFT) Figure 20-20-2
Testing
Figure 20-20-1
P-90617
1
Install a cap (Item 1) [Figure 20-20-2] on the hose and
P-90616 tighten.
Engage the parking brake. Lower the seat bar. Start the
Lower the lift arms. Stop the engine. Raise the seat bar. engine and press the PTOL button.

Operate the controls that lower the lift arms.
WARNING If there is any leakage from the fitting on the cylinder

(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair. Repeat the procedure to check the other lift
Hydraulic fluid escaping under pressure can have cylinder.
sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
Check only one cylinder at a time. Disconnect the hose

(Item 1) [Figure 20-20-1] which goes to the base end of
the lift cylinder.

CYLINDER (LIFT) (CONT'D)
Removal And Installation

WARNING
Lift and block the loader. (See Procedure on Page 10-10-
1.)
NOTE: Remove only one cylinder at a time.
explosion or fire.
WARNING W-2103-0508
Figure 20-20-4
W-2017-0286
2
1
IMPORTANT

When repairing hydrostatic and hydraulic systems,
2
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
P-90824
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888 Cap and plug both fittings on the cylinder (Item 1)
[Figure 20-20-4].
Figure 20-20-3
NOTE: Do not cap or plug the two hydraulic hoses
(Item 2) [Figure 20-20-4].
Place the hoses (Item 2) [Figure 20-20-4] in a suitable

container to collect the hydraulic oil as the lift arms are
raised.

safe manner.
1
WARNING
P-90616 AVOID INJURY OR DEATH
Mark and disconnect the two hydraulic hoses (Item 1) death. Fluid leaks under pressure may not be visible.
[Figure 20-20-3]. Use a piece of cardboard or wood to find leaks. Do
W-2072-0807

Removal And Installation (Cont’d)
Figure 20-20-5
P-90602A
Remove the retaining bolt and nut (Item 1) [Figure 20-

20-5] from the pin on the rod end of the cylinder.

Installation: Tighten the retainer bolt and nut to 48 - 54
N•m (35 - 40 ft-lb) torque.
Figure 20-20-6
P-90611
With a slide hammer, remove the pin (Item 1) [Figure 20-

20-6] from the rod end of the cylinder.

CYLINDER (LIFT) (CONT'D) Install a sling in the middle of the Bob-Tach as shown in
(Item 1) [Figure 20-20-7].
Using a chain hoist raise the lift arms and install an
approved lift arm support device on the cylinder that is
connected to the lift arm.
DANGER Figure 20-20-8
2 1
P-90328
AVOID DEATH
unless supported by an approved lift arm P-90823

D-1009-0409 Install a bolt (Item 1) [Figure 20-20-8] through the eyelet
of the cylinder and install a strap (Item 2) [Figure 20-20-
8] to secure the cylinder.
WARNING
W-2059-0598
Figure 20-20-7
P-90605

CYLINDER (LIFT) (CONT'D) Figure 20-20-11
Open the rear door.

1
NOTE: When removing the left side lift cylinder the
battery will need to be removed to gain access
to the lower retaining bolt and nut.
Remove the battery (If required). (See Removal And

Figure 20-20-9
P-90827
1
20-11] from the base end of the lift cylinder.
Figure 20-20-12

1
P-90834

20-9] from the pin on the base end of the lift cylinder.
Installation: Tighten the retainer bolt and nut to 48 - 54 1

Figure 20-20-10 P-90823
Using a chain hoist remove the lift cylinder (Item 1)

[Figure 20-20-12] from the loader.
P-90825
Remove the grease fitting (Item 1) [Figure 20-20-10]

from the base end of the lift cylinder.
Installation: Tighten the grease fitting to 20 N•m (15 ft-

lb) torque.

Parts Identification
1. Seal
2. Hydraulic Tubeline
3. Cylinder Case Tube
4. Plug
5. Clamp
6. Nut
7. Back-up Ring
8. O-ring 4
9. Piston Assembly
10. Spacer
11. O-ring
3
12. Back-up Ring
13. O-ring
14. Head 4
15. Rod Seal 5
16. Wiper Seal
17. Rod
18. Grease Fitting
6
7

8
2 9
10
1
13
14
15
16
11
12
17
18
NA1413S

Disassembly
2
Use the following tools to disassemble the cylinder:
MEL1074 - O-ring Seal Hook 1

Spanner Wrench
Hold the hydraulic cylinder over a drain pan and move

the rod in and out slowly to remove the fluid from the
cylinder.
Put the base end of the cylinder in a vise. 3
Figure 20-20-13 P-48038
1 Remove the back-up ring (Item 1) and O-ring (Item 2)

[Figure 20-20-15] from the piston.
NOTE: If the fiber surface (Item 3) [Figure 20-20-15]

on the piston, becomes damaged, the
complete piston must be replaced.

Figure 20-20-16
P-48033
Use a spanner wrench to loosen the head (Item 1)

[Figure 20-20-13] from the cylinder case.
3
2
Figure 20-20-14
4
3 P-48039
2
1 Remove the O-ring (Item 1). Remove the O-ring (Item 2)

and the back-up ring (Item 3) [Figure 20-20-16] from the
cylinder head.
NOTE: The O-ring (Item 2) and back-up ring (Item 3)

[Figure 20-20-16] are no longer available
parts. The seal kit will contain a one piece seal
that is used in place of the O-ring and back-up
P-48036 ring.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
and head (Item 4) [Figure 20-20-14].

CYLINDER (LIFT) (CONT'D) Assembly
Disassembly (Cont'd) Use the following tools to assemble the cylinder:
Figure 20-20-17 MEL1396 - Seal Installation Tool

MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
1 Figure 20-20-19
P-48040
Remove the wiper seal (Item 1) [Figure 20-20-17] from

the cylinder head.

P7424
Figure 20-20-18
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
Always install new O-rings and seals during assembly.

1
Lubricate all O-rings and seals with hydraulic oil during
installation.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-19].
P-48042 Allow the seal to stretch for 30 seconds before installing it

on the piston.
Remove the rod seal (Item 1) [Figure 20-20-18] from the
cylinder head.

Assembly (Cont’d)
Figure 20-20-20
1
2
P7425
Install the rod seal in the head [Figure 20-20-22].

P-48038
Figure 20-20-23
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

20-20] on the cylinder piston.

2
Figure 20-20-21
P-48041 P-48042
Install the wiper seal, with the wiper side of the seal (Item
1) toward the outside of the head (Item 2) [Figure 20-20-
P-48043 P7427 23].
Install the rod seal on the rod seal tool [Figure 20-20-21].
NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-20-21] must be installed
toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [Figure 20-

20-21].

Assembly (Cont'd)
Figure 20-20-24
1
1
2
P-48035
Put the base end of the hydraulic cylinder in a vise.

P101716
Using a spanner wrench, tighten the head (Item 1)
[Figure 20-20-26] until the head is flush with the end of
Install the O-ring (Item 1) and the seal (Item 2) [Figure the cylinder tube assembly.
20-20-24] on the cylinder head.

Figure 20-20-25
1
2
3
P-48036
NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the kit.
Install the head (Item 1), spacer (Item 2) piston (Item 3),
and nut (Item 4) [Figure 20-20-25].
Tighten the nut (Item 4) [Figure 20-20-25] to 1152 N•m

(850 ft-lb) torque.

CYLINDER (TILT) Figure 20-21-2
Testing
Figure 20-21-1
1 2
P100721
Install a cap (Item 1) [Figure 20-21-2] in the hydraulic

P-85553 hose and tighten.
Remove the attachment. Roll the Bob-Tach fully back. engine and press the PTOL button.
Stop the engine. Raise the seat bar.

Operate the controls that rolls the Bob-Tach forward.
If there is any leakage from the fitting on the cylinder

WARNING (Item 2) [Figure 20-21-2]. Remove the cylinder for repair.
Repeat procedure to check the other cylinder.

Hydraulic fluid escaping under pressure can have
immediately.
W-2145-0290
Disconnect the hose (Item 1) [Figure 20-21-1] which

goes to the rod end of the tilt cylinder.

CYLINDER (TILT) (CONT'D) Figure 20-21-5
Figure 20-21-3
2
1
1
P-85562
Disconnect the two hydraulic hoses (Items 1 & 2) [Figure

P-85554 20-21-5] from the cylinder.
Cap the hoses and plug the fittings on the cylinder.

Remove the attachment from the Bob-Tach. Roll the Bob-
Tach forward Figure 20-21-6

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

3] from the rod end pivot pin.
1
Installation: Tighten the retainer nut to 48 - 54 N•m (35 -
40 ft-lb) torque.
Figure 20-21-4
P-85648
Remove the base end pivot bolt and washer (Item 3)

[Figure 20-21-5].
Remove the retainer nut and washer (Item 1) [Figure 20-

21-6] from the base end pivot pin.
Installation: Tighten the retainer nut to 257,6 N•m (190

P-85649 ft-lb) torque.
Remove the rod end pivot pin (Item 1) [Figure 20-21-4].

CYLINDER (TILT) (CONT'D)
Removal And Installation (Cont'd)
Figure 20-21-7
P-85564
Slide the cylinder from the base pin and remove the
cylinder from the loader [Figure 20-21-7].

Base End Pivot Pin Removal And Installation
Use the following tools to assemble the cylinder:
MEL1396 - Seal Installation Tool

Spanner Wrench
Figure 20-21-8
P-85567
Check pivot pin and replace as needed [Figure 20-21-

10].

1
P-85565
Figure 20-21-9
P-85566
Remove the cylinder from the cylinder base pin (Item 1)

[Figure 20-21-8]. (See Removal And Installation on
Page 20-21-2.)
Use a shaft (Item 1) [Figure 20-21-9] and a hammer to

remove the cylinder base pin from the lift arms.

1. Tubeline
2. Case
3. Plug
4. Grease Fitting
5. Clamp
6. Nut
7. Back-up Ring
8. O-ring
9. Piston
10. O-ring
11. Back-up Ring
12. O-ring 4
13. Head
14. Seal
15. Wiper 5
16. Rod
17. Bushing 2
18. Seal

3 6
7
1
8
9
3
18
12
13
14
15
10
11 16
17
NA1210S

Disassembly

1
MEL1074 - O-ring Seal Hook
Spanner Wrench

cylinder.
Put the base end of the cylinder in a vise.
Figure 20-21-11 P-48035
1
Use a spanner wrench to loosen the head (Item 1)
[Figure 20-21-12] from the cylinder case.
2
Figure 20-21-13

3
1 2
P-85651
Remove the seals (Item 1) [Figure 20-21-11] on both

sides of the pivot bushing.
Remove and replace bushing (Item 2) with a driver tool P-48071

and hammer [Figure 20-21-11].
Remove the nut (Item 1), piston (Item 2) and head (Item
3) [Figure 20-21-13].

Disassembly (Cont'd)
Figure 20-21-14
1
2
P-48040
Remove the wiper seal (Item 1) [Figure 20-21-16] from

P-48073 the cylinder head.
Figure 20-21-17
Remove the seal (Item 1), and O-ring (Item 2) [Figure
20-21-14] from the piston.

Figure 20-21-15
2
P-48042
Remove the rod seal (Item 1) [Figure 20-21-17] from the

P-48039 cylinder head.
Remove the O-ring (Item 1). Remove the O-ring (Item 2)

and back-up washer (Item 3) [Figure 20-21-15].
NOTE: The O-ring (Item 2) and back-up ring (Item 3)

[Figure 20-21-15] are no longer available
parts. The seal kit will contain a one piece seal
that is used in place of the O-ring and back-up
ring.

Assembly
1
Use the following tools to assemble the cylinder:
MEL1396 - Seal Installation Tool 2

Spanner Wrench

P-48073
Lubricate all O-rings and seals with hydraulic oil during Install the O-ring (Item 1) and seal (Item 2) [Figure 20-
installation. 21-19] on the cylinder piston.
Figure 20-21-18 Figure 20-21-20

1
P7424 P-48043 P7427
Install the new seal on the tool and slowly stretch it until it Install the rod seal on the rod seal tool [Figure 20-21-20].
fits the piston [Figure 20-21-18].
Allow the seal to stretch for 30 seconds before installing it (Item 1) [Figure 20-21-20] must be installed
on the piston. toward the inside of the cylinder.

21-20].

Assembly (Cont'd) 1
Figure 20-21-21 2
P101716
Install the O-ring (Item 1) and seal (Item 2) [Figure 20-

P7425 21-16] on the cylinder head.
Figure 20-21-24

Figure 20-21-22
1
2
2 3
P-48071
P-48041 P-48042 NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Install the wiper seal, with the wiper side of the seal (Item Install the head (Item 1), piston (Item 2) and nut (Item 3)
1) toward the outside of the head (Item 2) [Figure 20-21- [Figure 20-21-24].
22].
Tighten the nut (Item 3) [Figure 20-21-24] to 1152 N•m
(850 ft-lb) torque.

Assembly (Cont'd)
Figure 20-21-25
P-48035
Using a spanner wrench, tighten the head (Item 1)

[Figure 20-21-25] until the head is flush with the end of

the cylinder tube assembly.
Figure 20-21-26
P-85650
Install the bushing (Item 1) and seals (Item 2) [Figure 20-

21-26] using a driver tool and hammer.

CYLINDER (BOB-TACH) Figure 20-22-2
Testing
WARNING 1
enters skin or eyes, get immediate medical attention P-85570
W-2072-0807
Disconnect the hose (Item 1) [Figure 20-22-2] from the
power Bob-Tach cylinder base end port.
WARNING Figure 20-22-3

1
explosion or fire.
W-2103-0508
Figure 20-22-1
P-85568
Install a plug in the hose (Item 1) [Figure 20-22-3] and

tighten.
engine.
Push and hold the BOB-TACH “WEDGES UP” Switch

(Front Accessory Panel).
P-85570
If there is any leakage from the base end cylinder port

Tilt the Bob-Tach forward, so it is parallel to the floor (Item 2) [Figure 20-22-3], remove the cylinder for repair.
[Figure 20-22-1].
Push and hold BOB-TACH “WEDGES UP” switch until

levers are in the unlocked position (Wedges fully raised).

CYLINDER (BOB-TACH) (CONT’D)
Figure 20-22-4
P-85570
Disconnect the hoses from the rod and base end cylinder
fitting (Item 1) [Figure 20-22-4].

Installation: Tighten the hoses to 29,8 - 32,5 N•m (22 -
24 ft-lb) torque.
Install plugs in the hoses and cap on fittings.
Figure 20-22-5
1
1
P-85569
Remove the bolts and washers (Item 1) [Figure 20-22-

5].
Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-

lb) torque.
Remove the cylinder from the lever pivots.

CYLINDER (BOB-TACH) (CONT’D)
1. Tube 8. Ring
2. Nut 9. O-ring
3. Piston 10. Head
4. O-ring 11. Seal
5. Ring 12. Seal
6. Spacer 13. Rod
7. O-ring

2
3
4
5
6
7
8
9
10
11
12
13
PE3954S

CYLINDER (BOB-TACH) (CONT’D) Figure 20-22-8
Disassembly 3 2 1
Figure 20-22-6
P16295
Piston: Remove the O-ring (Item 1), and seal (Item 2)

P-85647 from the piston (Item 3) [Figure 20-22-8].
Figure 20-22-9

MEL1074 - O-ring Seal Hook
Spanner Wrench 4

2
1
cylinder.
Put the base end of the cylinder in a vise.

5
Use a spanner wrench to loosen the head [Figure 20-22- 3
6].
Figure 20-22-7 N-20611
2
4 3 1 Remove the wiper seal (Item 1), and rod seal (Item 2),
the back-up washer (Item 3), the thin O-ring (Item 4), and
the thick O-ring (Item 5) [Figure 20-22-9] from the head.
P16294
Remove the head and rod assembly from the cylinder

[Figure 20-22-7]. Put the rod end in a vise.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3),
and head (Item 4) [Figure 20-22-7] from the rod.

Assembly
3 1
2
Figure 20-22-10
P16295
Piston: Install the O-ring (Item 1) and seal (Item 2) on the

P7424 piston (Item 3) [Figure 20-22-11].
NOTE: The piston center hole (Item 4) [Figure 20-22-

Use the following tools to assembly the cylinder: 11] has a bevel on one end. The bevel goes
toward the rod.

MEL1396 - Seal Installation Tool
MEL1033 - Rod Seal Installation Tool Figure 20-22-12
Spanner Wrench

Lubricate all O-rings and seals with hydraulic oil during

installation.
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-22-10]. N-20612
Allow the seal to stretch for 30 seconds before installing it

on the piston. Install the rod seal on the rod seal tool [Figure 20-22-12].

must be toward the inside of the cylinder.

Assembly (Cont’d)
Figure 20-22-13
2
3
P7422
Install the thin O-ring (Item 1) [Figure 20-22-15].

N-20613
Install the back-up washer (Item 2) and thick O-ring (Item
3) [Figure 20-22-15] into the groove on the head.
22-13]. NOTE: Clean and dry the threads before installing the

nut. Install the new nut from the seal kit.
Figure 20-22-14
Figure 20-22-16
3
2 4
1
P7425
P16294

Install the head (Item 1), and spacer (Item 2) [Figure 20-
Install the wiper seal with the wiper toward the outside of 22-16].
the head.
Install the piston (Item 3) [Figure 20-22-16].
Grease the piston where the nut contacts the piston. do

not get grease on the threads. Install the new nut (Item 4)
[Figure 20-22-16].
Tighten the nut to 122 N•m (90 ft-lb) torque.

CYLINDER (BOB-TACH) (CONT'D)
Assembly (Cont'd)
Figure 20-22-17
P-85647

Tighten the head using a spanner wrench [Figure 20-22-
17].


MAIN RELIEF VALVE
Description
The main relief valve limits the hydraulic system pressure

by opening at a certain pressure and allowing the
hydraulic oil to flow back to the hydraulic reservoir. (See
Hydraulic System on Page SPEC-10-3.)
The main relief valve is adjustable and is located on the

hydraulic control valve near the bottom, facing the front of
the loader.

MAIN RELIEF VALVE (CONT’D) Figure 20-30-1
Testing
1
2
IMPORTANT
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
P-85571
WARNING
Connect the IN port (Item 1) [Figure 20-30-1] of the
When the engine is running during service, the hydraulic tester to the bottom (female) quick coupler on
driving and steering controls must be in neutral and the loader.
the parking brake engaged. Failure to do so can
cause injury or death. Connect the OUT port (Item 2) [Figure 20-30-1] of the
W-2006-1209 hydraulic tester to the top (male) quick coupler on the

loader.
Figure 20-30-2
WARNING
W-2017-0286
2
1
The tools listed will be needed to do the following
procedure:
TWX-RFIK200-S-6 54 U.S. gpm FLOW METER

MEL10006 - Hydraulic Test Kit
P-76460C
NOTE: This procedure is for standard loaders,
loaders equipped with ACS option and
loaders equipped with SJC option. The main Start the engine and run at low idle.
relief valve is located in the same place on all
of the loaders. • Press the AUXILIARY HYDRAULICS Button (Item 1)
[Figure 20-30-2] once to engage the auxiliary
Lift and block the loader. (See Procedure on Page 10-10- hydraulics.
1.)
NOTE: The light (Item 2) [Figure 20-30-2] will be on.

MAIN RELIEF VALVE (CONT’D) Watch the flow meter on the hydraulic tester to make sure
the flow is correct. Increase the engine speed to full
Testing (Cont’d) RPM.
Figure 20-30-3 Refer to (See Hydraulic System on Page SPEC-10-3.) for

both flow and pressure specifications of the hydraulic
Right system.
Steering
Lever
Check the free flow specification.
Control
With the engine at high idle and hydraulic oil at 140 °F
turn the restrictor control on the tester until the flow
through the tester drops to zero. Check the relief
pressure.
1 If the relief pressure is not correct, stop the engine and

adjust the main relief valve.
P-85572
Figure 20-30-4

Joystick Option Only
Right
Steering
1 Lever
Control
P-26697
• Push the front switch (Item 1) [Figure 20-30-3] and

[Figure 20-30-4] to give the front quick couplers a
constant flow of fluid.
• To release from continuous operation, press the front

switch (Item 1) [Figure 20-30-3] and [Figure 20-30-
4] a second time.

MAIN RELIEF VALVE (CONT’D)
Adjusting

loaders equipped with ACS option and
loaders equipped with SJC option. The main
of the loaders.
Figure 20-30-5
1
2

P-85573
If the pressure is not correct, adjust the main relief valve.

Loosen the lock nut (Item 1) [Figure 20-30-5].
Turn the adjusting screw (Item 2) [Figure 20-30-5] in or

out until the pressure is correct. Turning screw in will
increase pressure.
NOTE: If the correct pressure can not be reached,

replace the main relief valve. Check the
pressure setting of the new relief valve.

MAIN RELIEF VALVE (CONT’D) Figure 20-30-7
IMPORTANT
damage the system.
I-2003-0888
P-37689
Clean the area around the control valve. Remove the O-rings and back-up washers from the main
relief valve [Figure 20-30-7].
loaders equipped with ACS option and Clean the main relief valve in clean solvent. Use air
loaders equipped with SJC option. The main pressure to dry the valve.

of the loaders. Install new O-rings and back-up washers. Install the main
relief valve and tighten [Figure 20-30-7].
Figure 20-30-6
Installation: Tighten the main relief valve to 48 - 54 N•m
(35 - 40 ft-lb) torque.
Check the pressure again. (See Testing on Page 20-30-

2.)
1
2
P-85573
If the pressure is not correct, adjust the main relief valve.

Loosen the lock nut (Item 1) [Figure 20-30-5].
Turn the adjusting screw (Item 2) [Figure 20-30-5] in or

out until the pressure is correct. Turning screw in will
increase pressure.
NOTE: If the correct pressure can not be reached,

replace the main relief valve. Check the
pressure setting of the new relief valve.


HYDRAULIC CONTROL VALVE (STANDARD)
Description
Figure 20-40-1
P-90327
The hydraulic control valve is located inside the main

frame on the right hand side, below the operators cab.

The hydraulic control valve is the hydraulic component
that uses spools to direct the flow of hydraulic fluid to the
lift, tilt and auxiliary functions.
The lift and tilt functions in the hydraulic control valve are
operated by linkage connected to the foot pedals.
The auxiliary function is operated by pilot pressure.

There is one solenoid located by each side of the spool.
Only one solenoid at a time is activated by the switch on
the right side control handle/lever. The activated solenoid
sends pilot pressure oil to one side of the spool and
forces the spool to shift.
The hydraulic control valve also contains a main relief

valve which is adjustable.

HYDRAULIC CONTROL VALVE (STANDARD) Drain the hydraulic reservoir. (See Removing And
(CONT’D) Replacing Hydraulic Fluid on Page 10-120-2.)
Removal And Installation Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Remove the control linkage. (See Linkage Removal And

DANGER Installation on Page 50-90-2.)
NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation.
NOTE: Cap and plug all hydraulic connection points

when tubelines or hoses are removed.
Clean area around control valve.
P-90328
Open rear door.
AVOID DEATH
• Disconnecting or loosening any hydraulic Figure 20-40-2
• Keep out of this area when lift arms are raised 3

D-1009-0409 1
WARNING
the lift arms are secured by an approved lift arm 2
P-90187
to fall and cause injury or death. Remove the two bolts (Item 1), move the hose clamp
W-2059-0598 (Item 2) to the middle of the hose, and the place the fuel
inlet assembly (Item 3) [Figure 20-40-2] off to the side.
IMPORTANT
damage the system.
I-2003-0888
Raise the lift arms and install an approved lift arm support
device. (See LIFT ARM SUPPORT DEVICE on Page 10-
20-1.)

HYDRAULIC CONTROL VALVE (STANDARD) Figure 20-40-5
(CONT’D)
Figure 20-40-3
2
1
P-90270
Disconnect the hose (Item 1) [Figure 20-40-5] that

routes from the control valve to the brake valve.
P-90267
routes from the control valve to the fan motor.
The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed

Figure 20-40-6
to the junction block at the rear of the loader where it
feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
1)[Figure 20-40-3].
Figure 20-40-4 1
P-90271
2

1 routes from the top of the control valve to the hydraulic
filter.
P-90269
Disconnect the wire harness connectors (Item 1) [Figure

20-40-4] from the control valve.

routes from the control valve to the drain manifold.

routes from the control valve to the inlet fitting of the
hydraulic pump.

(CONT’D)
Figure 20-40-7
1 1
2 2
1 1
P-90274
Disconnect the three tubelines (Item 1) [Figure 20-40-9]

that route from the control valve to the junction block at
P-90272 the rear of the loader.
Figure 20-40-10
Remove the tubeline clamp (Item 1) [Figure 20-40-7].

Disconnect the two tubelines (Item 2) [Figure 20-40-7]
that route from the control valve to the front auxiliary
1
hydraulics.
Figure 20-40-8
P-90275

1 routes from the control valve to the junction block at the
rear of the machine.
P-90273 Disconnect the lift arm bypass drain hose (Item 2)

[Figure 20-40-10] from the control valve.

HYDRAULIC CONTROL VALVE (STANDARD) Mount Bracket Removal And Installation
(CONT’D)
Figure 20-40-13
Figure 20-40-11
1
P-90280
P-90276 Support the mounting bracket (Item 1) [Figure 20-40-13].
Figure 20-40-14
routes from the bottom of the control valve to the outlet

2
fitting of the hydraulic pump.
Figure 20-40-12
P-90279
Remove the two control valve mount bolts (Item 1)

[Figure 20-40-14].
P-90278
Remove the two frame bolts (Item 2) [Figure 20-40-14]
Support the control valve and remove the two bolts (Item Installation: Torque the two frame bolts (Item 2) [Figure
1) [Figure 20-40-12]. 20-40-14] to 406 - 447 N•m (300 - 330 ft-lb).
Remove the control valve from the loader. Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (STANDARD) (CONT'D)
Identification Chart
Figure 20-40-15
C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 F4 E2
C4
D1
D2
A1
H3
F3 E1
H2 B1
F1 MR J3

H1 J1 C1
P-90307
ITEM S650 LOADER ITEM S650 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS Solenoid
D1 Anti-Cavitation Valve H2 BICS Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve – 27,6 MPa H3 BICS Lock Valve (Lift)
(275,8 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End) J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief/Anti-Cavitation Valve – 27,6 MPa J3 Lift Arm Bypass Orifice
(275,8 bar) (4000 psi)
J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 24,1 MPa (241,3 bar)
D4 Port Relief/Anti-Cavitation Valve – 27,6 MPa
(3500 psi)
(275,8 bar) (4000 psi)
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
27,6 MPa (275,8 bar) (4000 psi) (Optional)

(CONT'D)
Lift Load Check Valve Removal And Installation

1
Figure 20-40-16
3
1 P-90309
Remove and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-40-18].
P-90308
Check the free movement load check valve and spring
(Item 3) [Figure 20-40-18].
Remove the charge tubeline (Item 1) [Figure 20-40-16]
from the BICS valve fitting on the top of the lift load check

valve.
Figure 20-40-17
P-90310
Remove the lift load check valve (Item 1) [Figure 20-40-

17] and fitting from the top of the control valve.
Installation: Lubricate the O-ring and threads and

tighten to 75 - 88 N•m (55 - 65 ft-lb) torque.

(CONT'D)
Load Check Valve Removal And Installation (Tilt &

Auxiliary)
1
Figure 20-40-19
2
3
4
2
1
P-90312
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-20].
P-90311 Check the orifice (Item 3) [Figure 20-40-20] in the

poppet to be sure it is not plugged.
At the front side of the control valve locate the tilt section

Installation: Install a new O-ring (Item 4) [Figure 20-40-
load check valve (Item 1) [Figure 20-40-19]. 20] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 52 - 61 N•m (38 - 45 ft-lb)
At the front side of the control valve locate the auxiliary torque.
section load check valve (Item 2) [Figure 20-40-19].
NOTE: The tilt and auxiliary load check valves are

interchangeable.
IMPORTANT
damage the system.
I-2003-0888

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(CONT'D) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-40-23

Rod End)
Figure 20-40-21
P-90314
P-90314 Loosen the lift circuit port relief / anti cavitation valve
(Item 1) [Figure 20-40-23].
At the back side of the control valve, remove the lift

Figure 20-40-24
section anti-cavitation valve (Item 1) [Figure 20-40-21].
Figure 20-40-22
3 1
4
P-90315
P-90312 Replace the O-ring (Item 1) [Figure 20-40-24] before

installation.
Remove the spring (Item 1) and poppet (Item 2) [Figure Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
20-40-22].
Check the orifice (Item 3) [Figure 20-40-22] in the


22] on the plug and lightly lubricate with oil before
torque.

HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(CONT'D) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-27

Installation (Tilt, Base End)
Figure 20-40-25
P-90314
P-90314 Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-40-27] from the rod end of the tilt section.
Remove the tilt port relief / anti cavitation valve (Item 1)

Figure 20-40-28
[Figure 20-40-25] from the base end of the tilt section.
Figure 20-40-26
1
1
P-90319

installation.
Replace the O-ring (Item 1) [Figure 20-40-26] before Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
installation.
Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.

(CONT'D)
Port Relief Valve Removal And Installation 1
Figure 20-40-29
P-90318A
The control valve may be equipped with an optional

auxiliary port relief valve (Item 1) [Figure 20-40-31].
P-90314
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-40-29] Figure 20-40-32
from the auxiliary circuit of the control valve.

Figure 20-40-30
P-51640
2
P-90318 Installation: Always use new O-rings (Item 1) [Figure
20-40-32]. Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
Installation: Always use new O-rings (Item 1) [Figure


(CONT'D)
Plug Removal And Installation
Figure 20-40-33
1
P-51461
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-40-35].
P-68016
Figure 20-40-36
At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-33].

Figure 20-40-34
P-51462

1 20-40-36]. Tighten to 54 N•m (40 ft-lb) torque.
P-51460A

20-40-34]. Tighten to 54 N•m (40 ft-lb) torque.

(CONT'D)
Rubber Boot Removal And Installation
Figure 20-40-37
P-51506
Remove the three screws (Item 1) [Figure 20-40-37] on

the rubber boot retainer plate.

Installation: Tighten the screws to 10,2 - 11,3 N•m (90 -
100 in-lb) torque.
Figure 20-40-38
1
2
P-51701
Remove the rubber boots (Item 1) from the retainer plate

(Item 2) [Figure 20-40-38].

(CONT'D)
End Cap Block Removal And Installation
Figure 20-40-39
1 1
1 1
P-51699A
1
Figure 20-40-42
P-51697
1
Remove the lift spool lock solenoid (Item 1) and the tilt
spool lock solenoid (Item 2) [Figure 20-40-39] from the

end cap / spool lock block.
4
Figure 20-40-40
1
P-51701
Remove the four end cap / spool lock block mount

screws (Item 1) [Figure 20-40-41] and [Figure 20-40-
1 42].

100 in-lb) torque.
P-90320
Remove the rubber boots and retainer plate (Item 2)
[Figure 20-40-42] from the lift and tilt spools.
Disconnect the tube line (Item 1) [Figure 20-40-40] from
the end cap / spool lock block. Remove the end cap / spool lock block (Item 4) [Figure

(CONT'D)
Lift Spool And Detent Removal And Installation
The tool listed will be needed to do the following 1

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool
Remove the end cap / spool lock block from the control
valve.
Figure 20-40-43
P-90321
Remove the end cap (Item 1) [Figure 20-40-45].
Figure 20-40-46

P-51511A
1
Remove the O-ring (Item 1) [Figure 20-40-43]. 2
Installation: Replace the O-ring, and lubricate the o-ring

lightly with grease or oil before installation of the end cap/
P-51514
spool lock block.
Figure 20-40-44 Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-46].
Remove the washer (Item 2) [Figure 20-40-46].
P-51512
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-44] from the lift spool.

(CONT'D)

(Cont'd)
Figure 20-40-47
1 P-51516
Put a rag around the detent assembly [Figure 20-40-48].

This will prevent the detent balls and spring from being
1 lost when the detent sleeve is removed.
2
P-51515
Figure 20-40-49

Remove the screws (Item 1) [Figure 20-40-47] from the
detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-40-47].
Installation: Lubricate the screws and tighten to 10,2 -

11,3 N•m (90 - 100 in-lb) torque.
2 1
3
IMPORTANT
The detent assembly has small springs and balls. Do 2 P-51517
not lose these parts during disassembly and
assembly.
I-2012-0284
Remove the detent sleeve (Item 1), detent balls (Item 2)
and spring (Item 3) [Figure 20-40-49].

(CONT'D)

(Cont'd)
Figure 20-40-50
P-8988
Clamp the linkage end of the spool in a vise [Figure 20-

1 40-52].
P-51518 NOTE: Protect spool before clamping in vise.
Figure 20-40-53
Remove the lift spool assembly and seal (Item 1) [Figure

20-40-50] from the control valve. 2
Figure 20-40-51
1
3
1
N-18915
Install the spring tool (Item 1) [Figure 20-40-53] over the

P-51519 centering spring.
NOTE: Be careful when removing the detent adapter

Remove the lift spool seal (Item 1) [Figure 20-40-51] (Item 2) [Figure 20-40-53] from the centering
from the linkage end of the valve. spring, as it is under spring pressure.

(CONT'D)
Lift Spool And Detent Removal And Installation 1

(Cont'd)
Figure 20-40-54
N-19009
Remove spring tool (Item 1) [Figure 20-40-56] from the

1 spring assembly.
2
N-18916 Figure 20-40-57
Put a rag around the detent assembly [Figure 20-40-54]. 1

2
This will prevent the detent balls and spring from being
lost when the detent adapter is removed. 3
Remove the detent adapter with an Alan wrench.

4
Remove the back-up washer (Item 1) and spool seal
(Item 2) [Figure 20-40-54].
Figure 20-40-55
1
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-57].
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-55]

from the spring assembly.

(CONT'D)

(Cont'd)
2
Figure 20-40-58
1
N-18961
Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-40-60].
N-18918 NOTE: Check the O-ring for damage. The lift spool
will have an internal leak if there is damage to
Remove the stud from the end of the spool [Figure 20- this O-ring. Always replace the O-ring and

40-58]. recheck the lift spool before the control valve
is replaced.
Figure 20-40-59
Figure 20-40-61
N-18920
N-18963
Removal of the plastic plug:
Make a center point in the plug using a 1,6 mm (1/16 in) Install the plastic plug and O-ring in the spool [Figure 20-
drill. 40-61].
Drill a hole all the way through the plug using a 2,8 mm
(7/64 in) tap drill
Turn a 6-32 tap (Item 1) [Figure 20-40-59] into the plug.

Pull the tap and plug out of the spool. Be careful, do not
break the tap.
Clean all the debris from inside the spool bore.

NOTE: DO NOT USE Loctite® ON THE STUD
THREADS.

(CONT'D)

(Cont'd)
2
Figure 20-40-62
O-ring
1 3
2
N-18958
Plastic
Plug
15,2 mm Apply grease on all the detent component surfaces
(0.60 inch)
before assembly [Figure 20-40-64].
B-14712 Install the spring (Item 1) [Figure 20-40-64] and detent

balls (Item 2) [Figure 20-40-64] into the adapter (Item 3)
[Figure 20-40-64] and compress with the detent pliers
Install the stud and tighten until the other end of the stud

(Item 1) [Figure 20-40-65].
is out about 15,2 mm (0.600 in) from the spool [Figure
20-40-62]. Figure 20-40-65
Figure 20-40-63
N-18968
N-18967
Install the detent adapter to the collar [Figure 20-40-65].
Clamp the collar (Item 1) [Figure 20-40-63] in a vice. NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.

(CONT'D)

(Cont'd)
Figure 20-40-66
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-40-68].
N-19004 Remove the spring tool.
Check the alignment of the detent adapter and the


washer.
washer, spring, collar and detent adapter.
Tighten the adapter to 10,2 - 11,3 N•m (90 - 100 in-lb).
Figure 20-40-67
NOTE: The adapter must fit in the center of the
washer (Item 1) [Figure 20-40-68].
Figure 20-40-69
2
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-40-67].
CD-15051
Install the detent balls and spring [Figure 20-40-69].

(CONT'D)

(Cont'd)
Figure 20-40-70
2
P-51515
Install the lift spool assembly in the spool bore [Figure

20-40-72].
N-19007 Install the detent bonnet (Item 1) [Figure 20-40-72].
Install the mounting screws (Item 2) [Figure 20-40-72].

Hold the detent balls in place with the detent pliers

[Figure 20-40-70]. Installation: Lubricate the screws and tighten to 10,2 -
11,3 N•m (90 - 100 in-lb) torque.
Figure 20-40-71
Figure 20-40-73
1
N-19008
P-51514
Install the detent sleeve (Item 1) [Figure 20-40-71] to the

detent adapter. Install the washer (Item 1) and snap ring (Item 2) [Figure
20-40-73].

(CONT'D)

(Cont'd)
Figure 20-40-74
1
1
P-51512
Install the O-ring (Item 1) and bushing (Item 2) [Figure

20-40-76] on the lift spool.
P-90321 Figure 20-40-77
Install the end cap (Item 1) [Figure 20-40-74].

Figure 20-40-75
P-51511A
Install the O-ring (Item 1) [Figure 20-40-77] on the

control valve.
P-51520
Install the spool seal (Item 1) [Figure 20-40-75] on the

linkage end of the valve.

(CONT'D)

(Cont'd)
Figure 20-40-78
2
1
P-51697
3
Use an ohmmeter to measure the lock solenoid coils
resistance.
4
P-51701 The correct resistance for the coil is 16.02 - 19.58 ohm.
Installation: Install the lift spool (Item 1) and tilt spool

Install the end cap / spool lock block (Item 1) and the

(Item 2) lock solenoids and tighten to 52 - 61 N•m (38 -
mount bolt (Item 2) [Figure 20-40-78]. 45 ft-lb) torque [Figure 20-40-80].
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-78].

100 in-lb) torque.
Figure 20-40-79
P-90320
Connect the tubeline (Item 1) [Figure 20-40-79].

(CONT'D)
Tilt Spool Removal And Installation
Remove the lift and tilt end cap/spool lock block. (See
End Cap Block Removal And Installation on Page 20-40- 2
14.)
Figure 20-40-81
P-90323
Remove the spool centering block (Item 1) [Figure 20-

1 2
40-83] from the control valve.
Installation: Replace the O-ring (Item 2) [Figure 20-40-

83] and lubricate the O-ring lightly with grease or oil
before installation of the end cap / spool lock block.

P-51521
Figure 20-40-84

20-40-81] from the tilt spool.
Figure 20-40-82
P-51544
2 1 Remove the tilt spool, centering spring, back-up washer

and spool seal [Figure 20-40-84].
P-90321
Assembly: Always use a new spool seal.

from the spool centering block.
Remove the three screws (Item 2) [Figure 20-40-82]

Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100

in-lb) torque.

(CONT'D)
Tilt Spool Removal And Installation (Cont'd)

2 1
Figure 20-40-85
3
4
1
N-18944A
N-18942
Figure 20-40-88
Put the linkage end of the spool in the vice [Figure 20-
40-85]. 2

1
Install the spool tool (Item 1) [Figure 20-40-85] over the
centering spring.
Figure 20-40-86
1
1
P-51545 N-18943
Remove the spool seal(s) (Item 1) and the back-up

N-19014
Remove the bolt (Item 1) [Figure 20-40-86] holding the

centering spring to the spool.

in-lb) torque.
Remove spring tool from the spring assembly.

(CONT'D)
Auxiliary Spool Removal And Installation
Figure 20-40-89
1
1
2 3 2
P-51547
2 1 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-91] from the auxiliary spool.
P-90321
Figure 20-40-92
Remove the two tubelines (Item 1) [Figure 20-40-89]



2
in-lb) torque.
1
Figure 20-40-90
P-51549A
Remove the spring (Item 1) and center spring retainer

(Item 2) [Figure 20-40-92] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure

2 20-40-92] must be replaced, replace the
1 retainer on the opposite end also.
P-51546A


20-40-90] must be replaced, replace the
retainer on the opposite end also.

(CONT'D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-93
1
2
P-51550


Figure 20-40-94
P-51551
Remove the spool (Item 1) [Figure 20-40-94].

(CONT'D)
Auxiliary Solenoid Removal And Installation
Figure 20-40-95
1
2
P-85528
Remove the screws (Item 1) [Figure 20-40-95] from both

solenoids.

Remove the solenoids (Item 2) [Figure 20-40-95] from
the control valve.
Installation: Tighten the nut to 2,44 - 2,98 N•m (21.6 -

26.4 in-lb) torque.
Figure 20-40-96
P-85556
Check and remove the O-rings (Item 1) [Figure 20-40-

96] from the solenoid stem.
Use an ohmmeter to measure the solenoid coil

resistance.
The correct resistance for the coil is 4.1 - 6.1 ohm.

(CONT'D)
Solenoid Removal And Installation
Figure 20-40-97 1
1
2
P-85528
Remove the solenoid stem (Item 1) [Figure 20-40-99].
P-90310 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-40-97] from the Figure 20-40-100
solenoid stem.

Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-40-97]. 3

2
Figure 20-40-98
N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-100] from the stem.
Clean all parts in solvent and dry with compressed air.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-40-98] from
both ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-40-100] may be
cleaned with solvent. If it is torn or worn,
Use an ohmmeter to measure the solenoid coil replace the solenoid valve
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.5 - 10.08 ohm. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-40-98] and

[Figure 20-40-100] and new back-up rings (Item 2)
[Figure 20-40-100] on the solenoid stem.

(CONT'D)
Lock Valve Removal And Installation
Figure 20-40-101 1
1
1
1
2
2
1
2
2 P-51564

[Figure 20-40-103] from the lift lock valve, and replace
P-90310 with new.
Figure 20-40-104
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-101] is for the lift

circuit.
Figure 20-40-102
P-51705
Locate the tilt circuit lock valve (Item 1) [Figure 20-40-

104].
P-90321
Remove the lift lock valve (Item 1) [Figure 20-40-102]

from the back of the control valve.
Installation: Lightly lubricate the lock valve O-rings and


(CONT'D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-105 1
1
1
2
1
2
2
1 2
P-51564

[Figure 20-40-107] from the tilt lock valve, and replace
P-90325 with new.
Remove the lift spool lock solenoid (Item 1) [Figure 20-

40-105].

Remove the tilt spool lock solenoid (Item 2) [Figure 20-
40-105].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 52 - 61 N•m (38 - 45 ft-lb) torque.
Figure 20-40-106
P-90324
Remove the tilt lock valve (Item 1) [Figure 20-40-106]

from the front of the control valve.


HYDRAULIC CONTROL VALVE (STANDARD) Main Relief Valve Removal And Installation
(CONT'D)
Figure 20-40-110
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-108
1
P-51707
P-90308 Remove the main relief valve (Item 1) [Figure 20-40-

110].
Remove the fitting (Item 1) [Figure 20-40-108] from the Figure 20-40-111
valve.

Figure 20-40-109
P-51463
P-51437 Remove the O-rings from the main relief valve (Item 1)
[Figure 20-40-111].
Check the lift arm bypass orifice (Item 1) [Figure 20-40- Installation: Always use new O-rings. Tighten to 52 - 61
109]. N•m (38 - 45 ft-lb) torque.
NOTE: This orifice is not removable from the valve

casting.

(CONT'D)
Check Valve Removal And Installation
Figure 20-40-112
1
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-40-

114] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
P-90308 torque.
Figure 20-40-115
Remove the tubeline (Item 1) [Figure 20-40-112].

Figure 20-40-113
P-90326
P-90310 Inspect the screen (Item 1) [Figure 20-40-115].
Remove the check valve fitting (Item 1) [Figure 20-40-

113] from the hydraulic control valve.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Removal And Installation
Description
Figure 20-41-1
DANGER
P-90328
AVOID DEATH
P-90337
The hydraulic control valve is located inside the main support. Replace if damaged.
frame on the right hand side, below the operator’s cab. D-1009-0409

The hydraulic control valve is the hydraulic component
that uses spools to direct the flow of hydraulic fluid to the
lift, tilt and auxiliary functions.
WARNING
The lift and tilt functions in the hydraulic control valve are
operated using electronic control handles / levers that Never work on a machine with the lift arms up unless
send an electronic signal to the electronic actuators to the lift arms are secured by an approved lift arm
move the lift and tilt spools in the control valve. support device. Failure to use an approved lift arm
The auxiliary function is operated by pilot pressure. to fall and cause injury or death.
There is one solenoid located by each side of the spool. W-2059-0598
Only one solenoid at a time is activated by the switch on
the right side control handles / levers. The activated
solenoid sends pilot pressure oil to one side of the spool
and forces the spool to shift.
The hydraulic control valve also contains a main relief IMPORTANT

valve which is adjustable.
damage the system.
I-2003-0888

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-41-3
(CONT’D)
Raise the lift arms and install an approved lift arm

support device. (See LIFT ARM SUPPORT DEVICE on 1
Page 10-20-1.)
Drain the hydraulic reservoir. (See Removing And

Replacing Hydraulic Fluid on Page 10-120-2.)
Remove the control panel. (See Removal And Installation

on Page 50-100-2.)
P-90267
NOTE: Mark all tubelines, hoses, and electrical

connections for correct installation. The fixed end main valve hose assembly is connected to
a fixed end fitting on the control valve. The hose is routed
NOTE: Cap and plug all hydraulic connection points to the junction block at the rear of the loader where it
when tubelines or hoses are removed. feeds the base end of both lift cylinders. The hose can
only be removed by first removing it from the fitting (Item
Clean area around control valve. 1) [Figure 20-41-3].

Open rear door.
Figure 20-41-2
2
P-90187
Remove the two bolts (Item 1), move the hose clamp
(Item 2) to the middle of the hose, and the place the fuel

(CONT’D)
Figure 20-41-4
1
3
2
P-90271
1 Disconnect the hose (Item 1) [Figure 20-41-6] that

routes from the top of the control valve to the hydraulic
P-90269 filter.
Figure 20-41-7

routes from the control valve to the drain manifold.
2 2
routes from the control valve to the inlet fitting of the 1
hydraulic pump.
Figure 20-41-5
P-90272
2
1

that route from the control valve to the front auxiliary
hydraulics.
P-90270

routes from the control valve to the brake valve.

routes from the control valve to the fan motor.

(CONT’D)

1
Figure 20-41-8
P-90275
1
routes from the control valve to the junction block at the
P-90273 rear of the machine.
Disconnect the lift arm bypass drain hose (Item 2)

Remove the tubeline clamp (Item 1) [Figure 20-41-8]. [Figure 20-41-10] from the control valve.

Figure 20-41-9 Figure 20-41-11
1 1
1
1
P-90274
P-90276
Disconnect the three tubelines (Item 1) [Figure 20-41-9] Disconnect the hose (Item 1) [Figure 20-41-11] that
that route from the control valve to the junction block at routes from the bottom of the control valve to the outlet
the rear of the loader. fitting of the hydraulic pump.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Actuator Removal And Installation (In Loader)
(CONT’D)
Figure 20-41-12
WARNING
W-2059-0598
1
device. (See Installing on Page 10-20-1.)
Mark the actuator wiring harness connectors for proper

P-90278 installation.
Figure 20-41-13
Support the control valve and remove the two bolts and
nuts (Item 1) [Figure 20-41-12].

Remove the control valve from the loader.
P-90330
Unplug the actuator connectors (Item 1) [Figure 20-41-

13] from the loader harness.

(CONT’D)
Actuator Removal And Installation (In Loader)

(Cont’d)
Figure 20-41-14
1
2
1
P-54568
Inspect the O-ring (Item 1) [Figure 20-41-16] on the face

of the actuator, and replace as needed.
P-54587 Check the linkage pin (Item 2) [Figure 20-41-16] and

replace as needed.
Remove the two screws (Item 1) [Figure 20-41-14] from

the actuator retainer.
Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -

100 in-lb) torque.
Figure 20-41-15
P-54566
Pull the actuator (Item 1) [Figure 20-41-15] away from

the control valve.
Use a punch to remove the actuator pin (Item 2) [Figure

20-41-15] from the actuator and spool.
Remove the actuator from the hydraulic control valve.
NOTE: The calibration procedure must be followed

when replacing a lift or tilt actuator. (See Lift
And Tilt Calibration (SJC) on Page 60-160-4.)

(CONT’D)
Actuator Removal And Installation (Out Of Loader)
Remove the control valve from the loader.
Figure 20-41-17
P-54339
Using a punch and a hammer, remove the actuator

1 linkage pin (Item 1) [Figure 20-41-19] from the actuator
and the tilt spool.
P-54337 Remove the actuator and linkage pin from the valve.

Figure 20-41-20
Remove the two mount bolts (Item 1) [Figure 20-41-17]
from the tilt actuator.
Installation: Tighten the mounting bolts to 10,2 - 11,3

N•m (90 - 100 in-lb) torque.
Figure 20-41-18
P-54340
1 Inspect the O-ring (Item 1) [Figure 20-41-20] on the face

of the actuator, and replace as needed.
Check the linkage pin (Item 2) [Figure 20-41-20] and

P-54338 replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-41-

18] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-18].

(CONT’D)
Actuator Removal And Installation (Out of Loader)

(Cont’d)
Figure 20-41-21
1 1
P-54343
Using a punch and a hammer, remove the actuator

linkage pin (Item 1) [Figure 20-41-23] from the actuator
1 and the tilt spool.
P-54341
Remove the actuator and linkage pin from the valve.
Remove the two mount bolts (Item 1) [Figure 20-41-21]

Figure 20-41-24
from the lift actuator.

Figure 20-41-22
P-54340
Inspect the O-ring (Item 1) [Figure 20-41-24] on the face

1 of the actuator, and replace as needed.
P-54342 Check the linkage pin (Item 2) [Figure 20-41-24] and

replace as needed.
Slide the actuator mount bracket (Item 1) [Figure 20-41-

22] away from the control valve.
Pull the actuator away from the control valve [Figure 20-
41-22].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)
Actuator Removal And Installation (Out Of Loader)

(Cont’d)
Figure 20-41-25
4 3
1
3
P-90329
NOTE: The two longer bolts (Item 1) are used to

mount the lift actuator and end cap (Item 2)
[Figure 20-41-25] to the control valve.
The two shorter mount bolts (Item 3) are used
to mount the tilt actuator to the end cap (Item
4) [Figure 20-41-25].

N•m (90 - 100 in-lb) torque (Item 1) [Figure 20-41-25]

(CONT’D)
Figure 20-41-26
C2 C3
J4 J2
B3 E3
E3
F2
G1 G2
D5
A3 D3
B2
A2
D4 F4 E2
C4
D1
D2
A1
H3
F3 E1
H2 B1

F1 MR J3
H1 J1 C1
P-90307
ITEM S650 LOADER ITEM S650 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Detent
A2 Tilt Cylinder Base End E2 Tilt Spool Centering Spring
A3 Auxiliary Hydraulic Rod End E3 Auxiliary Spool/Centering Springs
B1 Lift Cylinder Rod End F1 Lift Spool
B2 Tilt Cylinder Rod End F2 Tilt Spool
B3 Auxiliary Hydraulics Base End F3 Lift Spool Lock Solenoid
C1 Load Check F4 Tilt Spool Lock Solenoid
C2 Load Check Valve Tilt Function G1 Auxiliary Solenoid Stem
C3 Load Check Valve Auxiliary Function G2 Auxiliary Solenoid Stem
C4 Check Valve H1 BICS Solenoid
D1 Anti-Cavitation Valve H2 BICS Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve – 27,6 MPa H3 BICS Lock Valve (Lift)
(275,8 bar) (4000 psi) J1 Inlet Fluid Flow (From Pump)
Lift (Base End) J2 Outlet Fluid Flow (Return to Tank)
D3 Port Relief/Anti-Cavitation Valve – 27,6 MPa J3 Lift Arm Bypass Orifice
(275,8 bar) (4000 psi)
J4 Drain (Case)
Tilt (Base End)
MR Main Relief Valve – 24,1 MPa (241,3 bar)
D4 Port Relief/Anti-Cavitation Valve – 27,6 MPa
(3500 psi)
(275,8 bar) (4000 psi)
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
27,6 MPa (275,8 bar) (4000 psi) (Optional)

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
(CONT’D)
Figure 20-41-29
Mount Bracket Removal And Installation
Figure 20-41-27
P-90308
P-90280 Remove the charge tubeline (Item 1) [Figure 20-41-29]

from the BICS valve fitting on the top of the lift load check
valve.
Support the mounting bracket (Item 1) [Figure 20-41-27].

Figure 20-41-30
Figure 20-41-28
P-90310
P-90279
Remove the lift load check valve (Item 1) [Figure 20-41-

Remove the two control valve mount bolts (Item 1) 30] and fitting from the top of the control valve.
[Figure 20-41-28].
Installation: Lubricate the O-ring and threads and
Remove the two frame bolts (Item 2) [Figure 20-41-28] tighten to 75 - 88 N•m (55 - 65 ft-lb) torque.
Installation: Torque the two frame bolts (Item 2) [Figure

20-41-28] to 406 - 447 N•m (300 - 330 ft lb).
Remove the control valve bracket from the loader.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt &
(CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-41-32

(Cont’d)
Figure 20-41-31
2
P-90311
3
P-90309 At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-41-32].
Remove and install new O-rings (Item 1) and back-up

At the front side of the control valve locate the auxiliary
ring (Item 2) [Figure 20-41-31]. section load check valve (Item 2) [Figure 20-41-32].
Check the free movement load check valve and spring NOTE: The tilt and auxiliary load check valves are
(Item 3) [Figure 20-41-31]. interchangeable.
Figure 20-41-33
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
parts clean. Always use caps and plugs on hoses, 2
damage the system. 3
I-2003-0888 4
P-90312
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-41-33].


torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Lift, Base End)
Anti-Cavitation Valve Removal And Installation (Lift, Figure 20-41-36

Rod End)
Figure 20-41-34
P-90314
P-90314 Loosen the lift circuit port relief / anti cavitation valve
(Item 1) [Figure 20-41-36].
At the back side of the control valve, remove the lift

Figure 20-41-37
section anti-cavitation valve (Item 1) [Figure 20-41-34].
Figure 20-41-35
3 1
4
P-90315

installation.
Remove the spring (Item 1) and poppet (Item 2) [Figure Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
20-41-35].


torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Tilt, Rod End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-41-40

Installation (Tilt, Base End)
Figure 20-41-38
P-90314
P-90314 Remove the tilt port relief / anti cavitation valve (Item 1)
[Figure 20-41-40] from the rod end of the tilt section.
Remove the tilt port relief / anti cavitation valve (Item 1)

Figure 20-41-41
[Figure 20-41-38] from the base end of the tilt section.
Figure 20-41-39
1
1
P-90319

installation.
Replace the O-ring (Item 1) [Figure 20-41-39] before Installation: Tighten to 52 - 61 N•m (38 - 45 ft-lb) torque.
installation.

(CONT’D)
Port Relief Valve Removal And Installation 1
Figure 20-41-42
P-90318A
The control valve may be equipped with an optional

auxiliary port relief valve (Item 1) [Figure 20-41-44].
P-90314
Remove the auxiliary port relief valve.
Remove the port relief plug (Item 1) [Figure 20-41-42] Figure 20-41-45
from the auxiliary circuit of the control valve.

Figure 20-41-43
P-51640
P-90318 Installation: Always use new O-rings (Item 1) [Figure



(CONT’D)
Plug Removal And Installation
Figure 20-41-46
1
P-51461
At the bottom side of the control valve remove the plug

(Item 1) [Figure 20-41-48].
P-68016
Figure 20-41-49
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-46].

Figure 20-41-47
P-51462

1 20-41-49]. Tighten to 81,3 N•m (60 ft-lb) torque.
P-51460A

20-41-47]. Tighten to 81,3 N•m (60 ft-lb) torque.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Spool Removal And Installation
(CONT’D)
End Cap Block Removal And Installation procedure:
Remove the lift and tilt actuators from the control valve. MEL 1285 - Spring Tool
(See Actuator Removal And Installation (In Loader) on
Page 20-41-5.) Remove the end cap block from the control valve.
Figure 20-41-50 Figure 20-41-52
1 2

P-90338
P-68042
Disconnect the tube line (Item 1) [Figure 20-41-50] from Remove the O-ring (Item 1) [Figure 20-41-52].
the end cap block.
Installation: Replace the O-ring, and lubricate lightly
Remove the two end cap block mount screws (Item 2) with oil before installation of the end cap block.
[Figure 20-41-50].
Figure 20-41-53
100 in-lb) torque.
Figure 20-41-51
P-68047
1
P-90339 20-41-53] from the lift spool.
Remove the end cap block (Item 1) [Figure 20-41-51]

from the control valve.

(CONT’D)
Lift Spool Removal And Installation (Cont'd)
Figure 20-41-54
1
1
P-68045
1
Remove the lift spool assembly and seal (Item 1) [Figure

P-68043
Figure 20-41-57

the lift spool end cap.

11,3 N•m (90 - 100 in-lb) torque.
Figure 20-41-55
P-68046
1 Remove the lift spool seal (Item 1) [Figure 20-41-57]

from the linkage end of the valve.
P-68044
Remove the lift spool end cap (Item 1) [Figure 20-41-55]

from the control valve.

(CONT’D)

1
Figure 20-41-58
N-190146

P-51772
in-lb) torque.
Clamp the linkage end of the spool in a vise [Figure 20-
41-58].

Remove spring tool from the spring assembly.
NOTE: Protect spool before clamping in vise. Figure 20-41-61
Figure 20-41-59
3
4 1
1
P-51776
P-51773
centering spring.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) NOTE: Check the O-ring for damage. The lift spool
(CONT’D) will have an internal leak if there is damage to
this O-ring. Always replace the O-ring and
Lift Spool Removal And Installation (Cont'd) recheck the lift spool before the control valve
is replaced.
Figure 20-41-62
Figure 20-41-64
N-18920
P-74184
Removal of the plastic plug:
Make a center point in the plug using a 1,6 mm (1/16 in)

Install the plastic plug and O-ring in the spool [Figure 20-
drill. 41-64].
Drill a hole all the way through the plug using a 2,8 mm Figure 20-41-65
(7/64 in) tap drill.
Turn a 6-32 tap (Item 1) [Figure 20-41-62] into the plug.

Pull the tap and plug out of the spool. Be careful, do not 2
1
break the tap.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE Loctite® ON THE STUD

THREADS.
1
Figure 20-41-63
P-68046 P-51775
2
1 Remove the spool seal(s) (Item 1) and the back-up

P-74183
Install the O-ring (Item 1) over the nipple on the plastic


(CONT’D)
Figure 20-41-66
1 1
2
2
P-68047
3
3
Install the O-ring (Item 1) and bushing (Item 2) [Figure
20-41-68] on the lift spool.
P-68044
Figure 20-41-69
Install the lift spool assembly (Item 1) [Figure 20-41-66]

in the spool bore.

1
Install the end cap (Item 2) [Figure 20-41-66].
Install the mounting screws (Item 3) [Figure 20-41-66].

11,3 N•m (90 - 100 in-lb) torque.
Figure 20-41-67
P-68042
Install the O-ring (Item 1) [Figure 20-41-69] on the

1
control valve.
Installation: Replace the O-ring, lubricate lightly with oil

or grease before installation of the end cap block.
P-68048
Install the spool seal (Item 1) [Figure 20-41-67] on the

linkage end of the valve.

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Tilt Spool Removal And Installation
(CONT’D)
Remove the end cap block. (See End Cap Block
Lift Spool Removal And Installation (Cont'd) Removal And Installation on Page 20-41-17.)
Figure 20-41-70 Figure 20-41-71
2
2
1
P-68040
P-68049
Install the end cap block (Item 1) and the two mount bolts Remove the spacer (Item 1) and O-ring (Item 2) [Figure
(Item 2) [Figure 20-41-70].

20-41-71] from the tilt spool.
Installation: Tighten the screws to 10,2 - 11,3 N•m (90 - Figure 20-41-72
100 in-lb) torque.
Connect the tubeline (Item 3) [Figure 20-41-70] to the

end cap block.
1
Install the lift and tilt actuators to the control valve.
P-90321
Disconnect the two tubelines (Item 1) [Figure 20-41-72].


in-lb) torque.

(CONT’D)
Figure 20-41-73 1
N-18942
1
Put the linkage end of the spool in the vice [Figure 20-
41-75].
P-90342
centering spring.

Figure 20-41-76

73] and lubricate lightly with oil / grease before
installation of the end cap block.
1
Figure 20-41-74
1
N-19014

P-68052 Installation: Tighten the bolt to 10,2 - 11,3 N•m (90 - 100
in-lb) torque.
Remove the tilt spool, centering spring, back-up washer Remove spring tool from the spring assembly.
and spool seal (Item 1) [Figure 20-41-74].

HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Auxiliary Spool Removal And Installation
(CONT’D)
Figure 20-41-79
Figure 20-41-77
2 1
3
2
4
1
P-90321
N-18944A Disconnect the two tubelines (Item 1) [Figure 20-41-79]

Inspect the adapter (Item 1), collar (Item 2), spring (Item Remove the three screws (Item 2) [Figure 20-41-79]

Figure 20-41-78 Installation: Tighten the bolts to 10,2 - 11,3 N•m (90 -
100 in-lb) torque.
2
1 Remove the spool centering block from the control valve.
Figure 20-41-80
2
P-51545 N-18943
Remove the spool seal(s) (Item 1) and the back-up 1

P-68053



(CONT’D)
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-41-81
2
2
P-68077
1
P-68054
Figure 20-41-84


Figure 20-41-82
2
1 P-68078
Remove the auxiliary spool (Item 1) [Figure 20-41-84].
P-68076



(CONT’D)
Auxiliary Solenoid Removal And Installation
Figure 20-41-85
1
2
P-90337
Remove the screws (Item 1) [Figure 20-41-85] from both

solenoids.

Remove the solenoids (Item 2) [Figure 20-41-85].
Installation: Tighten the screws to 2,44 - 2,98 N•m (21.6

- 26.4 in-lb) torque.
Figure 20-41-86
P-85556
Check and remove the O-rings (Item 1) [Figure 20-41-

86] from the solenoid stem.
Use an ohmmeter to measure the solenoid coil

resistance.
The correct resistance for the coil is 4.1 - 6.1 ohm.

(CONT’D)
Figure 20-41-87 1
P-90346
P-90337 Installation: Lubricate the O-rings and tighten the stem

to 27 - 33 N•m (20 - 24 ft-lb) torque.
Remove the nut (Item 1) [Figure 20-41-87] from the Figure 20-41-90
solenoid stem.

Installation: Tighten the nut to 6 N•m (53 in-lb) torque.
Remove the solenoid coil (Item 2) [Figure 20-41-87]. 3

2
Figure 20-41-88
N-18694

[Figure 20-41-90] from the stem.
Clean all parts in solvent and dry with compressed air.

N-18693A
Inspect all parts for wear and replace any showing
excessive wear.
Remove the O-rings (Item 1) [Figure 20-41-88] from
both ends of the solenoid coil. NOTE: The screen (Item 3) [Figure 20-41-90] may be
cleaned with solvent. If it is torn or worn the
Use an ohmmeter to measure the solenoid coil solenoid needs to be replaced.
resistance.
Use only new O-rings and apply oil to all O-rings and
The correct resistance for the coil is 9.5 - 10.08 ohm. back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-41-88] and

[Figure 20-41-90] and new back-up rings (Item 2)
[Figure 20-41-90] on the solenoid stem.

(CONT’D)
Lock Valve Removal And Installation
Figure 20-41-91
1
2 P-51792
Remove the tilt lock valve (Item 1) [Figure 20-41-93]

P-90310
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-41-91] is for the lift circuit.

Figure 20-41-94
Figure 20-41-92
1
1
1
1
1
2
2
2
P-51564
P-90321
[Figure 20-41-94] from the valve, and replace with new.
Remove the lift lock valve (Item 1) [Figure 20-41-92]


HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Main Relief Valve Removal And Installation
(CONT’D)
Figure 20-41-97
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-95
1
P-51794
P-90308 Remove the main relief valve (Item 1) [Figure 20-41-97].
Figure 20-41-98
Remove the fitting (Item 1) [Figure 20-41-95] from the
valve.

Figure 20-41-96
1
1
P-90344
Remove the O-rings from the main relief valve (Item 1)

P-51437 [Figure 20-41-98].
Installation: Always use new O-rings. Tighten to 52 - 61

Check the lift arm bypass orifice (Item 1) [Figure 20-41- N•m (38 - 45 ft-lb) torque.
96].
NOTE: This orifice is not removable from the valve

casting.

(CONT’D)
Check Valve Removal And Installation
Figure 20-41-99
1
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-41-

101] and tighten the fitting to 27 - 33 N•m (20 - 24 ft-lb)
P-90308 torque.
Figure 20-41-102
Remove the tubeline (Item 1) [Figure 20-41-99].

Figure 20-41-100
P-90326
P-90310 Inspect the screen (Item 1) [Figure 20-41-102].
Remove the check valve fitting (Item 1) [Figure 20-41-

100] from the hydraulic control valve.

LIFT ARM BYPASS CONTROL VALVE
Description
The lift arm bypass control valve is located on the right

side of the machine.
The lift arm bypass control valve is manually operated by

pulling on the valve (Item 1) [Figure 20-50-1] and turning
the knob 90° clockwise. The valve releases the hydraulic
fluid from the base end of the lift cylinder(s) which allows
the lift arm to slowly come down to the transport position.
Testing
Figure 20-50-1

P-85290B P-85290A
Raise the lift arms 2 m (6 ft) off the ground. Stop the
engine. Turn the Lift Arm Bypass Control Knob (Item 1)
[Figure 20-50-1] 90° clockwise. Then pull up and hold
the Lift Arm Bypass Control Knob until the lift arms slowly
lower.
The knob should return to its normal position.

LIFT ARM BYPASS CONTROL VALVE (CONT’D) Figure 20-50-2
1
3
DANGER
2
P-85670
P-90328
AVOID DEATH Hold the lift arm bypass control knob (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 50-2] and loosen the jam nut on the lift arm bypass valve
tubeline, hose, fitting, component or a part failure shaft.
• Keep out of this area when lift arms are raised Remove the lift arm bypass control knob (Item 1).
unless supported by an approved lift arm Remove the jam nut (Item 2) from the valve shaft [Figure

20-50-2].
D-1009-0409
Remove the rubber washer (Item 3) [Figure 20-50-2].
Figure 20-50-3
WARNING 2
W-2059-0598
Lower the lift arms.

1
P-85671
Disconnect and cap the hydraulic tubeline and hose

(Item 1) [Figure 20-50-3].
Remove the two mounting bolts and nuts (Item 2)

[Figure 20-50-3].
Installation: Tighten the mounting bolts to 21 - 23 N•m

(180 - 200 in-lb) torque.
Remove the lift arm bypass valve.

LIFT ARM BYPASS CONTROL VALVE (CONT'D) Disassembly And Assembly
Bracket Removal And Installation Figure 20-50-5
Figure 20-50-4
1 2
P-85673
P-85672
Remove the lift arm bypass valve (Item 1) [Figure 20-50-
5] from the valve block. Inspect the bypass valve for
Remove the two bolts (Item 1) [Figure 20-50-4] to damage and replace if necessary.
replace the bypass valve mounting bracket if necessary.

Installation: Tighten the valve to 45 - 50 N•m (33 - 37 ft-
Reverse the removal procedure to install the lift arm lb) torque.
bypass valve in the loader.
Inspect the hydraulic fittings (Item 2) [Figure 20-50-5] on
the valve block for damage and replace if necessary.


HYDRAULIC PUMP Start the engine and run at low idle RPM. Press the
Auxiliary hydraulics button. Engage the front auxiliary
Description with the trigger on the right handle or joystick. Make sure
the tester is connected correctly. If no flow is indicated on
The hydraulic pump is attached to the end of the the tester, the hoses are connected wrong. With the
hydrostatic pumps and is located on the right side of the hoses connected correctly, increase the engine speed to
loader between the hydraulic control valve and the full RPM*.
engine.
Warm the fluid to 60°C (140°F) by turning the restrictor
The hydraulic pump is a combination of gear pumps that control clockwise on the tester so it reads about 6,9 MPa
provide hydraulic flow to several hydraulic systems. (69 bar) (1000 psi).
The hydraulic pump has a dedicated charge pump. This NOTE: DO NOT EXCEED 25,5 MPa (255 bar) (3700
supplies flow to the hydraulic fan motor and charge psi).
pressure to the hydrostatic pump.
Turn the restrictor control (Item 2) [Figure 20-60-1] on
A seal kit is available to service the hydraulic pump. If any the tester counterclockwise to obtain free flow, the flow
of the main components of the pump are damaged, the should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.
entire pump must be replaced. gpm). Start turning the restrictor clockwise, causing more
restriction on the flow. The gpm should drop off slightly
Pump Test At Quick Couplers until the pressure reaches approximately 21,4 MPa
(213,7 bar) (3100 psi). At approximately 21,4 MPa (213,7
The tools listed will be needed to do the following bar) (3100 psi) the flow should start decreasing rapidly
procedure: until the pressure reaches 23,8 - 24,1 MPa (237,9 - 241,3

bar) (3450 - 3500 psi). At 23,8 - 24,1 MPa (237,9 - 241,3
TWX-RFIK200-S-6 54 U.S. gpm Flow Meter bar) (3450 - 3500 psi) the flow should be at zero U.S.
MEL10006 - Fitting Kit gpm. Turn the restrictor (Item 2) [Figure 20-60-1]
counterclockwise to free flow. Shut the auxiliary
Figure 20-60-1 hydraulics off.
1 If flow and pressure specifications are not obtained, go to

Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-60-2.)
*Refer to (See Hydraulic System on Page SPEC-10-3.)

for system relief pressure and full RPM.
2 P-90171
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,1 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 189,3 L/min (50 U.S. gpm).
Install a hydraulic tester (Item 1) [Figure 20-60-1] onto

the front auxiliary quick couplers.
This procedure will require one operator in the cab and

one operator running the tester.

HYDRAULIC PUMP (CONT'D) Figure 20-60-2
Direct Pump Test (Standard Section)

procedure:
MEL1563 or 7003031 - Remote Start Tool 2

TWX-RFIK200-S-6 54 U.S. gpm Flow Meter
MEL10006 - Fitting Kit
1
1
WARNING 2
P-90178 P-90176
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-60-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)

WARNING
1 2
P-90580
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-60-3] from
the tester to the OUTLET hose (Item 1) [Figure 20-60-2]
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT-MEL1563 on Page 10-60-1.) or (See 20-60-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-60-2] on the control valve.
7003031 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.
IMPORTANT
I-2024-0284

HYDRAULIC PUMP (CONT'D)
Direct Pump Test (Standard Section) (Cont'd)
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
RPM*.

control on the tester to about 6,9 MPa (69 bar) (1000 psi).
DO NOT exceed system relief pressure. Open the
restrictor control and record the free flow (U.S. gpm) at
full rpm*.
On the remote start tool engage the auxiliary hydraulics,

the light will come ON. Pull the trigger on the right handle
or joystick for fluid flow to the quick coupler (fluid
pressure will go over main relief). Record the highest
pressure (psi) and flow (gpm). The high pressure flow
must be at least 80% of free flow.
%= HIGH PRESSURE FLOW (U.S. gpm) X 100

FREE FLOW (U.S. gpm)
A low percentage may indicate a failed pump.


HYDRAULIC PUMP (CONT'D) Figure 20-60-4
Direct Pump Test (Charge Section)

procedure:
MEL1563 or 7003031 - Remote Start Tool

1
WARNING
P-85897A
Failure to use jackstands can allow the machine to Disconnect the inlet hose (Item 1) [Figure 20-60-4].
W-2017-0286
Figure 20-60-5

1.)

WARNING 1 2

P-90580
W-2059-0598 Connect the INLET hose (Item 1) [Figure 20-60-5] from
NOTE: The fluid from the charge pump must be of the pump. Connect the OUTLET hose (Item 2) [Figure
filtered after it passes through the Hydraulic 20-60-5] from the tester to the inlet fitting on the fan (Item
Tester, to prevent any contamination to the 1) [Figure 20-60-4].
Hydrostatic Pumps.
Connect the remote start tool. (See REMOTE START

TOOL KIT-MEL1563 on Page 10-60-1.) or (See
7003031 on Page 10-61-1.)

Direct Pump Test (Charge Section) (Cont’d)
IMPORTANT
I-2024-0284
tester, the hoses are connected wrong. With the hoses
RPM*.

control on the tester to about 4,1 MPa (41,4 bar) (600
psi). DO NOT exceed 8,3 MPa (82,7 bar) (1200 psi).
Open the restrictor control and record the free flow (U.S.
gpm) at full rpm*.

Turn the restrictor down to system operating pressure
approximately 6,9 MPa (69 bar) (1000 psi). DO NOT
EXCEED 8,3 MPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
HIGH PRESSURE FLOW (U.S. gpm)
%= X 100
*Refer to the Hydraulic Schematics for pump flow and

rpm.

HYDRAULIC PUMP (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)

WARNING
Figure 20-60-6
W-2059-0598 1
1
1
DANGER 1
P-90180
Disconnect and cap the four hoses (Item 1) [Figure 20-

60-6] from the hydraulic pump.
P-90328 Remove the Power Bob-Tach block if equipped. (See

Removal And Installation on Page 20-130-1.)
AVOID DEATH
• Disconnecting or loosening any hydraulic Figure 20-60-7
support. Replace if damaged. 1
D-1009-0409
2
IMPORTANT 1

P-90509
damage the system. Disconnect and cap the outlet hoses (Item 1) [Figure 20-
I-2003-0888 60-7] from the hydraulic pump.
Lift and block the rear of the loader. (See Procedure on Remove the two mounting bolts (Item 2) [Figure 20-60-
Page 10-10-1.) 7] from the hydraulic pump.
Raise the lift arms and install an approved lift arm support Installation: Tighten the mounting bolts to 75 - 85 N•m
device. (See Installing on Page 10-20-1.) (55 - 60 ft-lb) torque.
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the hydraulic pump (Item 3) [Figure 20-60-7]
from the loader.

HYDRAULIC PUMP (CONT'D) Hydraulic Pump Startup
Removal And Installation (Cont’d) NOTE: This procedure is necessary to prevent a dry
startup of the hydraulic pump.
Figure 20-60-8
Fill the system with hydraulic fluid. (See Removing And
Figure 20-60-9
Momentary Switch
P-43940 P-43938A
Replace the O-ring (Item 1) [Figure 20-60-8] on the

hydraulic pump. Starter Bypass Tool
P-59354

Reverse the removal procedure to install the hydraulic
pump. To crank the engine without starting, the machine key
switch can be bypassed. Obtain a starter bypass tool
from a local source which can be used as a universal
connection to remotely crank the engine without starting.
The starter bypass tool consists of two wires, each with a

clamp. The momentary switch, when depressed, will
allow current to pass through the circuit.
Connect the starter bypass tool to the starter solenoid

battery terminal and S terminal. Crank the engine for 15
seconds, then stop for at least 30 seconds. Again, crank
the engine for 15 seconds. Remove the starter bypass
tool.
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.
After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
of cylinder stroke.
With the loader parked on a level surface and lift arms

down, check and fill the hydraulic reservoir as required.
Check for hydraulic leaks.

Figure 20-60-10
18
12
6
11
4
17

2 15
5
5 13 14
6
2
3
7
6
10
2
5
8 9
6
4 5
3
16 2
P-66540

HYDRAULIC PUMP (CONT'D) Disassembly And Assembly
Parts Identification (Cont’d)
The items listed below refer to Page 20-60-8 [Figure 20-

60-10]. IMPORTANT
1. Auxiliary Pump End Section When repairing hydrostatic and hydraulic systems,
2. Section Seal parts clean. Always use caps and plugs on hoses,
3. Pre-Load Seal damage the system.
I-2003-0888
4. Load Seal
Mark the pump sections for correct assembly.
5. Wear Plate
To disassemble and assemble the hydraulic pump, follow
6. Alignment Pins the Parts Identification page (See Parts Identification on
Page 20-60-8.) for proper placement of components
7. Drive Gear (Auxiliary Pump) along with the information below.
8. Idler Gear (Auxiliary Pump) NOTE: A seal kit is available through Bobcat Service
Parts.
9. Auxiliary Pump Center Section

Assembly: Tighten the eight pump housing bolts (Item
10. Auxiliary Pump End Section 19) [Figure 20-60-10] to 50 N•m (37 ft-lb) torque.
11. Spline Shaft NOTE: Position the wear plate (Item 5) [Figure 20-60-
10] inlets and traps as shown with the bronze
12. Drive Gear (Charge Pump) side toward the gears on all wear plates.
13. Idler Gear (Charge Pump) NOTE: Inspect all gears, shafts and pump end
sections. If any of these components have
14. Charge Pump Center Section excessive wear or damage is visible, the
complete pump must be replaced.
15. Charge Pump End Section
16. Shaft Seal
17. Bolts (4)
18. Bolts (4)


HYDRAULIC PUMP (HIGH FLOW) Install a hydraulic tester (Item 1) [Figure 20-61-1] onto
the front auxiliary quick couplers.
Description
This procedure will require one operator in the cab and
The hydraulic gear pump is attached to the end of the one operator running the tester.
hydrostatic pumps and is located on the right side of the
loader between the hydraulic control valve and the Start the engine and run at low idle RPM. Press the
engine. Auxiliary hydraulics button. Engage the front auxiliary
with the trigger on the right handle or joystick. Make sure
The hydraulic gear pump is a combination of gear pumps the tester is connected correctly. If no flow is indicated on
that provide hydraulic flow to several hydraulic systems. the tester, the hoses are connected wrong. With the
hoses connected correctly, increase the engine speed to
The hydraulic gear pump has a dedicated charge pump. full RPM*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 60°C (140°F) by turning the restrictor
control clockwise on the tester so it reads about 6,9 MPa
The high flow hydraulic pump has an additional pump (69 bar) (1000 psi).
section that provides an additional amount of flow that is
controlled by an external valve. The valve is switched NOTE: DO NOT EXCEED 25,5 MPa (255 bar) (3700
from a button on the panel in the cab. psi).
A seal kit is available to service the hydraulic pump. If any Turn the restrictor control (Item 2) [Figure 20-61-1] on
of the main components of the pump are damaged, the the tester counterclockwise to obtain free flow, the flow
entire pump must be replaced. should be approximately 87,1 - 90,8 L/min (23 - 24 U.S.

gpm). Start turning the restrictor clockwise, causing more
Pump Test At Quick Couplers restriction on the flow. The gpm should drop off slightly
until the pressure reaches approximately 21,4 MPa
The tools listed will be needed to do the following (213,7 bar) (3100 psi). At approximately 21,4 MPa (213,7
procedure: bar) (3100 psi) the flow should start decreasing rapidly
until the pressure reaches 23,8 - 24,1 MPa (237,9 - 241,3
TWX-RFIK200-S-6 54 U.S. gpm Flow Meter bar) (3450 - 3500 psi). At 23,8 - 24,1 MPa (237,9 - 241,3
MEL10006 - Fitting Kit bar) (3450 - 3500 psi) the flow should be at zero U.S.
gpm. Turn the restrictor (Item 2) [Figure 20-61-1]
Figure 20-61-1 counterclockwise to free flow. Shut the auxiliary
hydraulics off.
1
If flow and pressure specifications are not obtained, go to
Direct Pump Testing. (See Direct Pump Test (Standard
Section) on Page 20-61-2.)

2 P-90171
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 19,1 mm (0.75 in) in
diameter and connected directly to the
hydraulic tester without using any type of
“quick coupler” on the connection to the
tester. Also make sure your hydraulic tester is
capable of at least 189,3 L/min (50 U.S. gpm).

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Figure 20-61-2
Direct Pump Test (Standard Section)

procedure:
MEL1563 or 7003031 - Remote Start Tool 2

1
1
WARNING 2
P-90178 P-90176
Failure to use jackstands can allow the machine to Disconnect the OUTLET hose (Item 1) [Figure 20-61-2]
fall or move and cause injury or death. that comes from the gear pump, and connects to the
W-2017-0286
control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-61-3
1.)

WARNING 2
1
P-90580
W-2059-0598
Raise the operator cab. (See Raising on Page 10-30-2.) Connect the INLET hose (Item 1) [Figure 20-61-3] from
Connect the remote start tool. (See REMOTE START of the pump. Connect the OUTLET hose (Item 2) [Figure
TOOL KIT-MEL1563 on Page 10-60-1.) or (See 20-61-3] from the tester to the control valve fitting (Item
REMOTE START TOOL (SERVICE TOOL) KIT - 2) [Figure 20-61-2] on the control valve.
7003031 on Page 10-61-1.)
NOTE: The control panel is shown removed for photo

clarity.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Direct Pump Test (Charge Section)
Direct Pump Test (Standard Section) (Cont'd) The tools listed will be needed to do the following
procedure:
tester is connected correctly. If no flow is indicated on the MEL1563 or 7003031 - Remote Start Tool
tester, the hoses are connected wrong. With the hoses TWX-RFIK200-S-6 54 U.S. gpm Flow Meter
connected correctly, increase the engine speed to full MEL10006 - Fitting Kit
RPM*.

DO NOT exceed system relief pressure. Open the
WARNING
restrictor control and record the free flow (U.S. gpm) at
full rpm*. Put jackstands under the front axles and rear corners
On the remote start tool engage the auxiliary hydraulics, Failure to use jackstands can allow the machine to
the light will come ON. Pull the trigger on the right handle fall or move and cause injury or death.
or joystick for fluid flow to the quick coupler (fluid W-2017-0286
pressure will go over main relief). Record the highest
pressure (psi) and flow (gpm). The high pressure flow Lift and block the loader. (See Procedure on Page 10-10-
must be at least 80% of free flow. 1.)
%= HIGH PRESSURE FLOW (U.S. gpm) X 100 Raise the lift arms and install an approved lift arm support

FREE FLOW (U.S. gpm) device. (See Installing on Page 10-20-1.)

WARNING
W-2059-0598
NOTE: The fluid from the charge pump must be

filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the
Hydrostatic Pumps.

7003031 on Page 10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Start the engine and run at low idle RPM. Make sure the
Direct Pump Test (Charge Section) (Cont’d) tester, the hoses are connected wrong. With the hoses
Figure 20-61-4 RPM*.

control on the tester to about 4,1 MPa (41,4 bar) (600
psi). DO NOT exceed 8,3 MPa (82,7 bar) (1200 psi).
gpm) at full rpm*.
Turn the restrictor down to system operating pressure

1 approximately 6,9 MPa (69 bar) (1000 psi). DO NOT
EXCEED 8,3 MPa (82,7 bar) (1200 psi). Refer to
Hydraulic Schematics for flow. The high pressure flow
HIGH PRESSURE FLOW (U.S. gpm)
%= X 100
P-85897A
Disconnect the inlet hose (Item 1) [Figure 20-61-4].
*Refer to the Hydraulic Schematics for pump flow and
rpm.

Figure 20-61-5
1 2
P-90580
Connect the INLET hose (Item 1) [Figure 20-61-5] from

of the pump. Connect the OUTLET hose (Item 2) [Figure
20-61-5] from the tester to the inlet fitting on the fan (Item
1) [Figure 20-61-4].
IMPORTANT
I-2024-0284

Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-90186
WARNING Install a jumper hose (Item 1) [Figure 20-61-6] onto the

front auxiliary quick couplers.

W-2059-0598
IMPORTANT
I-2024-0284

procedure:

MEL10003 - Hydraulic Tester
MEL10006 - Hydraulic Test Kit

1.)

7003031 on Page 10-61-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Warm the fluid to 60°C (140°F) by turning the restrictor
Direct Pump Test (High Flow Section) (Cont'd)
NOTE: DO NOT EXCEED 3700 PSI.
Figure 20-61-7
gpm) at full rpm. Increase the restriction and the flow
should drop to zero U.S. gpm between 24,1 MPa (241,3
1 bar) (3500 psi) and 25,5 MPa (255,1 bar) (3700 psi).
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Removal And Installation on Page 20-61-8.)
Record the highest pressure (psi) and flow (U.S. gpm).

The high pressure flow must be at least 80% of free flow.
2
%= HIGH PRESSURE FLOW (U.S. gpm) X100
P-90183

Disconnect the high flow pump OUTLET hose (Item 1)
from the high flow check valve INLET fitting (Item 2) *Refer to Hydraulic Schematics for system relief pressure
and full rpm.

[Figure 20-61-7].
Figure 20-61-8
1 2
P-90580
Connect the INLET hose (Item 1) [Figure 20-61-8] from

the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-61-7]. Connect the OUTLET hose (Item 2)
[Figure 20-61-8] from the tester, to the high flow check
valve INLET fitting (Item 2) [Figure 20-61-7].
Lower the cab.
Start the engine and run at low idle rpm. Press the front
auxiliary button. Press the High Flow button. Push the
button (on the right control lever) for fluid flow to the quick
coupler. Make sure the tester is connected correctly. If no
flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
engine speed to full rpm*.

High Flow Relief Valve Adjustment
If the pump is unable to reach 3500 PSI stop the engine.

The relief screw (Item 1) [Figure 20-61-11] will need to
be turned clockwise 90° and retested with the procedure
above. (90° equals approximately 1,4 MPa (13,8 bar)
(200 PSI).)
NOTE: If the relief screw has been turned in 1/4 turn

and the pressure remains the same, go to the
high flow relief valve removal and installation 1
section. (See High Flow Relief Valve Removal
And Installation on Page 20-61-8.) If relief
valve has been checked and is OK, go to the 2 P-45443
high flow pump disassembly and assembly
section. (See Disassembly And Assembly on
Page 20-61-13.) Locate the high flow relief valve (Item 1) [Figure 20-61-
10] along the right side of the engine.
Remove right rear wheel. (See Wheel Nuts on Page 10-
160-1.) Remove the plug (Item 2) [Figure 20-61-10] located on
the bottom of the high flow relief valve.
Figure 20-61-9

Figure 20-61-11
P-90577 1
P-45445
Remove the mounting bolts (Item 1) [Figure 20-61-9]

from the access cover and remove the cover from the NOTE: [Figure 20-61-11] shows adjusting the relief
loader. screw.
If the pump reaches 25,5 MPa (255,1 bar) (3700 psi) and
there is flow stop the engine. The relief screw must be
turned 90° counterclockwise and retested with the
procedure above.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Locate the high flow relief valve through rear door along
the right side of the engine.
High Flow Relief Valve Removal And Installation
Remove the relief valve (Item 1) [Figure 20-61-13] from
the pump.
WARNING Installation: Tighten the relief valve to 41 - 47 N•m (30 -

35 ft-lb) torque.
Figure 20-61-14
W-2017-0286
1 1
Remove right rear wheel. (See Wheel Nuts on Page 10-

160-1.)
3
Figure 20-61-12
2

P-45459
Inspect the relief valve and replace the two O-rings (Item
If the relief valve is bad, it must be replaced as a

complete unit.
P-90577 Remove the plug (Item 3) and inspect the O-ring [Figure
20-61-14] damage and replace as needed.
Remove the mounting bolts (Item 1) [Figure 20-61-12]

from the access cover and remove the cover from the
loader.
Figure 20-61-13
P-45444

Solenoid Removal And Installation 2
Figure 20-61-15
P-45461
NOTE: Mark the pump housing (Item 1) [Figure 20-61-

P-43958 17] for proper installation of the solenoid
valve cartridge.
At the right side access hole, disconnect the electrical Remove the valve cartridge (Item 1) [Figure 20-61-17].
connector (Item 1) [Figure 20-61-15] from the high flow

pump solenoid. Installation: Tighten the solenoid valve to 47 - 54 N•m
(35 - 40 ft-lb).
Figure 20-61-16
Figure 20-61-18
P-45460
P-45462
Remove the solenoid nut (Item 1) [Figure 20-61-16].

Inspect the O-ring (Item 1) [Figure 20-61-18] and
Remove the solenoid (Item 2) [Figure 20-61-16]. replace as needed.
Installation: Tighten the solenoid nut to 5 - 8 N•m (48 - Inspect the O-ring and back-up washer (Item 2) [Figure
72 in-lb) 20-61-18] and replace as needed.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Drain the hydraulic fluid from the reservoir. (See
Removing And Replacing Hydraulic Fluid on Page 10-
Removal And Installation 120-2.)
Never work on a machine with the lift arms up unless 1

1
W-2059-0598
DANGER 1
1
P-90184

Disconnect and cap the inlet hoses (Item 1) [Figure 20-
61-19] from the front of the hydraulic pump.
Figure 20-61-20
P-90328
AVOID DEATH
D-1009-0409
1
IMPORTANT P-90185

Disconnect and cap the hoses (Item 1) [Figure 20-61-20]
from the back of the hydraulic pump.
Remove the Power Bob-Tach block if equipped. (See
damage the system.
I-2003-0888
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)

HYDRAULIC PUMP (HIGH FLOW) (CONT'D) Hydraulic Pump Startup
Removal And Installation (Cont’d) NOTE: This procedure is necessary to prevent a dry
startup of the hydraulic pump.
Figure 20-61-21
Fill the system with hydraulic fluid. (See Removing And
1 Replacing Hydraulic Fluid on Page 10-120-2.)
2
Figure 20-61-23
Momentary Switch
2
3
P-90509A
Disconnect and cap the outlet hoses (Item 1) [Figure 20-

61-21] from the hydraulic pump. Starter Bypass Tool
P-59354

Remove the two mounting bolts (Item 2) [Figure 20-61-
21] from the hydraulic pump. To crank the engine without starting, the machine key
switch can be bypassed. Obtain a starter bypass tool
Installation: Tighten the mounting bolts to 75 - 85 N•m from a local source which can be used as a universal
(55 - 60 ft-lb) torque. connection to remotely crank the engine without starting.
Remove the hydraulic pump (Item 3) [Figure 20-61-21] The starter bypass tool consists of two wires, each with a
from the loader. clamp. The momentary switch, when depressed, will
allow current to pass through the circuit.
Figure 20-61-22
Connect the starter bypass tool to the starter solenoid
battery terminal and S terminal. Crank the engine for 15
seconds, then stop for at least 30 seconds. Again, crank
the engine for 15 seconds. Remove the starter bypass
tool.
Start the loader from the operators cab and run the
engine at low idle for 1 - 2 minutes without operating the
hydraulics.
1
After operating the engine at low idle, remove the lift arm
support device and fully raise and lower the loader lift
arms several times or until air is purged from the system.
Avoid running over the relief valve setting at the end
P-43940 P-43938A of cylinder stroke.
With the loader parked on a level surface and lift arms

Replace the O-ring (Item 1) [Figure 20-61-22] on the down, check and fill the hydraulic reservoir as required.
hydraulic pump. Check for hydraulic leaks.
Reverse the removal procedure to install the hydraulic

pump.

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Figure 20-61-24
21
1. Stem
22
2. Valve
5 3. Wear Plate
4 4. Seal Section
3
6 5. Rear Housing
6. Bolt
7. Pre-load Seal
8. Load Seal
22 9. Spline Connector
24 10. Pin
11. Gear Set
1 12. Gear Housing
10 13. Gear Housing
2

14. Gear Set
3
11 15. Gear Housing
8 9
7 16. Gear Set
23 4 17. Center Housing
10
17 12 18. Center Housing
19. Front Housing
4 20. Shaft Seal
3
21. High Flow Relief
22. Seal
10 23. Nut
3 24. Coil
9 14
8
7
4
10 13
18
4
3
10
4
8
7
4 15
16
19
20
10
MS1456S

HYDRAULIC PUMP (HIGH FLOW) (CONT'D)
Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
Mark the pump sections for correct assembly.
To disassemble and assemble the hydraulic pump, follow

the Parts Identification page (See Parts Identification on
Page 20-61-12.) for proper placement of components
along with the information below.
NOTE: A seal kit is available through Bobcat Service

Parts.
Assembly: Tighten the eight pump housing bolts (Item 6)

[Figure 20-61-24] to 50 N•m (37 ft-lb) torque.
NOTE: Position the wear plate (Item 3) [Figure 20-61-

19] inlets and traps as shown with the bronze
side toward the gears on all wear plates.
NOTE: Inspect all gears, shafts and pump end

sections. If any of these components have
excessive wear or damage is visible, the
complete pump must be replaced.
NOTE: The relief valve and the solenoid can be

replaced along with the o-rings and back-up
washers.


HYDRAULIC / HYDROSTATIC FILTERS Figure 20-70-1
Description
2
The hydraulic / hydrostatic filters help to remove 2
contaminants from the fluid when the hydraulic /
hydrostatic systems are operating.
The hydraulic / hydrostatic filter system consists of one

main filter and one charge flow filter.
The main filter removes contaminants before entering

gear pumps including oil returning from the main valve.
1
2
The charge flow filter removes contaminants after the
charge pump. P-90010
Housing Removal And Installation

support device. (See Installing on Page 10-20-1.)
DANGER Raise the operator cab. (See Raising on Page 10-30-2.)
Drain the fluid from the reservoir. (See Removing And

Disconnect the electrical connector (Item 1) [Figure 20-

70-1] from the hydraulic / hydrostatic filter sender.
Disconnect and plug the three hoses (Item 2) [Figure 20-

P-90328 70-1] from the hydraulic / hydrostatic filter housing.
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598

HYDRAULIC / HYDROSTATIC FILTERS (CONT’D)
Housing Removal And Installation (Cont’d)
Figure 20-70-2
P-90011
Remove and plug the two hoses (Item 1) [Figure 20-70-

2] from the bottom of the hydraulic / hydrostatic filter

housing.
Figure 20-70-3
1
1 P-90537
Remove the two bolts (Item 1) [Figure 20-70-3].
Remove the hydraulic / hydrostatic filter housing from the

loader.

HYDRAULIC FLUID RESERVOIR Figure 20-80-2
Description
The hydraulic fluid reservoir is a storage container for the

loader’s hydraulic / hydrostatic fluid. The reservoir
contains a vented fill cap with a fluid screen to prevent
contaminants from entering the reservoir while adding
fluid. 1
The hydraulic fluid reservoir is located behind the
operator’s cab under the rear grille on the right side of the
loader.

P-90579
Remove the hydraulic fluid reservoir from the loader.
Drain the fluid from the reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) Installation: Tighten the mount bolts and nuts to 21,7 -
24,4 N•m (16 - 18 ft-lb) torque.

Remove the Hydraulic / Hydrostatic Filter Housing (See
Housing Removal And Installation on Page 20-70-1.)
Remove the rear grille (See Removal And Installation on

Page 50-60-1.)
Figure 20-80-1
P-90013
Remove the clamp and the hose (Item 1) [Figure 20-80-

1].

HYDRAULIC FLUID RESERVOIR (CONT'D)
Hydraulic Fluid Screen
Remove the rear grille (See Removal And Installation on

Page 50-60-1.)
Figure 20-80-3
P-90506

Remove the hydraulic fluid reservoir breather cap
[Figure 20-80-3] from the reservoir.
Remove the hydraulic fluid screen (Item 1) [Figure 20-

80-3] from the reservoir.
Wash the screen in clean solvent and air dry, before

replacing.

OIL COOLER Figure 20-90-2
Description
1
The oil cooler is used to cool the loaders hydraulic and 2
hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil.
3
The oil cooler is located underneath the rear grille
between the A/C condenser (if so equipped) and the
radiator.
P-90589
IMPORTANT Slide the plastic sleeve (Item 1) away from the oil cooler
(Item 2). Remove the clip (Item 3) [Figure 20-90-2] and
When repairing hydrostatic and hydraulic systems, pull hose out.
parts clean. Always use caps and plugs on hoses, Cap or plug all hoses and fittings.

damage the system. Figure 20-90-3
I-2003-0888
4 4
Remove the rear grille from the loader. (See Removal
2
And Installation on Page 50-60-1.) 5
Figure 20-90-1 3
2
1 2
P-90501
3
Undo the rubber straps (Item 1) [Figure 20-90-3]
Remove the bolts (Item 2) and remove the condenser

guards (Item 3) [Figure 20-90-3].
P-85938
Remove the clips and pins (Item 4) [Figure 20-90-3].

Slide the plastic sleeve (Item 1) away from the oil cooler
(Item 2). Remove the clip (Item 3) [Figure 20-90-1] and Remove the bolt (Item 5) [Figure 20-90-3] from the prop
pull hose out. rod.
Cap or plug all hoses and fittings. NOTE: When installing the cooler hoses, the fittings
should make a clicking sound when pushed
together.
Lift up the oil cooler and remove the cooler from the
loader.


BUCKET POSITION VALVE Remove the two bolts (Item 1), move the hose clamp
Description inlet assembly (Item 3) [Figure 20-100-1] off to the side.
The Bucket Position Valve is an option that allows the Cover the fuel tank inlet.
operator to hold the attachment at the same angle from
Figure 20-100-2
the ground to maximum lift height without using the tilt
function.
The bucket position valve is mounted to the inside lower

right rear side of the loader frame. 3
See Hydraulic Schematic for more circuit information.

2
DANGER
1 P-90197
Disconnect the wire harness connector (Item 1) [Figure

20-100-2] from the bucket position shut-off solenoid.

Disconnect the cap the two tubelines (Item 2) [Figure 20-
100-2].
P-90328 Remove the solenoid nut, coil, and stem (Item 3) from the
bucket positioning valve [Figure 20-100-2].
AVOID DEATH
• Disconnecting or loosening any hydraulic Installation: Put oil on O-rings and back-up washers and
tubeline, hose, fitting, component or a part failure tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
can cause lift arms to drop. torque.
Installation: Tighten the solenoid nut to 8 N•m (6 ft-lb)
torque. Overtightening may cause valve failure.
D-1009-0409 NOTE: The engine is shown removed for photo
clarity.
Drain the hydraulic reservoir. (See Removing And Figure 20-100-3
Figure 20-100-1
1
3 2
N-18191
2 Inspect the solenoid stem and replace the O-rings (Item

P-90187 1) and the back-up washer (Item 2) [Figure 20-100-3].

BUCKET POSITION VALVE (CONT'D) Cover the fuel tank inlet.
Solenoid Testing Figure 20-100-5
Refer to Bobcat Advanced Troubleshooting System

(B.A.T.S.) for electrical testing and troubleshooting
information. It is recommended that these procedures be
performed by authorized Bobcat Service Personnel only.
DANGER
1 P-90197
NOTE: The engine is shown removed for photo

clarity.
P-90328 NOTE: Mark all hoses and tubelines for correct

installation.
AVOID DEATH
• Disconnecting or loosening any hydraulic Disconnect the electric solenoid connector (Item 1)
tubeline, hose, fitting, component or a part failure [Figure 20-100-5].
• Keep out of this area when lift arms are raised Figure 20-100-6
D-1009-0409
1
Figure 20-100-4
3 2
4 3
1
P-90188
Disconnect and cap the tilt base inlet hose (Item 1), the
tilt rod inlet hose (Item 2), the lift rod inlet hose (Item 3),
and the lift base inlet hose (Item 4) [Figure 20-100-6]
that route from the control valve.
2
P-90187
Remove the two bolts (Item 1), move the hose clamp

BUCKET POSITION VALVE (CONT'D) Figure 20-100-9
Figure 20-100-7
P-90190A
2
1
Remove the mounting screws (Item 1) [Figure 20-100-
P-90189A 9].
Remove the bucket position valve from the loader.

Disconnect and cap the tilt cylinder hose (Item 1) and the
tilt cylinder base end hose (Item 2) [Figure 20-100-7]

from the valve block.
Figure 20-100-8
2
2
1
P-90197A
Disconnect and cap the lift base outlet hose and tubeline
(Item 1) and the lift rod outlet hose and tubeline (Item 2)
[Figure 20-100-8] that route from the lift cylinders.

BUCKET POSITION VALVE (CONT'D) Figure 20-100-12
Figure 20-100-10
3
1
2
1 3
2
P-90194
Remove the tilt cylinder check valve (Item 1), spring (Item
P-90192 2), and plug (Item 3) [Figure 20-100-12]. Inspect for
wear, inspect the O-ring and replace as needed.
Remove the solenoid nut (Item 1), coil (Item 2), and the Assembly: Tighten the plug to 75,9 - 86,8 N•m (56 - 64
stem (Item 3) [Figure 20-100-10]. ft-lb) torque.

Assembly: Tighten the nut to a maximum of 8 N•m (6 ft- Figure 20-100-13
lb) torque. Overtightening may cause valve failure.
Assembly: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 40,7 - 50,2 N•m (30 - 40 ft-lb)
1
torque. 2 3
Figure 20-100-11
P-90193
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-100-13].
Inspect all parts and replace as needed. Install a new O-

P-90195 ring on the plug before installing.
Assembly: Tighten the plug to torque.

Remove the flow adjustment valve and O-ring (Item 1)
[Figure 20-100-11].
Assembly: Tighten the flow adjustment valve to 36,6 -

48,8 N•m (27 - 36 ft-lb) torque.
NOTE: Always install new O-rings before any parts

are installed into the valve. Inspect the parts
for wear or damage and replace as needed.

REAR AUXILIARY DIVERTER VALVE
Description
The rear auxiliary diverter valve is an optional valve that

diverts oil from the main valve inlet to two sets of rear
auxiliary couplers. The couplers are used for rear
mounted attachments.The right side auxiliaries are used
for older attachments.
The rear couplers are located, one set on each side of

the rear frame uprights.
See Hydraulic Schematic for more circuit information.
Solenoid Testing
Figure 20-110-1

P9137
Use a test meter to measure coil resistance [Figure 20-

110-1]. Coil wires do not have polarity. Correct resistance
is 8.6 - 9.5 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.

REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-110-3
1
DANGER 1
P-93303
P-90328
AVOID DEATH Disconnect and cap the tubelines (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 110-3]
can cause lift arms to drop. Figure 20-110-4

D-1009-0409
1
Put jackstands under the rear corners of the loader.

P-93312
Figure 20-110-2
Disconnect the accessory wiring harness (Item 1)
[Figure 20-110-4] from the main harness.
P-90583
Disconnect and cap the tubelines (Item 1) [Figure 20-

110-2]

REAR AUXILIARY DIVERTER VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-110-6
Figure 20-110-5
1
1
P-48751
P-90581
Figure 20-110-7
Remove the two bolts (Item 1) and remove the valve

(Item 2) [Figure 20-110-5]

1
P-48752
Clean the diverter valve to remove dirt before

disassembly. Valve ports are labeled for correct
assembly.
Several plugs (Item 1) [Figure 20-110-6] and [Figure 20-

110-7] are located all over the diverter valve and can be
removed for clean out purposes.
Assembly: Put oil on O-rings and back-up washers.

Tighten to 13,6 N•m (10 ft-lb) torque.

Disassembly And Assembly (Cont'd)
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
P-48755
Figure 20-110-8
Figure 20-110-11
1
2
2

1
P-48755
P-48757
Figure 20-110-9
Remove the differential sensing valve (Item 1) [Figure

20-110-10] and [Figure 20-110-11] from diverter valve
and inspect the O-rings and back-up washers (Item 2)
[Figure 20-110-11] for damage.
2
2 2
Assembly: Put oil on O-ring and back-up washers.
1 Tighten to 68 - 75 N•m (50 - 55 ft-lb) torque.
P-48756
Remove the shuttle valve (Item 1) [Figure 20-110-8] and

[Figure 20-110-9] from diverter valve and inspect the O-
rings and back-up washers (Item 2) [Figure 20-110-9] for
damage.
Assembly: Put oil on the O-rings and back-up washers.

Tighten to 14 - 16 N•m (10 - 12 ft-lb) torque.

Figure 20-110-12
P-48759
1
Figure 20-110-15
P-48753
Figure 20-110-13

1
3
1
2 2
P-48760
NOTE: Before removing the solenoid coils mark the

P-48754 coils for proper alignment.
Remove the nut (Item 1) [Figure 20-110-14] and [Figure

Remove the relief valve (Item 1) [Figure 20-110-12] and 20-110-15] from the solenoid valve stem.
[Figure 20-110-13] from the diverter valve and inspect
the O-rings and back-up washers (Item 2) [Figure 20- Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)
110-13] for damage. torque.
Assembly: Put oil on O-ring and back-up washers. Remove the spacer (Item 2) and solenoid valve coils
Tighten to 27 - 34 N•m (20 - 25 ft-lb) torque. (Item 3) [Figure 20-110-15].

Figure 20-110-16
1
1
P-48762
Figure 20-110-18
P-48761
NOTE: Before removing the solenoid coils mark the

coils for proper alignment.

Remove the nuts (Item 1) [Figure 20-110-16] from the
solenoid valve stems.
Assembly: Tighten the nut to 5 - 8 N•m (4 - 6 ft-lb)

2 2
torque. 1 1
P-48763
Remove the solenoid valve stem (Item 1) [Figure 20-

110-17] and [Figure 20-110-18] and inspect the O-rings
and back-up washers (Item 2) [Figure 20-110-18] for
damage.


Figure 20-110-19
P-48765
Remove the plug (Item 1) [Figure 20-110-21].

P-48763A
Assembly: Tighten the plug to 51,5 N•m (38 ft-lb) torque.
Figure 20-110-20 Figure 20-110-22

1 2
1
P-48764 P-48766
Remove the solenoid valve stem (Item 1) [Figure 20- Remove and inspect the orifice (Item 1) [Figure 20-110-
110-19] & [Figure 20-110-20] and inspect the O-rings 22] for dirt and debris.
and back-up washers (Item 2) [Figure 20-110-20] for
damage. Assembly: Tighten the orifice to 29,8 N•m (22 ft-lb)
torque.

Figure 20-110-23
1
1
P-48758
Remove the plugs (Item 1) [Figure 20-110-25].

P-48765
Assembly: Tighten the plug to 19 N•m (14 ft-lb) torque.
Remove the plug (Item 1) [Figure 20-110-23]. Inspect cartridges, check valves, solenoid valves and
sealing washers for contamination or damage. Wash all

Assembly: Tighten the plug to 13,6 N•m (10 ft-lb) torque. parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.
Figure 20-110-24
Inspect diverter valve cavities for contamination. Wash
valve in clean solvent. Use air pressure to dry.
P-48786
Remove the orifice (Item 1) [Figure 20-110-24].
Assembly: Tighten the orifice to 4,5 N•m (3.3 ft-lb)

torque.

BOB-TACH (POWER) BLOCK Removal And Installation
Description
The power Bob-Tach is an option that allows the operator

to hydraulically control the Bob-Tach levers for mounting
WARNING
and dismounting the attachments.
The power Bob-Tach is operated by a switch on the right the lift arms are secured by an approved lift arm
switch panel. support device. Failure to use an approved lift arm
The power Bob-Tach block is mounted on the right side of to fall and cause injury or death.
the machine in front of the engine on the back side of the W-2059-0598
hydraulic pump.
DANGER

P-90328
AVOID DEATH
D-1009-0409
IMPORTANT
damage the system.
I-2003-0888

BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-120-2
Removal And Installation (Cont'd) 1
Figure 20-120-1
2 4
3
3
3
P-90969
Mark the hydraulic hoses for proper installation.

P-90968
Disconnect and cap the outlet hose (Item 1) [Figure 20-
120-2] from block.
1.) Remove the hydraulic muffler (if equipped) (Item 2)

[Figure 20-120-2] from block.
support device. (See Installing on Page 10-20-1.) Disconnect and cap the hoses (Item 3) [Figure 20-120-2]
from block.
Remove the four mounting bolts (Item 4) [Figure 20-120-
Drain the hydraulic reservoir. (See Removing And 2] from block.
Disconnect and cap the two electrical solenoid (35 - 40 ft-lb) torque.
connectors (Item 1) [Figure 20-120-1] from the loader
electrical harness. Remove the power Bob-Tach block.

Figure 20-120-3
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-120-4].
Inspect the O-ring (Item 4) [Figure 20-120-4] on the plug

Clean the block (Item 1) [Figure 20-120-3] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct

assembly. Figure 20-120-5
Remove the plug (Item 2) [Figure 20-120-3].
Installation: Tighten the plug to 34 - 40,6 N•m (25 - 30 ft-

lb) torque.
IMPORTANT 1

P-48116
damage the system.
I-2003-0888
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-120-5].
Installation: Tighten the plug to 16,3 - 19 N•m (12 - 14 ft-

lb) torque.

Figure 20-120-6
1
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-120-8].

P-48382
NOTE: Do not remove plugs. If the plugs are removed
the internal pressure relieving spring setting
Remove the check valve (Item 1) [Figure 20-120-6]. will be altered.

Installation: Oil the check valve and O-rings and tighten Figure 20-120-9
the check valve to 27,1 - 34 N•m (20 - 25 ft-lb) torque.
Figure 20-120-7
1
2
1
P-48384
3
P-48119 Remove the plug (Item 1) [Figure 20-120-9], inspect the

O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Installation: Tighten the plug (Item 1) [Figure 20-120-9]
(Item 2) [Figure 20-120-7]. to 16,3 - 19 N•m (12 - 14 ft-lb) torque.
Inspect the O-rings and back-up washers (Item 3)

[Figure 20-120-7] on the check valve and piston
assembly and replace as needed.

Figure 20-120-10 2
2
1
P-48106A
Remove the first solenoid coil (Item 1) and the second

P-48664 solenoid coil (Item 2) [Figure 20-120-12].
NOTE: Remember the solenoid coil orientation for

Remove the orifice screw (Item 2) located behind the ease of installation.

Figure 20-120-13
Installation: Tighten the orifice screw (Item 2) [Figure
20-120-10] to 8,1 - 10,8 N•m (6 - 8 ft-lb) torque.
Figure 20-120-11
1
1
2
P-48386

P-48127
Installation: Tighten the solenoid stem to 27,1 - 34 N•m
NOTE: This plug is a zero leak plug and should not be
removed. If removed damage may occur and
the plug and O-ring must be replaced.
Do not remove the plug (Item 1) [Figure 20-120-11].
Remove the solenoid nut (Item 2) [Figure 20-120-11].
Installation: Tighten the solenoid valve stem nut to 1,7 -

5,1 N•m (15 - 45 in-lb) torque.

Figure 20-120-14
1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-

P-48175 120-16].
Installation: Tighten the screened orifice plug to 14,9 -

Remove the armature assembly (Item 1) [Figure 20-120- 16,3 N•m (11 - 12 ft-lb) torque.
14].

Figure 20-120-17
Figure 20-120-15
2 2
1 1
P-48138
P-48173
Inspect the screened orifice plug (Item 1) [Figure 20-

Inspect the solenoid stem (Item 1), armature assembly 120-17] for damage replace as needed. If the screened
(Item 2) and the spool (Item 3) for damage [Figure 20- orifice plug is blocked replace with a new plug.
120-15].
Inspect the O-ring (Item 2) [Figure 20-120-17] and
NOTE: If the solenoid stem is damaged (Item 1) replace as needed.
inspect the armature assembly (Item 2) for
damage.
The armature assembly (Item 2) and spool

(Item 3) are non-serviceable parts. If they are
damaged, order a new power Bob-Tach block
assembly from Bobcat parts [Figure 20-120-
15].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
Description Figure 20-130-2
The front auxiliary hydraulic coupler block is the 1

connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers
are for suppling hydraulic flow for various attachments.
2
The front auxiliary coupler block is located at the front of
the left side lift arm.
Removal And Installation 3
IMPORTANT P-90002

clean the work area before disassembly and keep all Figure 20-130-3
damage the system. 1

I-2003-0888
Figure 20-130-1 2
P-90003
P-85281

1].
Pull the block away from the lift arms and disconnect the
auxiliary hoses from the coupler block [Figure 20-130-1].

FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-130-5
(CONT’D)
Disassembly And Assembly (Cont’d)

1
Figure 20-130-4
4
4 1
4
4 2
2
P-34665
3
Check the O-rings (Item 1) back-up O-rings (Item 2) for

damage and replace as needed [Figure 20-130-5].
P-90001
Figure 20-130-6
Remove the male coupler, spring, and fitting (Item 1)
[Figure 20-130-2], [Figure 20-130-4] and [Figure 20-

1
130-4]
Assembly: Tighten the male coupler (Item 1) [Figure 20-

130-3] and [Figure 20-130-4] to 80 N•m (59 ft-lb)
Remove the drain coupler, spring, and fitting (Item 2)

130-4].
Assembly: Tighten the drain coupler (Item 2) [Figure 2

20-130-3] and [Figure 20-130-4] to 50 N•m (37 ft-lb)
P-34664
Remove the female coupler, spring, and fitting (Item 3)
130-4]. Check the O-rings (Item 1) back-up O-rings (Item 2) for
damage and replace as needed [Figure 20-130-6].
Assembly: Tighten the female coupler (Item 3) [Figure
20-130-3] and [Figure 20-130-4] to 80 N•m (59 ft-lb)
Check the O-rings (Item 4) [Figure 20-130-4] and

replace as needed.

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-21-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-21-11
HYDROSTATIC MOTOR CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-5
HYDROSTATIC MOTOR CARRIER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-31-6
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Replenishing / High Pressure Relief Valve Removal And Installation . . . . . . . . . . . . 30-50-4
Parts Identification (Left Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-5
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-6
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-14

HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-1
Hydraulic Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-2
Hydrostatic Pump Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-6
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-8
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-9
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-23
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-51-26
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-3
Tensioner Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
TWO-SPEED / BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1

Valve Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2
Valve Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-4
DRAIN MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1
Drain Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

HYDROSTATIC SYSTEM INFORMATION
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat service personnel adjustments can cause injury or death.
only. W-2004-1285
If a service code appears in the left instrument panel.

(See DIAGNOSTIC SERVICE CODES on Page 60-90-
1.)
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7, 10
The hydrostatic system is overheating. 8, 9
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump relief / replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The hydrostatic pump is not properly calibrated, and/or incorrect steering drift compensation setting.

HYDROSTATIC SYSTEM INFORMATION (CONT’D)
Description
The hydrostatic system consists of a tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion of the loader.
The hydrostatic pump is connected to the engine by a

drive belt and provides fluid to the hydrostatic motors.
The charge pressure system assists in replenishing the
fluid that is lost due to internal leakage in the components
of the hydrostatic system.

HYDROSTATIC DRIVE MOTOR
Description
The hydrostatic motors are driven by high pressure from

the hydrostatic pumps.
The hydrostatic motors do not have an internal brake.
Inside the endcap of the hydrostatic motor, there is a

shuttle valve. The shuttle valve helps to keep the motor
cool by mixing case drain oil with cooled low pressure oil
from the charge circuit. The shuttle valve is shifted by the
high pressure oil coming from the hydrostatic pumps. If
the shuttle valve sticks, a delay or lack of drive may or
may not be felt in the controls and/or an overheated
hydrostatic motor will result.
There are two hydrostatic motors mounted to motor

carriers. The motor carriers are mounted to the
transmission chaincase which houses the drive chains.

HYDROSTATIC DRIVE MOTOR (CONT'D) Drain the hydraulic reservoir. (See Removal And
Figure 30-20-1
DANGER
1
2
P-90328
AVOID DEATH
P-90510
• Keep out of this area when lift arms are raised Remove the motor cover.
support. Replace if damaged. Mark the hoses for correct installation.

D-1009-0409 Disconnect the case drain hose (Item 1) [Figure 30-20-
1].
Disconnect the high pressure hoses (Item 2) [Figure 30-
WARNING 20-1].
Figure 30-20-2
support device. Failure to use an approved lift arm 1
support device can allow the lift arms or attachment 1
to fall and cause injury or death. 2
1 1
W-2059-0598
1
1
IMPORTANT
clean the work area before disassembly and keep all P-90495
damage the system. Remove the ten mounting bolts (Item 1) [Figure 30-20-
I-2003-0888 2].
Installation: Tighten the mounting bolts to 149,2 N•m

(110 ft-lb) torque.
1.)
NOTE: The two bolts (Item 2) [Figure 30-20-2] mount
the cam ring to the motor, and do not have to
be removed, to remove the motor from the
Raise the operator cab. (See Raising on Page 10-30-2.) loader.
Remove the motor/cam ring section from the loader.

HYDROSTATIC DRIVE MOTOR (CONT'D)
Figure 30-20-3
P5405
Remove the piston / roller section (Item 1) [Figure 30-20-

3] from the loader, if it was not removed with the motor/

cam ring.
To remove the motor carrier. (See Removal And


HYDROSTATIC DRIVE MOTOR (CONT'D)
1. Distributor 16. Bolt

2. Spring 17. Plug
3. Seal 18. O-ring
4. O-ring 19. Spring
5. Plug 20. Shim
6. O-ring 21. Poppet
7. Spring 22. O-ring
8. Washer 23. Seal
9. Spool 24. O-ring
10. Spring 25. Seal
11. Rear Housing 26. O-ring
12. Plug 27. Cam 3
13. O-ring 28. Roller 3
14. O-ring 29. Piston 2
1
15. Stop Pin 30. Block
4
5
6

4
8 7
9
10
11
12
13
23
25
15
28
29 14
16
22 16
24 21
20
19
18
26
17
27
30
B-17125

HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-20-5
IMPORTANT 2 1

damage the system.
I-2003-0888
P5765
Figure 30-20-4
Apply low air pressure to each port in the cylinder block

1 to remove the roller (Item 1) and piston/ring assembly
(Item 2) [Figure 30-20-5].
Inspect the cylinder block surface and the roller/piston

assemblies for scratches or wear.

NOTE: Put all the roller/piston assembly back in their
original position.
Assembly: Install the roller (Item 1) in the piston (Item 2)

[Figure 30-20-5].
N-17861 Assembly: Dip the roller / piston assembly into oil and
install into the bore in the cylinder.
Remove the piston / roller section (Item 1) [Figure 30-20- Repeat for each roller / piston assembly.
4] from the motor.
Assembly: Install the motor on the loader and tighten the

mount bolts to 149,2 N•m (110 ft-lb) torque.
NOTE: Before operating the hydrostatic motor, make

sure it is full of oil. There are several methods
to fill the motor with oil; (1) with the case drain
hose disconnected, fill the motor with oil
through the case drain port; (2) with the case
drain hose disconnected, BICS] brake locked,
engine running, stroke the steering lever until
oil comes out of the case drain port.

Disassembly And Assembly (Cont'd) 1
Figure 30-20-6 2
N-17864
Remove the stop pin (Item 1) [Figure 30-20-8] from the

N-17860 rear motor housing.
Assembly: Install the stop pin (Item 1) [Figure 30-20-8]

Remove the two cam ring mounting bolts (Item 1) and tighten to 10-12 N•m (7-9 ft-lb) torque.
[Figure 30-20-6].

Figure 30-20-9
Assembly: Install the two cam ring mounting bolts (Item
1) [Figure 30-20-6] and tighten to 67,8 N•m (50 ft-lb)
torque. 3
Figure 30-20-7
1
1
4
2
N-17868
NOTE: The distributor removal, is best accomplished

by lifting the housing (Item 2) [Figure 30-20-8]
N-17863 50,8 - 76,2 mm (2 - 3 in) above a wooden
surface, and dropping the housing.
Remove the cam ring (Item 1) [Figure 30-20-7] from the Assembly: Install the stop pin (Item 1) [Figure 30-20-8]
motor housing. and tighten to 10 - 12 N•m (7 - 9 ft-lb) torque.
Inspect the cam ring for surface scratches or wear. Assembly: Install the distributor (Item 2) [Figure 30-20-
9] into the housing.
Assembly: Install the cam ring (Item 1) [Figure 30-20-7]
and align the mounting bolt holes. Assembly: Align the distributor hole (Item 3) [Figure 30-
20-9] with the stop pin. When aligned correctly, the
distributor can be depressed slightly.
Assembly: Install and lightly smear grease on the O-ring

(Item 4) [Figure 30-20-9].

Figure 30-20-10 5
1 2 3 4
1
N-17872
Remove, inspect and install the plug (Item 1), spring

N-17869 (Item 2), shim (Item 3) and poppet (Item 4) [Figure 30-
20-12].
Remove and replace the two seals and back-up O-rings Assembly: Remove and replace the O-ring (Item 5)
(Item 1) [Figure 30-20-10] on the distributor. [Figure 30-20-12].

Inspect the distributor and springs (Item 2) [Figure 30- Assembly: Tighten the plug to 12 - 15 N•m (9 - 11 ft-lb)
20-10] for damage or surface scratches. torque.
Assembly: Put grease on the springs to hold them in Figure 30-20-13

place.
Assembly: Install the springs into the distributor.

5
Figure 30-20-11
2 3 4 2 1
1
N-17871
Remove, inspect and install the plug (Item 1), springs

(Item 2), spool (Item 3) and washer (Item 4) [Figure 30-
N-17866 20-13].
Assembly: Remove and replace the O-ring (Item 5)

Remove the two seals (Item 1) [Figure 30-20-11] from [Figure 30-20-13].
the housing and replace with new seals.
Assembly: Tighten the plug to 25 - 30 N•m (18 - 22 ft-lb)
Remove the two O-rings and replace with new O-rings. torque.
The O-rings are located under the seals.
Assembly: Lightly smear grease over the seals.


HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Removal And Installation
Description
The hydrostatic motors are driven by high pressure from

DANGER
the hydrostatic pumps.
This hydrostatic motor contains a spring applied pressure

release braking system to stop the loader. This braking
system is located on the end of the hydrostatic motor.
The hydrostatic motor contains a shuttle valve. The

shuttle valve helps to keep the motor cool by mixing case
drain oil with cooled low pressure oil from the charge P-90328
circuit. The shuttle valve is shifted by the high pressure
oil coming from the hydrostatic pumps. If the shuttle valve AVOID DEATH
sticks, a delay or lack of drive may or may not be felt in • Disconnecting or loosening any hydraulic
the controls and/or an overheated hydrostatic motor will tubeline, hose, fitting, component or a part failure
result. can cause lift arms to drop.
There are two hydrostatic motors mounted to motor unless supported by an approved lift arm
carriers. The motor carriers are mounted to the support. Replace if damaged.
transmission chaincase which houses the drive chains. D-1009-0409

WARNING
W-2059-0598
IMPORTANT
damage the system.
I-2003-0888

1.)

Drain the hydraulic reservoir. (See Removal And


HYDROSTATIC DRIVE MOTOR (TWO-SPEED) Figure 30-21-3
(CONT'D)
Figure 30-21-1
1
P-90257
Disconnect the hydraulic hose (Item 1) [Figure 30-21-3]

that goes to the drain manifold.
P-90256
Figure 30-21-4
Remove the motor cover mount bolts (Item 1) [Figure

30-21-1].

Remove the motor cover from the loader. 1
Mark the hoses for correct installation.
Figure 30-21-2
1
P-90257
1
Remove the eight flange bolts (Item 1) [Figure 30-21-4]

from the high pressure hoses on the motor.
2 Installation: Install the lower collar to the motor and

connect the high pressure hoses behind the collar, then
install the upper collar and tighten the bolts to 34 N•m (25
P-90258 ft-lb) torque.

that goes to the two-speed port on the two-speed/brake
block.

that goes to the brake port on the two-speed / brake
block.

that goes to the make-up port on the two-speed / brake
block.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Figure 30-21-5
P-90496
Remove the 10 (12 mm) mount bolts (Item 1) [Figure 30-

21-5] from the motor.

NOTE: The two smaller diameter bolts (8 mm), hold
the cam ring to the motor and do not have to
be remove for motor removal.
Remove the motor from the loader.
Figure 30-21-6
N-22535

6] and hold it in place with a light cover of lithium base
grease. Tighten the 10 mounting bolts to 149 N•m (110 ft-
lb) torque.

HYDROSTATIC DRIVE MOTOR (TWO-SPEED) (CONT'D)
Ref. Description
15
14
1. Roller
2. Piston 13
3. Ring 13
4. Clamp 12
5. Ring 11
6. Block
7. Cam 10
9
8. Quad Ring 8
9. Distributor
10. Spring
11. Seal/O-ring 1 7
12. Seal/O-ring
13. Seal/O-ring 2
14. Seal/O-ring
15. Seal/O-ring
16. Poppet 3
17. Spool 6
18. Spring 5
19. O-ring
20. Plug 4 4 36

21. Pin 34
22. Plug 5 35
23. Housing 33
24. Spring
25. Spool 32
26. Washer 2728
27. O-ring
28. Plug 24 31
26
29. Quad Ring 25 30
30. Bushing 24 29
31. Shaft 22
32. Dowel
33. Housing 23
34. Bolt 16
35. Shim 37
36. Brake Disc 17 38
37. O-ring 18 39
40 51
38. Snap Ring 19 50
39. Washer 41
40. Spring 49
20
41. Spool 42
42. Bolt 48
43. Seal 21 47
44. O-ring
45. Clamp 46
46. Piston
47. O-ring 45
48 Spring 44
49. Gasket 43
50. Cover
51. Bolt
MS1467S

(CONT'D)
Disassembly
Figure 30-21-7
1
2
N-22492
Remove the cover plate from the brake housing.

1
N-22489 Remove the cover plate gasket (Item 1) [Figure 30-21-
9].
NOTE: Install a mark on the motor, brake, and motor Remove the brake spring (Item 2) [Figure 30-21-9] from
carrier housings for correct assembly [Figure

the brake housing.
30-21-7].
NOTE: Mark the top side of the brake spring for
NOTE: Always protect any sealing surfaces. Any proper installation.
scratches or marks will cause premature
failure. Figure 30-21-10
Place the cam sealing surface (Item 1) [Figure 30-21-7]

on a protective material.
Drain the oil from the motor casing.

1
Figure 30-21-8 2
N-22493
1
Remove the piston from the brake housing (Item 1)

[Figure 30-21-10].
NOTE: The use of air pressure through the brake line

N-22490
connection (Item 2) [Figure 30-21-10] will aid
in piston removal.
Remove the twelve mounting bolts (Item 1) [Figure 30-
21-8] from the brake cover plate. Check the brake piston for damage and replace the seal.
NOTE: Remove and / or tightened the bolts one turn

at a time to maintain equal preload on the end
cap and the brake spring.

(CONT'D)
1
Figure 30-21-11
P-69985
Remove the brake disks (Item 1) [Figure 30-21-13] from

the brake shaft. Mark the position of the brake disks and
P-69973 the shims.
Figure 30-21-14
Remove the five mounting bolts (Item 1) [Figure 30-21-
11] from the brake housing.

1
Remove the brake housing (Item 2) [Figure 30-21-11]
from the rear housing. 2
Figure 30-21-12
P-69978
Remove the two-speed spool (Item 1) [Figure 30-21-14]

from the housing assembly.
1
Remove and discard the o-rings (Item 2) [Figure 30-21-
P-73062 14] on the housing.
Protect the sealing surface. Remove the snap ring (Item

1) [Figure 30-21-12] to remove the seal from the brake
housing.

(CONT'D)
Figure 30-21-15
1
P-73057
2
4
3 Remove the flushing spool assembly (Item 1) [Figure 30-
21-17] from the housing.
N-22501
Figure 30-21-18
Inspect the spool (Item 1), the spring (Item 2), washer
(Item 3) and the snap ring (Item 4) and replace as

needed [Figure 30-21-15]. 1
2 4 3
NOTE: The spool (Item 1) [Figure 30-21-15] is marked
with either an A or B. The spool must be
replaced with a spool with the same mark.
Figure 30-21-16
N-22504
Remove the spring (Item 1), washer (Item 2) and rear

2 spring (Item 3) from the spool (Item 4) [Figure 30-21-18].
Inspect all parts and replace as needed.
P-69979
Remove the flushing spool plug (Item 1) [Figure 30-21-

16] from the housing.
Installation: Tighten the plug to 30 Nm (22 ft-lb) torque.
NOTE: Current motor housings are provided with

break off plugs (Item 2) [Figure 30-21-16] on
the side of the flushing spool housing. Earlier
motors were equipped with threaded plugs.

(CONT'D)
Figure 30-21-19
1
2
1 3
N-22507
Inspect the poppet (Item 1), shim (Item 2) and spring

(Item 3) for wear and replace as needed [Figure 30-21-
P-69981 21].
Figure 30-21-22
Remove the plug (Item 1) [Figure 30-21-19] from the
housing.

Installation: Tighten the plug to 22 N•m (18 ft-lb) torque.
1 1
Figure 30-21-20
P-73058
Remove the two (8 mm) cam ring mount bolts (Item 1)

[Figure 30-21-22].
P-69982 Turn the housing, cam ring, and rotating group assembly
over and place on a stand. Remove the cam ring from the
housing.
Remove the poppet assembly (Item 1) [Figure 30-21-20]
from the housing.

(CONT'D)
Figure 30-21-23
N-22511
Protect the sealing surfaces. Remove the roller/piston

assembly (Item 1) [Figure 30-21-25] from the cylinder
N-22510 block.
Check all roller and piston assemblies for wear and

Protect the sealing surfaces. Check the cam ring inside replace as needed.
surface for wear and scratches [Figure 30-21-23].

NOTE: Put all roller/piston assembles back in the
Figure 30-21-24 original bore.
Figure 30-21-26
1
1
N-22509
P-73059
Remove the cylinder block (Item 1) [Figure 30-21-24]
from the housing.
Remove the shaft from the distributor [Figure 30-21-26].
Remove the O-ring (Item 2) [Figure 30-21-24] from the
housing. NOTE: The end of the shaft with the snap ring (Item 1)
[Figure 30-21-26] must be toward the brake
housing during assembly.
Remove the distributor from the housing.

(CONT'D)
Disassembly (Cont'd) 1
Figure 30-21-27
N-22523
Remove the bushing (Item 1) [Figure 30-21-29] from the

distributor, if worn or scratched.
P-69984
Figure 30-21-30
NOTE: The distributor removal is best accomplished

by lifting the housing (Item 1) [Figure 30-21-

27] 2-3 inches above a wooden surface, and
dropping the housing [Figure 30-21-27].
Figure 30-21-28
1 1
2 N-22519
Remove the six seals (Item 1), and six back-up O-rings
(Item 2) from the distributor [Figure 30-21-30].
N-22521
Protect the sealing surfaces. Remove the locating pin

(Item 1) [Figure 30-21-28] from the distributor.
Remove the springs (Item 1) [Figure 30-21-28] from the

distributor.
Inspect the springs, distributor surface and bushing for

damage or wear and replace as needed.

(CONT'D)
Assembly 1
NOTE: Always use new O-rings and seals during

motor and brake assembly.
Figure 30-21-31
N-22525
Install a new bushing (Item 1) [Figure 30-21-33] in the

distributor if the old bushing was removed.
1
Install new O-rings and seals on the distributor [Figure
30-21-34].
N-22511

NOTE: When installing seals, apply a light coating of
oil to the seal and the mating surfaces of the
During installation of pistons in the bore, position the distributor. Install the O-rings and seals, allow
piston ring gap 180° from one piston to the next. One 30 minutes for the seals to set on the
piston installed with the gap to the right, the next piston distributor before installing the distributor in
installed with the gap to the left. the housing.
Dip each of the roller/piston assemblies (Item 1) [Figure Figure 30-21-34

30-21-31] in oil and replace back its original bore.
Figure 30-21-32
P-73060
N-22518 Using a small amount of grease, install the springs into

the distributor valve (Item 1) [Figure 30-21-34].
Apply a small amount of grease to the locating pin (Item

1) [Figure 30-21-32] and install the locating pin in the
housing

(CONT'D)
Assembly (Cont'd) 1
Figure 30-21-35
N-22509
Install the cylinder block assembly (Item 1) [Figure 30-

21-37].
N-22515
Install the cam ring to the rear housing. Apply liquid
adhesive (Loctite® 243) to the two cam ring mounting
Install the distributor (Item 1) [Figure 30-21-35] in the bolts. Install the bolts finger tight.
housing. Protect the sealing surface of the distributor.

Figure 30-21-38
Figure 30-21-36
1
1
P-69983
P-73061
Turn the motor so that it sets on the cam ring, and

The pin in the distributor must align with the hole in the cylinder block [Figure 30-21-38].
housing (Item 1) [Figure 30-21-36]. Use a hand press to
push the distributor in place. NOTE: Be careful when turning or moving the motor
so the cylinder block stays in the motor
When installed correctly, the distributor will spring back housing and the sealing surfaces are
slightly when pushed by hand into the housing. protected.
Tighten the two cam ring mounting bolts to 35 - 39 N•m


(CONT'D)
1
Assembly (Cont'd)
Figure 30-21-39 2
P-69986
Install the brake housing (Item 1) [Figure 30-21-41] on

the motor housing.
P-69978
Apply liquid adhesive (Loctite® 243) to the five mounting
bolts. Install the bolts (Item 2) [Figure 30-21-41] and
Install new o-rings (Item 1) [Figure 30-21-39] on the tighten evenly to 117 - 122 N•m (86 - 90 ft-lb) torque.
housing assembly and apply grease to the o-rings.

Figure 30-21-42
Install the two speed spool (Item 2) [Figure 30-21-39].
Install the shaft into the distributor [Figure 30-21-39].
Figure 30-21-40
1
P-73064
If needed, install the shims first, then install the brake

disc pack starting with an outer disc (Item 1) [Figure 30-
N-18347 21-42] and alternating with an inner disc, throughout the
pack.
Clamp the disc pack in a vise and measure the height End the disc pack with an outer disc.
[Figure 30-21-40]. The height must be 31,1 mm (1.22
in).
The normal thickness of the individual brake disc is 1 mm

(0.039 in).
If any individual disc's thickness is 0,95 mm (0.037 in) or

less, replace the complete disc pack.

(CONT'D)
Assembly (Cont'd)
Figure 30-21-43
1
2
N-22493
Install the piston (Item 1) [Figure 30-21-45] in the brake

housing.
P-73055
Figure 30-21-46
Install the brake seal (Item 1) [Figure 30-21-43].

NOTE: Install the seal with the metal case end
towards the brake pack. 2
1
Install the snap ring (Item 2) [Figure 30-21-43] to secure
the seal in the brake housing.
Install a new o-ring (Item 3) [Figure 30-21-43] in the

seal.
Figure 30-21-44
N-22492
Install the brake spring (Item 1) [Figure 30-21-46].

1
Install the end plate gasket (Item 2) [Figure 30-21-46].
N-22498
Lightly coat the piston with oil and install a new piston
seal (Item 1) [Figure 30-21-44].

HYDROSTATIC DRIVE MOTOR (TWO-SPEED)
(CONT'D)
Assembly (Cont'd)
Figure 30-21-47
N-22490
Install the brake end cover (Item 1) [Figure 30-21-47].

Install the twelve end cover mount bolts and tighten
evenly to 14 - 16 N•m (10 - 12 ft-lb) torque.


HYDROSTATIC MOTOR CARRIER
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission chain
case.
The hydrostatic motor carrier contains a shaft that rotates

on two tapered roller bearings. The shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case oil from the hydrostatic motor case drain
oil.
The hydrostatic motor carriers are made to fit on both the

right and left hand side of the loader.

HYDROSTATIC MOTOR CARRIER (CONT’D) Remove the control pedal linkages. (See Linkage
Figure 30-30-1
DANGER
1
P-90328
AVOID DEATH
P5467A
• Keep out of this area when lift arms are raised Remove the six mounting bolts (Item 1) [Figure 30-30-1]
unless supported by an approved lift arm from the carrier.

D-1009-0409
Slide the motor carrier toward the rear and remove the
rear drive chain.

W-2059-0598

1.)
Raise the lift arm and install an approved lift arm support

P5489A
Remove the fluid from the chain case. (See CHAINCASE
on Page 40-30-1.)
NOTE: For easier access for the motor carrier
Remove the center chain case cover. (See Center Cover coming out and going into the chain case, tie
Removal And Installation on Page 40-30-2.) the front drive chain to the chain case with a
wire [Figure 30-30-2].
Remove the front axle sprocket. (See Chain Removal
And Installation on Page 40-20-9.) Slide the motor carrier out of the chain case far enough to
install a chain and chain hoist to the carrier [Figure 30-
If the motor carrier is removed from the right side, remove 30-2].
the lift arm bypass valve, (See Removal And Installation
on Page 20-50-2.) and remove the control panel. (See Pull the motor carrier away from the chain case and out
Removal And Installation on Page 50-100-2.) of the loader. [Figure 30-30-2].

HYDROSTATIC MOTOR CARRIER (CONT'D)
1. Shaft
2. Bearing
3. Race
4. Housing
5. Seal (2)
6. Race
7. Bearing
8. Snap Ring

1
2
3
7
8
TS-1227B

HYDROSTATIC MOTOR CARRIER (CONT'D) Figure 30-30-5
Disassembly
Figure 30-30-3
P-76544
Remove the snap ring (Item 1) [Figure 30-30-5] from the

P5760 shaft.
Figure 30-30-6
Remove the large O-ring from the groove (Item 1)
[Figure 30-30-3] in the housing.

Figure 30-30-4
P5766
Use a hydraulic press to remove the shaft from the

housing [Figure 30-30-6].
P5768
Put the motor carrier in a hydraulic press [Figure 30-30-

4].
Put a small amount of pressure on the shaft to release

the pre-load on the snap ring.

HYDROSTATIC MOTOR CARRIER (CONT'D) Assembly
Disassembly (Cont’d) Figure 30-30-9
Figure 30-30-7
P5764
P5761
The tool listed will be needed to the following procedure:
Install the bearing puller tool under the bearing flange, MEL1431 - Seal Driver Tool
use the hydraulic press to remove the bearing from the

shaft [Figure 30-30-7]. Install the first seal (Item 1) [Figure 30-30-9] into the
housing with the seal lip facing away from you.
Figure 30-30-8
Use the tool (Item 2) [Figure 30-30-9] as shown in the
figure.
Figure 30-30-10
2
1
2
P5763
Remove the two seals (Item 1) [Figure 30-30-8] from the

housing.
P5762
Check the bearing cup (Item 2) [Figure 30-30-8] (both

sides) and replace as needed. Install the second seal (Item 1) [Figure 30-30-10] into the
housing with the seal lip facing toward you.

figure.

HYDROSTATIC MOTOR CARRIER (CONT'D) NOTE: Slight press pressure may be used to preload
both bearings. After installation of the snap
Assembly (Cont’d) ring a back press operation may be necessary
to reduce the preload and remove the
Figure 30-30-11 clearance from between the snap ring and the
main bearing.
Use the press and apply pressure to the end of the spline
1
shaft to reduce preload and clearance.
P5767

Install the bearing on the shaft [Figure 30-30-11].
Use a pipe (Item 1) [Figure 30-30-11] with O.D. that

seats on the I.D. of the bearing.
Figure 30-30-12
P5769
install the shaft/bearing assembly into the housing.
Install the bearing (Item 1) using the tool (Item 2) [Figure

30-30-12] (MEL1431).
After the bearing is seated. Install the snap ring on the

shaft and reposition the motor carrier to allow back press
operation.

HYDROSTATIC MOTOR CARRIER (SJC)
Description
The hydrostatic motor carrier is the mating connection

from the hydrostatic drive motor to the transmission
chaincase.
The hydrostatic motor carrier contains a shaft that rotates

on two tapered roller bearings. The shaft has two
sprockets that turn the drive chains.
The hydrostatic motor carrier has a seal which isolates

the chain case oil from the hydrostatic motor case drain
oil.
The hydrostatic motor carrier with (SJC) uses a speed

sensor installed in the motor carrier housing. The speed
sensor senses a disk that is fixed to the shaft in the motor
carrier.
A brake disk is installed on each hydrostatic motor

carrier. The brake disk is mounted to the shaft in the
motor carrier (single speed loaders only).

The hydrostatic motor carriers are made to fit on both the
right and left hand side of the loader.

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D) on Page 20-50-2.) and remove the control panel. (See
Shock Removal And Installation on Page 50-100-18.)
Figure 30-31-1
DANGER
1
1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic P5467A
Remove the six mounting bolts (Item 1) [Figure 30-31-1]
from the carrier.
support. Replace if damaged. Installation: Tighten the mounting bolts to 461 - 488 N•m

D-1009-0409 (340 - 360 ft-lb) torque.
Figure 30-31-2
WARNING
W-2059-0598

1.)
Raise the lift arms and install an approved lift arm P5489A
Raise the operator cab. (See Raising on Page 10-30-2.) Slide the motor carrier toward the rear and remove the
rear drive chain.
Remove the fluid from the chaincase. (See CHAINCASE
on Page 40-30-1.) NOTE: For easier access for the motor carrier
coming out and going into the chaincase, tie
Remove the center chaincase cover. (See Center Cover
the front drive chain to the chaincase with a
wire [Figure 30-31-2].
Remove the brake disc. (Single speed loaders only) (See
Axle, Sprocket And Bearings Removal And Installation on Slide the motor carrier out of the chaincase far enough to
Page 40-20-4.) install a chain and chain hoist to the carrier [Figure 30-
31-2].
Remove the front axle sprocket. (See Axle, Sprocket And
Bearings Removal And Installation on Page 40-20-4.) NOTE: When installing the motor carrier into the
loader, use caution to protect the wheel speed
If the motor carrier is removed from the right side, remove washer from damage.
the lift arm bypass valve, (See Removal And Installation

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D)
Ref. Description
1. Snap Ring
2. Bearing
3. Race
4. Seal
5. Housing
6. Speed Washer
7. Shaft
8. Cover
7
5

6 8
2 3
4 3
2
1
PE3328SA

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D) Figure 30-31-5
Disassembly
Figure 30-31-3
P-28155

P5760 shaft.
Figure 30-31-6
Remove the large O-ring from the groove (Item 1)
[Figure 30-31-3] in the housing.

Figure 30-31-4
P5766
Use a hydraulic press, remove the shaft from the housing

P-76540 [Figure 30-31-6].
Put the motor carrier in a hydraulic press [Figure 30-31-

4].
Put a small amount of pressure on the shaft to release

the pre-load on the snap ring.

Disassembly (Cont’d)
Figure 30-31-7
P-28158
Use the hydraulic press to remove the bearing from the

P-76462 shaft [Figure 30-31-9].
Figure 30-31-10
NOTE: The bearing (Item 1) [Figure 30-31-7] and the
wheel speed washer (Item 2) [Figure 30-31-7],

must both be replaced, due to damage to the
wheel speed washer from removing the
bearing.
Figure 30-31-8
1
P-76464
Remove the wheel speed washer (Item 1) [Figure 30-31-

10] from the shaft.
P-28157
Install the bearing puller tool (Item 1) [Figure 30-31-8]

under the bearing flange, between the bearing and the
speed washer.

HYDROSTATIC MOTOR CARRIER (SJC) (CONT'D) Assembly
Disassembly (Cont’d) Figure 30-31-12
Figure 30-31-11
2
1
P5764
P-28164
The tool listed will be needed to the following procedure:
Remove the two seals (Item 1) [Figure 30-31-11] from MEL1431 - Seal Driver Tool
the housing.

Install the first seal (Item 1) [Figure 30-31-12] into the
Check the bearing cup (Item 2) [Figure 30-31-11] (both housing with the seal lip facing away from you.
sides) and replace as needed.
figure.
Figure 30-31-13
P5762
Install the second seal (Item 1) [Figure 30-31-13] into the

housing with the seal lip facing toward you.

figure.

Assembly (Cont'd)
Figure 30-31-14
1 2
P-76542
Inspect the wheel speed washer for damage to the

P-76541 magnetic surface (Item 1) [Figure 30-31-15].
NOTE: Do not contact the magnetic surface of the

The wheel speed washer, has one alignment pin (Item 1) wheel speed washer (Item 1) [Figure 30-31-
[Figure 30-31-14]. 15], with a magnet. This may cause damage to

the magnetic surface.
Check the new wheel speed washer with a straight edge,
to be sure it is square [Figure 30-31-14]. Install the wheel speed washer on the shaft [Figure 30-
31-15].
If the washer is more than 0.080 (2,03 mm) out of square,
it must be replaced. Align the one pin (Item 2) [Figure 30-31-15] in the
sprocket.

Assembly (Cont'd)
2
Figure 30-31-16
P-76539
Install the bearing on the shaft [Figure 30-31-16].

P-5769

Use a pipe (Item 1) [Figure 30-31-16] with O.D. that
seats on the I.D. of the bearing.
Install the shaft/bearing assembly into the housing.
Seat the bearing on the shaft, down against the wheel
speed washer. Install the bearing (Item 1) using the tool (MEL1431)
(Item 2) [Figure 30-31-17].
NOTE: The wheel speed washer should be tight on
the shaft. After the bearing is seated. Install the snap ring on the
shaft and reposition the motor carrier to allow back press
operation.
NOTE: Slight press pressure may be used to preload

both bearings. After installation of the snap
ring a back press operation may be necessary
to reduce the preload and remove the
clearance from between the snap ring and the
main bearing.
Use the press and apply pressure to the end of the spline
shaft to reduce preload and clearance.

CHARGE PRESSURE Testing
Charge pressure is a supply of oil to the hydrostatic

pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is also used to operate other hydraulic

functions, such as shifting the auxiliary spool, and to pilot
open the BICS system for the lift and tilt in the main
2 4
hydraulic control valve. 1 3
The charge pressure sender is located on the hydraulic

fan motor. Charge pressure alarm settings are pre- P-43196
programmed into the main controller and are based on
loader type and options installed.
The tools needed to check charge pressure, hydraulic
hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic
gauge 6,9 MPa (69,0 bar) (1000 psi) (Item 3) and adapter
fitting (P/N 93F-5) (Item 4) [Figure 30-40-1].

Figure 30-40-2
3
2
P-43197
Connect the gauge (Item 1), to the adapter fitting (P/N

93F5) (Item 2) [Figure 30-40-2].
Connect the hydraulic hose (Item 3) [Figure 30-40-2] to

the adapter fitting. Tighten all connections.

CHARGE PRESSURE (CONT’D) Figure 30-40-4
Testing (Cont’d)
WARNING
1
to fall and cause injury or death. 2
W-2059-0598 3
P-90301
Raise the loader lift arms and install an approved lift arm
Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-40-4].
Place the loader on jackstands. (See Procedure on Page
10-10-1.) Install the hose (Item 2) [Figure 30-40-4], that was
disconnected from the motor, to the T fitting.
Install the hose (Item 3) [Figure 30-40-4], that is

Figure 30-40-3 attached to the pressure gauge, to the T fitting.
Tighten the hydraulic fittings.

7003031 on Page 10-61-1.)
Start the loader and warm the hydraulic fluid to 140° F.
1 On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is 3,0
- 3,4 MPa (30,0 - 34,1 bar) (435 - 495 psi) with the pump
in neutral.
P-90302
NOTE: If the machine is equipped with SJC option
the charge pressure should be set at 2,5 - 2,8
Disconnect the hydraulic hose (Item 1) [Figure 30-40-3]. MPa (24,8 - 28,2 bar) (360 - 410 psi) at 60°C
(140°F) fluid @ High idle.

CHARGE PRESSURE (CONT’D)
Sender Removal And Installation
Figure 30-40-5
P-90302
Disconnect the wire (Item 1) [Figure 30-40-5] from the

sender.

Remove the sender (Item 2) [Figure 30-40-5] from the
motor.
Installation: Tighten the charge pressure sender to 10 -

10,9 N•m (7.4 - 8.1 ft-lb) torque.
NOTE: Inspect the O-ring on the sender before

installation.

CHARGE PRESSURE (CONT’D) Figure 30-40-7
Adjusting
Non SJC Machines
IMPORTANT
damage the system.
N-17231
I-2003-0888
Figure 30-40-6 Remove the plug, spring and poppet [Figure 30-40-7].
Check the poppet, spring and poppet seat for wear or

1 damage.
Figure 30-40-8

P-43856
1
If the charge pressure is not correct loosen the charge
relief valve plug (Item 1) [Figure 30-40-6].
N-19568
Always use a new O-ring. Tighten the plug to 41 - 68 N•m
There are several different thickness of the shims (Item
1) [Figure 30-40-8] and are used to adjust the charge
pressure.
NOTE: 0,254 mm (0.010 in) is approximately 55,2 kPa

(0,6 bar) (8 psi) increase in pressure. Do not
add more than 5 shims without retesting. If
testing is still low more shims may be added.
On non-SJC equipped loaders the charge pressure at

high idle, with the fluid temperature of 60°C (140°F) is 3,0
- 3,4 MPa (30,0 - 34,1 bar) (435 - 495 psi) with the pump
in neutral.

CHARGE PRESSURE (CONT'D) Figure 30-40-10
Adjusting (Cont’d)
SJC Machines
IMPORTANT
damage the system.
P-64435
I-2003-0888
Figure 30-40-9 Check the poppet and spring for wear or damage.
Inspect the seat inside the hydrostatic pump case for

wear or damage.
There are several different thickness of shims (Item 1)

[Figure 30-40-10] used to adjust the charge pressure.
1 NOTE: 1,0 mm shim (Item 1) [Figure 30-40-10] = 300,0

kPa (3 bar) (43.5 PSI) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.
The charge pressure should be set at 2,5 - 2,8 MPa (24,8

- 28,2 bar) (360 - 410 psi).
P-64431
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-40-9].
NOTE: The pump has been removed for photo clarity.

The charge pressure relief valve is located on
the engine side of the hydrostatic pump when
installed in the loader.
Assembly: Always use a new O-ring. Tighten the plug to

41 - 68 N•m (30 - 50 ft-lb) torque.


HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic

piston pumps connected together. The pumps provide bi-
directional flow to two separate drive motors. The pump
flow and direction are controlled by two hand levers, one
for each pump.
The hydrostatic pump contains replenishing valves. The

function of these valves is to give replacement fluid to the
low pressure side of the hydrostatic circuit. Replacement
fluid is needed because of normal internal leakage and
the controlled flow to the oil cooler for cooling. Another
function of the replenishing valve is to keep high pressure
fluid out of the low pressure side of the hydrostatic circuit.
The hydrostatic pump is located in the center of the

mainframe mounted to the engine flywheel housing.

HYDROSTATIC PUMP (CONT’D) Figure 30-50-2
Remove the hydrostatic pump / engine assembly from

the loader. (See Engine Removal And Installation on
Page 70-10-7.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

60-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-50-2] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.

I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-50-1 Remove the pump pulley and key from the pump drive
shaft.
Figure 30-50-3
1
1
P-90221
Loosen the nut (Item 1) [Figure 30-50-1] on the P-90223

hydrostatic pump drive shaft.
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 Remove the two mounting bolts and nuts (Item 1)
ft-lb) torque [Figure 30-50-3].
Installation: Tighten the mounting bolts and nuts to 88 -

95 N•m (65 - 70 ft-lb) torque.

HYDROSTATIC PUMP (CONT’D) Hydrostatic Pump Startup
Removal And Installation (Cont’d) Follow the hydraulic pump startup procedure. (See
Hydrostatic Pump Startup on Page 30-50-3.)
Figure 30-50-4
P-90224

4] at the hydraulic pump mounting bracket.

Installation: Tighten mounting bolt to 125 - 135 N•m (90
- 100 ft-lb)
Remove the hydrostatic pump from the mounting bracket

and drive belt housing.
BEFORE START UP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before start up. (See Hydrostatic
Pump Startup on Page 30-50-3.)

HYDROSTATIC PUMP (CONT'D) Figure 30-50-6
Replenishing / High Pressure Relief Valve Removal

And Installation 1
Figure 30-50-5
1
2
P-66670
Remove the high pressure relief valve (Item 1) [Figure

30-50-5] and [Figure 30-50-6] from the pump.
P-43857
Assemble: Tighten the plug to 41 - 68 N•m (30 - 50 ft-lb)
torque.
There are four replenishing / high pressure relief valves

(Item 1) [Figure 30-50-5] in the hydrostatic pump Check for damage and replace as needed.
assembly. Two are located at the top of the pumps and
two at the bottom of the pumps for valve function. Check the O-ring (Item 2) [Figure 30-50-6] for damage
and replace as needed.
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the If the high pressure relief valve must be replaced, it must
forward drive loop. be replaced as a complete unit.
The pressure setting for a new high pressure relief valve

is 36,2 MPa (362 bar) (5250 PSI).

HYDROSTATIC PUMP (CONT'D)
Parts Identification (Left Half)
Ref. Description
1
11
4 1. Snap Ring
10 1 2. Washer
5 2 3. Seal
8 3
4. Bearing
3 4 7 1
5. Key
9 1 6. Shaft
26
6 7. Housing
9 8. Plug
9. O-ring
9 10. Cover
10
11. Bolt
12. Pin
12 4 13. Swash Plate
9 14. Wear Plate
15. Piston Assembly
8 11 16. Piston Retainer
17. Retainer
14 18. Block

19. Spring
20. Valve Plate
16 21. Gasket
13 22. Poppet
2
23. Shim
17 15 24. Replenishing/High
Pressure Relief Valve
2 17 25. Coupler
12
2 26. Dust Seal
20
18
19
8
17
9
12
23
19
22 21
24
42
9 9
8
12 4
9
25 9
9 12
24
9
11 D-2428C

HYDROSTATIC PUMP (CONT'D)
Parts Identification (Right Half)
Ref. Description
1. Bolt
2. End Cap
3. Plug 3
4. O-ring 4
5
5. Replenishing/High 3
Pressure Relief Valve 4
6. Gasket 2
7. Bearing 1
1
8. Pin
4
9. Valve Plate
10. Washer 5
6
11. Spring
12. Block
13. Retainer
14. Piston Assembly 7 4 9
3
15. Wear Plate
16. Swash Plate
17. Housing 10

18. Seal
10 8
19. Cover
20. Shaft 13
21. Snap Ring 11
13
22. Dust Seal
23. Piston Retainer 10
23
12
8
15
13
14
22 1
16 3
4
4
7 17
8
19
18
7
4
19
21 4
21
4 20 3
1
7
21
D-2427B

Disassembly
Figure 30-50-7
3
1
1 3
2
N-19571
1 Remove the pump coupler (Item 1) [Figure 30-50-9].

P-43858
Remove the large O-ring (Item 2) [Figure 30-50-9].
Remove the four mounting bolts (Item 1) [Figure 30-50- Remove the two small O-rings (Item 3) [Figure 30-50-9].
7].

Figure 30-50-10
Figure 30-50-8
1 1
N-19550
N-19570
Remove the four bolts (Item 1) [Figure 30-50-10] from

Separate the two hydrostatic pumps [Figure 30-50-8]. the pump housing end cap.

2
1
Figure 30-50-11
N-17194
2
Check the valve plate locating pin (Item 1) [Figure 30-50-
N-19551 13] for wear and replace if needed.
Check the needle bearing (Item 2) [Figure 30-50-13] for

Remove the pump housing end cap (Item 1) [Figure 30- wear and replace if needed.
50-11].

Figure 30-50-14
Remove the gasket (Item 2) [Figure 30-50-11].
Figure 30-50-12
1
1
N-17197
N-17193 Remove the rotating group (Item 1) [Figure 30-50-14]

from the pump.
Remove the valve plate (Item 1) [Figure 30-50-12].
Check the valve plate for wear. (Both Sides.)

3 3
Figure 30-50-15
1 1
3 2
3
2
N-17200
Check the ball guide retainer (Item 1) and washer (Item

N-17198 2) [Figure 30-50-17] for wear and replace as needed.
Remove the four pins (Item 3) [Figure 30-50-17] from the

Remove the slipper guide and pistons (Item 1) [Figure cylinder block.
30-50-15] from the cylinder block.

Check the cylinder block for wear and replace as needed.
Check all the pistons (Item 2) [Figure 30-50-15] for wear
and replace the rotating group as needed. Check pins (Item 3) [Figure 30-50-17] to see if they are
all the same length.
Figure 30-50-16
Figure 30-50-18
N-17199
N-17201
Remove the ball guide retainer (Item 1) [Figure 30-50-

16] from the cylinder block. Remove the thrust plate (Item 1) [Figure 30-50-18] from
the pump housing.

Figure 30-50-19
1
1
2
N-17240
3
Remove the snap ring (Item 1) [Figure 30-50-21] from
N-17481 the pump housing and remove the driveshaft and bearing
from the housing.
Remove the driveshaft key (Item 1) the snap ring (Item 2) Figure 30-50-22
and the support washer (Item 3) [Figure 30-50-19] from

the drive shaft end of the pump.
Figure 30-50-20
N-17241
Remove the snap ring (Item 1) [Figure 30-50-22] from

N-17239 the driveshaft and remove the bearing.
Check the bearing for wear and replace if worn.

Use a seal puller and remove the seal (Item 1) [Figure
30-50-20] from the pump housing.

Figure 30-50-23
N-17244
Remove the O-ring (Item 1) and bearing race (Item 2)

N-17242 [Figure 30-50-25] from the pump housing.
Figure 30-50-26
Check the pump shaft (Item 1) [Figure 30-50-23] for
wear and replace if needed.

Figure 30-50-24
N-17245
1 1
Check the bearing race (Item 1) and O-ring (Item 2)
N-17243 [Figure 30-50-26] for wear and replace as needed.
Remove the four mount bolts (Item 1) [Figure 30-50-24]

from the lower trunnion cover. Remove the cover.

Figure 30-50-27
1
2
1 N-17250
1
Inspect the seal (Item 1) [Figure 30-50-29] in the upper

N-17246 trunnion cover and replace if needed.
Figure 30-50-30
Inspect the dust seal on the pintle shaft.

Remove the four mount bolts (Item 1) from the pump
housing and remove the linkage bracket (Item 2) [Figure
30-50-27].
Figure 30-50-28
N-17248
1 Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-50-30] from the pump housing.
N-17247
Remove the upper trunnion cover (Item 1) [Figure 30-50-

28].

1
Figure 30-50-31
N-17252
2
Tilt the swash plate (Item 1) [Figure 30-50-33] and

N-17249 remove the swash plate and lower bearing from the
pump housing.
Inspect the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-50-31] and replace as needed.

Figure 30-50-32
N-17251
Slide the swash plate from side to side and remove the
tapered roller bearing (Item 1) [Figure 30-50-32] from
the swash plate shaft.

Assembly
Figure 30-50-34
1
1
2
N-17249
Install the tapered bearing (Item 1) [Figure 30-50-36] on

N-17253 the swash plate shaft.
Figure 30-50-37
Install the lower bearing (Item 1) [Figure 30-50-34] on
the swash plate.

Figure 30-50-35
N-17248
Install the bearing race (Item 2) [Figure 30-50-36] and O-

N-17252 ring (Item 3) [Figure 30-50-36] as shown in [Figure 30-
50-37].
Install the swash plate and bearing into the pump

housing [Figure 30-50-35].

Assembly (Cont’d)
Figure 30-50-38
1 N-17245
Figure 30-50-41
N-17247
Install the upper trunnion seal (Item 1) [Figure 30-50-38]

and cover.

Figure 30-50-39
1
N-17244
Install the bearing race (Item 1) [Figure 30-50-40] and O-

ring (Item 2) [Figure 30-50-40] at the lower trunnion as
shown in [Figure 30-50-41].
N-17246
Install the linkage bracket (Item 1) [Figure 30-50-39] and

the four mounting bolts and tighten to 24 - 30 N•m (18 -
22 ft-lb) torque.
Install the dust seals onto the pintle shafts

Assembly (Cont’d)
Figure 30-50-42
N-17241
Install the bearing and snap ring (Item 1) [Figure 30-50-

N-17243 44] on the pump shaft.
Figure 30-50-45
Align the marks on the lower trunnion cover and pump
housing as shown in [Figure 30-50-42].

Install the four mounting bolts and tighten to 24 - 30 N•m
Figure 30-50-43
1
1
N-17240
Install the pump shaft into the pump housing [Figure 30-
50-45].
Install the snap ring (Item 1) [Figure 30-50-45].

N-17242
Install the snap ring (Item 1) [Figure 30-50-43] on the

pump shaft.

Assembly (Cont’d)
Figure 30-50-46
1
1
1
1 2 3
N-17198
Assemble the piston assemblies into the slipper guide.

N-17200 Lubricate the pistons and cylinder block bores and insert
the piston assemblies into the cylinder bores [Figure 30-
50-48].
Install the four slipper pins (Item 1) [Figure 30-50-46]
into the cylinder block. Lay the pump housing on its side and install the cylinder

block, piston assembly into the housing.
Apply a small amount of grease to the washer (Item 2)
and install into the ball guide retainer (Item 3) [Figure 30- Figure 30-50-49
50-46].
Figure 30-50-47
N-17197
N-17199 Place the pump on a work surface with the end cap
opening up [Figure 30-50-49].
Install the ball guide retainer and washer (Item 1) [Figure

30-50-47] onto the slipper holddown pins.

Assembly (Cont’d)
Figure 30-50-50
1
1
2
N-17193
Coat the backside of the valve plate with petroleum jelly

N-17194 to hold it in position and install the valve plate onto the
charge pump, bronze face up [Figure 30-50-52].
Replace the needle bearing (Item 1) and valve plate The notch (Item 1) [Figure 30-50-52] on the valve plate
locating pin (Item 2) [Figure 30-50-50] in the charge must engage the locating pin.

pump.
Figure 30-50-53
Figure 30-50-51
2
1
N-19551
N-17196
Coat a new end cap gasket (Item 1) [Figure 30-50-53]

The bearing cage (Item 1) [Figure 30-50-51] will with petroleum jelly and install onto the end cap.
protrude from 2,0 - 2,5 mm (0.08 - 0.10 in) from the
surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

50-51] will protrude from 4,19 - 4,70 mm (0.165 - 0.185
in) from the surface of the charge pump.

Assembly (Cont’d)
Figure 30-50-54
1 1
N-19570
Install the two pumps together [Figure 30-50-56].

N-19550
Figure 30-50-57
Install the valve plate and end cap on the pump housing.
Tighten the bolts (Item 1) [Figure 30-50-54] to 47 - 61

N•m (35 - 45 ft-lb) torque. 1
Figure 30-50-55
1
1
3 P-43858
2 Tighten the four bolts (Item 1) [Figure 30-50-57] to 47 -

1 61 N•m (35 - 45 ft-lb) torque.
N-19571
Install the two small O-rings (Item 1) [Figure 30-50-55].
Install the large new O-ring (Item 2) [Figure 30-50-55].
Install the pump coupler (Item 3) [Figure 30-50-55].


HYDROSTATIC PUMP (SJC) The servo piston strokes the swash plate in the rotating
group. The rotating group generates flow to the A or B
Description ports on the hydrostatic pump. The flow from the A and B
ports is sent to the hydrostatic drive motors where
The SJC hydrostatic pump is a fully proportional dual forward or reverse drive motor rotation is obtained.
piston pump in one pump casing. The endcaps are
removable to gain access to the rotating assemblies. There are swash plate angle sensors on the bottom of
the pump that monitor swash plate movement.
The hydraulic controllers are fed charge pressure from an
external charge pump. 12 volt electrical solenoids shift a Ports are labeled on the hydrostatic pump casting.
spool in the hydraulic controller that directs flow to a
servo piston.
Figure 30-51-1

P-90206
A,B Service Line Ports (High Pressure Outlet Ports to Drive Motors)
T1 Case Drain Port
MA Operating Pressure of “A” Port
MB Operating Pressure of “B” Port
R Air Bleed Port
X1,X2 Control Pressure Gauge Port
G Charge Pressure Inlet Port
MG Gauge Port For Charge Pressure

HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-51-3
Hydraulic Controller Removal And Installation
The loader’s right hand side hydraulic controller can be

removed with the hydrostatic pump still in the loader. The
loader’s left hand side hydraulic controller can only be 1
removed when the hydrostatic pump is separated from
the engine / hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
1
Raise the lift arms and install an approved lift arm P-90239
Place the loader on jackstands. (See Procedure on Page Disconnect the electrical harness connectors (Item 1)
10-10-1.) [Figure 30-51-3] from both sides of the hydrostatic
pump.
Removal:
WARNING

of the frame before running the engine for service. IMPORTANT
fall or move and cause injury or death. When repairing hydrostatic and hydraulic systems,
W-2017-0286 clean the work area before disassembly and keep all
Raise the operator cab. (See Raising on Page 10-30-2.) tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
Figure 30-51-2 I-2003-0888
Figure 30-51-4
1
1
1
P-90207
P-90208
Locate the two hydraulic controllers (Item 1) [Figure 30-
51-2] on the hydrostatic pumps.
Remove the four mount bolts (Item 1) [Figure 30-51-4]
from the hydraulic controller.

HYDROSTATIC PUMP (SJC) (CONT'D) Use a small amount of grease on a new gasket and
install the gasket on the hydraulic controller (Item 1)
Hydraulic Controller Removal And Installation [Figure 30-51-5].
(Cont'd)
Figure 30-51-7
Figure 30-51-5
1
1 2
3 1
P-90210
P-90210
Alternately tighten bolts (Item 1) [Figure 30-51-7] to 10,4

Remove the controller (Item 1) [Figure 30-51-5] from the N•m (7.7 ft-lb) torque. Ensure bolts are tightened to

pump. specifications.
Remove the controller gaskets (Item 2) [Figure 30-51-5] NOTE: When a hydraulic controller is replaced, the
from the pump. hydrostatic pumps must be calibrated. (See
Hydraulic Controller Neutral Adjustment on
Installation: Page 30-51-26.)
1
2 2
P-90209 P-64978
NOTE: Do NOT remove the three screens (Item 2) With the engine running and the loader on jack stands:
[Figure 30-51-6] they will be damaged during Bleed the trapped air in the controller by loosening the
removal and must be replaced. small set screw (Item 1) [Figure 30-51-8] a maximum of
2 turns. Leave the screw loose until oil comes dripping
Be sure the feedback lever (Item 3) [Figure 30-51-5] is in out of the set screw. Tighten set screw to 2 N•m (18 in-lb)
the center of the servo piston groove (Item 1) [Figure 30- torque.
51-6].
Repeat the bleed procedure for all the solenoids.


Page 70-10-7.)
Remove the Hydraulic Pump. (See Removal And

Remove the Drive Belt. (See DRIVE BELT on Page 30- 1

60-1.)
P-90222
IMPORTANT
Use a puller (Item 1) [Figure 30-51-10] to loosen the
When repairing hydrostatic and hydraulic systems, pulley from the pump drive shaft.
parts clean. Always use caps and plugs on hoses, NOTE: DO NOT strike puller or pump shaft with a
tubelines and ports to keep dirt out. Dirt can quickly hammer. Internal pump damage may result.
damage the system.

I-2003-0888 Remove the nut and washer from the pump drive shaft.
Figure 30-51-9 Remove the pump pulley from the pump drive shaft.
Figure 30-51-11
1
1
P-90221
P-90223
Loosen the nut (Item 1) [Figure 30-51-9] on the
hydrostatic pump drive shaft.
Remove the two mounting bolts and nuts (Item 1)
Installation: Tighten the nut to 258 - 325 N•m (190 - 240 [Figure 30-51-11].
ft-lb) torque

HYDROSTATIC PUMP (SJC) (CONT'D)
Figure 30-51-12
P-90224

12] at the hydraulic pump mounting bracket.

Installation: Tighten mounting bolt to 125 - 135 N•m (90
- 100 ft-lb)
Remove the hydrostatic pump from the mounting bracket

and drive belt housing.
BEFORE START UP: Fill the hydrostatic pump with

hydraulic oil. This will remove trapped air in the
hydrostatic pumps before start up. (See Hydrostatic
Pump Start Up on Page 30-51-6.)

Hydrostatic Pump Start Up
Before putting a hydrostatic pump back into operation,

the hydrostatic pump should be filled with hydrostatic
fluid. This should be performed when installing a new
hydrostatic pump or a pump that has been disassembled.
Starting a hydrostatic pump dry may cause premature

wear or permanent pump damage.
Under normal operation, the charge pump will keep the

hydrostatic pumps filled.
Filling the hydrostatic pump is best done by removing a

plug at the top of the hydrostatic pump. A clean funnel
should be used to avoid washing contaminants into the
hydrostatic pump. The goal is to fill the hydrostatic pump
as much as possible before start up.
Figure 30-51-13

1
P-90226
Remove the air bleed plugs (Item 1) [Figure 30-51-13].
BEFORE START UP: Fill one of the air bleed ports with
new hydraulic oil until the hydraulic oil flows out of the
other air bleed port. This will remove trapped air in the
hydrostatic pumps before start up.
Assembly: Tighten plugs to 25 N•m (18 ft-lb) torque.

3 1
1. O-ring 5 4
2. Bolt
3. End Housing 7
4. O-ring 6
5. Right Rotating Assembly 8
6. Timing Pin
7. Bearing
8. Spacer/Coupler
9. Pin
10. Positioning Pin
11. O-ring 10
12. O-ring 11 9 2
13. Position Sensor 12
14. Washer 13
15. Bolt 14
15
16
22 17
21 19
24

23
20 18
26
18
25 27
19
29 26
16. Steel Cover

17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
6 21. Bolt
2 7 22. Plug
23. Plug
24. Dowel Pin
28 25. Charge Pressure Relief
26. Left Servo
4 27. Right Servo
28. Left Rotating Assembly
29. End Housing
P-90240

High Pressure Relief And Bypass Valve
Figure 30-51-14
1
1
P-64437
Check the valve seat surface (Item 1) [Figure 30-51-16]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-51-16] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-51-14] in the back of the hydrostatic pump.

Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-51-14].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 150 - 170 N•m (111 - 125 ft-lb) replacement is required, replace as an assembly.
torque.
Factory setting on the relief valve is 36,2 MPa (362 bar)
Figure 30-51-15 (5250 PSI).
4
3
2 1
P-64436
Check the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-51-15], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-51-15]

from the valve cap.
Check the conical spring (Item 4) [Figure 30-51-15] to

ensure it is not broken or flattened.

Charge Relief Valve
Figure 30-51-17 3 4
2 5
1
1 P-64435
Inspect the poppet (Item 1) and the mating seat (Item 2)

P-64431 [Figure 30-51-19] for damage or foreign material. Ensure
the poppet moves freely in it’s bore.
The charge relief valve (Item 1) [Figure 30-51-17] is Inspect the sealing ring (Item 3) [Figure 30-51-19] and
located on the back of the hydrostatic pump. the mating seat in the pump housing for damage or

foreign material.
Remove the charge relief valve.
Inspect the spring (Item 4) and the charge relief valve
Assembly: Tighten charge relief valve to 70 N•m (52 ft- shims (Item 5) [Figure 30-51-19].
lb) torque.
NOTE: 1,0 mm shim (Item 5) [Figure 30-51-19] = 296,5
Figure 30-51-18 kPa (3 bar) (43.5 psi) in pressure change.
Adding shims increases charge pressure.
Removing shims decreases charge pressure.
1
P-64435
Check and replace the O-ring (Item 1) [Figure 30-51-18].

HYDROSTATIC PUMP (SJC) (CONT'D) Note the connectors facing each other.
Disassembly And Assembly Figure 30-51-22

Page 70-10-7.)
1
Remove the hydrostatic pump. (See Removal And
Figure 30-51-20
2
P-90228
1 1 Remove the mounting bolts (Item 1) for the swash plate

angle sensor (Item 2) [Figure 30-51-22].
Assembly: Tighten bolts to 3,1 N•m (27.4 in-lb) torque.

P-90226
Remove the hydraulic controllers (Item 1) [Figure 30-51-

20]. (See Hydraulic Controller Removal And Installation
on Page 30-51-2.)
Figure 30-51-21
3 3
2 2
1 1
3
3
P-90227
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-51-21].
Remove the two bolts (Item 3) and the steel cover (Item
2) [Figure 30-51-21] from both sides.
Assembly: Tighten bolts to 51 N•m (38 ft-lb) torque.


3
1
Figure 30-51-23
2 2
1
1
P-64445
Left End Housing

P-90217
Figure 30-51-26
Assembly: Note the slotted portion (Item 1) of the 3 1

positioning pin tightly fits the machined section on the

swash plate angle sensor shaft (Item 2) [Figure 30-51-
23].
Figure 30-51-24
2
1
P-64447
Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
[Figure 30-51-25] and [Figure 30-51-26].
P-90218 Assembly: Alternately, tighten mount bolts to 130 N•m

(96 ft-lb) torque.
Check and replace the O-ring (Item 1) [Figure 30-51-24].
Right End Housing

Figure 30-51-27
P-64466
Ensure servo follower (Item 2) [Figure 30-51-28] is

P-64464 swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-51-29].
Pull the end housings from the case housing [Figure 30- Figure 30-51-30
51-27].

Figure 30-51-28
1 1 2
2
P-64463
P-64465 Assembly: Ensure dowel pin (Item 1) is aligned with hole

in case housing (Item 2) [Figure 30-51-30] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-51-28].

Figure 30-51-31
RIGHT SIDE
P-64454
Figure 30-51-32

LEFT SIDE
P-64501
Remove valve plate (Item 1) [Figure 30-51-31] and

[Figure 30-51-32] from the case housing.
Inspect valve plate for scratches or scoring. Replace a

valve plate if the scratches are deep enough to catch with
a fingernail.
NOTE: Pay attention to the notches (Item 2) [Figure

30-51-31] and [Figure 30-51-32] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.


LEFT SIDE
Figure 30-51-33 1
2
RIGHT SIDE
1 P-64503
2
Assembly: Align the timing pin (Item 1) [Figure 30-51-
P-64455 33] and [Figure 30-51-34] in the case housing with the
notch (Item 1) [Figure 30-51-35] and [Figure 30-51-36]
that does not go through the valve plate.
Figure 30-51-34
Align the shoulder of the roller bearing (Item 2) [Figure

LEFT SIDE 30-51-33] and [Figure 30-51-34] with the beveled edge
on the valve plate (Item 2) [Figure 30-51-35] and [Figure
30-51-36].
NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.
1
2
P-64502
Figure 30-51-35
RIGHT SIDE
1
2
P-64456

Figure 30-51-37
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-51-39].

B25012
Figure 30-51-40
Right Side Rotating Group [Figure 30-51-37].

Figure 30-51-38
1
P-64475
Remove the pistons (Item 1) [Figure 30-51-40] from the

B25011 rotating block.
Left Side Rotating Group [Figure 30-51-38].


1
Figure 30-51-41
P-64471
Remove the spherical washer (Item 1) [Figure 30-51-

P-64476 43].
Figure 30-51-44
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-51-41] in the
1

slippers, are not plugged.
Figure 30-51-42
1
P-64472
Inspect the pins (Item 1) [Figure 30-51-44]. They should

be all the same length. Do not remove.
P-64477
Inspect the mating surface of the spherical washer for

scoring or scratches (Item 1) [Figure 30-51-42].


3
Figure 30-51-45
1
1
P-64479
Inspect mating surface for the slippers on the swash

P-64474 plate (Item 1) [Figure 30-51-47].
Remove the swash plate from the endcap housing (Item

Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-51-47].
1) [Figure 30-51-45].

Remove the slide ring (Item 3) [Figure 30-51-47], ensure
Figure 30-51-46 it pivots freely.
Figure 30-51-48
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-51-46] where the valve plate seals. Ensure
there is no scratches or scoring. Assembly: Carefully align bearing pin eyelets (Item 1)
into holes in endcap housing (Item 2) [Figure 30-51-48].
Visually ensure spring (Item 2) and c-clip (Item 3) [Figure
30-51-46] are not bent or damaged.

Disassembly And Assembly (Cont'd) 2

1 1
Figure 30-51-49
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-51-

P-64481 51].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-51-51] on them. The edges face towards
swash plate (Item 1) [Figure 30-51-49]. the outside of the endcap housing

Figure 30-51-50 Inspect bearing surfaces for scratches or scoring.
Remove the positioning pin (Item 3) [Figure 30-51-51].

2
Figure 30-51-52
2 1
P-64482
Remove the shell bearing (Item 1) [Figure 30-51-50].

P-64485
Inspect individual roller bearings and machined surfaces
(Item 2) [Figure 30-51-50] on swash plate.
Replace O-ring (Item 1) [Figure 30-51-52].
Inspect wear surfaces (Item 2) [Figure 30-51-52] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.

Figure 30-51-53
LEFT SIDE
1
P-76742
The pump seal (Item 1) [Figure 30-51-55] is removed by

P-64486 inserting a screw into the seal and prying out.
Figure 30-51-56
Figure 30-51-54
RIGHT SIDE

1
P-64488
P-76743
The drive shaft can be tapped out of the end housing with
Remove the snap ring (Item 1) [Figure 30-51-53] and a rubber mallet.
[Figure 30-51-54] from the end housing.
Inspect wear surfaces for scratches, and inspect splines
for excessive wear.
Inspect bearing (Item 1); if bearing needs replacement,

remove snap ring (Item 2) [Figure 30-51-56] and remove
bearing.

Figure 30-51-57
1 1
P-90232
Remove servo piston mounting bolts (Item 1) [Figure 30-

51-59].
Installation: Tighten bolts to 10,4 N•m (7.7 ft-lb) torque.
Figure 30-51-60

B25013
Servo Piston Assembly [Figure 30-51-57].

1
The Servo Piston Assembly [Figure 30-51-57] cannot be
removed unless the hydraulic controller and rotating
group is removed first.
Figure 30-51-58
P-90231
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-51-60].
P-64490
Measure and record servo piston depth at the adjustment

screw [Figure 30-51-58].

Figure 30-51-61
P-64466
Assembly: Align the servo piston so the guide slot

P-90237 (Item 1) [Figure 30-51-63] is parallel to the driveshaft
centerline. Measure with a straight-edge [Figure 30-51-
62].
Slide the servo piston assembly out of the bore. [Figure
30-51-61]. Figure 30-51-64

Figure 30-51-62
2
1
P-64493
P-64467
Remove the bushings (Item 1), seals and O-rings (Item
2) [Figure 30-51-64] from the pump housing.

Figure 30-51-65 1
2
P-64496
3 Remove the servo cover (Item 1) [Figure 30-51-67] from

P-64494 the servo piston.
Figure 30-51-68
Each servo has a pair of bushings (Item 1), O-rings (Item
2) and square-cut seals (Item 3) [Figure 30-51-65].

Figure 30-51-66
P-64497
1
Remove snap ring (Item 1) [Figure 30-51-68] from the
P-64495 servo piston.
Remove the lock nut (Item 1) [Figure 30-51-66] from the

servo piston.
Assembly: Tighten lock nut to 30 N•m (22 ft-lb) torque.

HYDROSTATIC PUMP (SJC) (CONT'D) Mechanical Neutral Adjustment
Disassembly And Assembly (Cont'd) The pump mechanical neutral adjustment sets the
position of the servo piston and pump swash plate
Figure 30-51-69 relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
1 disassembled for servicing the servo piston and the
2 setting has been disrupted.

10-10-1.)
WARNING
P-64498
W-2017-0286
Remove the piston stop adjustment mechanism (Item 1)
[Figure 30-51-69] from the servo piston. Raise the lift arms, and install an approved lift arm

Inspect mechanism for broken parts.
Replace O-ring (Item 2) [Figure 30-51-69]
Figure 30-51-70 TOOL KIT-MEL1563 on Page 10-60-1.)
Disconnect the swash plate angle sensors in the

electrical harness. This prevents unwanted swash plate
movement error codes from occurring during
adjustments. Disconnecting the sensors does not have to
be done directly at the sensor, follow the harness back to
2 find an accessible connector to disconnect.
1 Disconnect the speed sensors located on the top of the

motor carriers. This prevents uncommanded wheel
movement error codes from occurring during
adjustments.
P-64502
Bearings (Item 1) [Figure 30-51-70] in case housing are

WARNING
replaced by using a press and bearing driver.
Inspect center coupler (Item 2) [Figure 30-51-70]. sufficient force to enter a person’s body by
immediately.
W-2145-0290

Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-71
1
P-64438
Remove the plugs (Item 1) [Figure 30-51-73] from the

P-64973 MA ports on the bottom of the pump, and install 51,7
MPa (517 bar) (7500 psi) pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-51-71] Figure 30-51-74

between port X1 and port X2 on each side of the

hydrostatic pump, to equalize the pressures on both ends
of the servo pistons.
Figure 30-51-72
1 1
1
1
1 1
P-90243
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-51-74]. Plug the ports with metal caps. The
P-90242 caps must be able to handle at least 51,7 MPa (517 bar)
(7500 psi). Plugging the A and B ports eliminates leakage
at the drive motors from causing errors in the pump
Remove the plugs (Item 1) [Figure 30-51-72] from the mechanical neutral setting.
MB ports on the front side of the pump, and install 51,7
MPa (517 bar) (7500 psi) pressure gauges.

Mechanical Neutral Adjustment (Cont’d)
Figure 30-51-75
1 1
P-90238
Turn the adjustment screw (Item 1) [Figure 30-51-77]

P-90226 counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the
adjustment screw.
Loosen the pump neutral adjustment lock nut (Item 1)
[Figure 30-51-75]. Figure 30-51-78

Start the loader using the remote start tool and run at idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-51-76
P-90238

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-90238

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

HYDROSTATIC PUMP (SJC) (CONT'D) Hydraulic Controller Neutral Adjustment
Mechanical Neutral Adjustment (Cont’d) The hydraulic controller neutral adjustment, aligns the
pump swash plate and the control spool so that a zero
Figure 30-51-79 angle control setting provides a zero degree swash plate
setting. This adjustment should be performed whenever
any part of the control or swash plate mechanisms are
adjusted or removed or after the pump mechanical
neutral setting is adjusted. Ensure the pump mechanical
neutral setting is correct before performing hydraulic
controller neutral adjustments.
NOTE: Procedure is shown for the left side hydraulic

2
controller. Procedure is the same for the right
side hydraulic controller, except you
disconnect the electrical connectors for the
1 right side hydraulic controller and connect
pressure gauges in the X1 and X2 ports on the
right side of the pump.
P-90238
10-10-1.)
While holding the adjustment screw (Item 1) in position,
tighten the lock nut (Item 2) [Figure 30-51-79] to 30 N•m

(22 ft-lb) torque.
Shut loader OFF.

WARNING
Remove the hydraulic hose from the X1 and X2 ports on Put jackstands under the front axles and rear corners
the pump. Install the plugs and tighten to 25 N•m (18 ft- of the frame before running the engine for service.
lb) torque. Failure to use jackstands can allow the machine to
Remove the pressure gauges from the MA and MB ports W-2017-0286
on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque. Raise the lift arms, and install an approved lift arm
NOTE: The Hydraulic Controller Neutral Adjustment
must be performed whenever the Mechanical Raise the operator cab. (See Raising on Page 10-30-2.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-51- Connect the remote start tool. (See REMOTE START
26.) TOOL KIT-MEL1563 on Page 10-60-1.) or (See
7003031 on Page 10-61-1.)
WARNING
immediately.
W-2145-0290

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-80
P-64975
1 Install 3,4 MPa (34,5 bar) (500 psi) pressure gauges in

P-90239 the X1 and X2 ports pertaining to the side of the
hydrostatic pump you are adjusting.
Disconnect the hydraulic controller connectors (Item 1) Figure 30-51-83

[Figure 30-51-80] from the loader wiring harness for the

hydraulic controller you are adjusting.
Figure 30-51-81
1
1
P-90236
Loosen the locking screw (Item 1) [Figure 30-51-83].

P-90226
Start the loader using the remote start tool and run at an
idle.
Remove the X1 plug (Item 1) and X2 plug (Item 2)
[Figure 30-51-81] pertaining to the side of the hydrostatic
pump you are adjusting.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297

Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-51-84
P-90236

P-90236 clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
clockwise, until one of the gauges registers an increase Figure 30-51-87

in system pressure. Mark the position of the adjustment
screw.
Figure 30-51-85
1
2
P-90236
While holding the adjustment screw (Item 1) in position,

P-90236 tighten the locking screw (Item 2) [Figure 30-51-87] to
6,1 N•m (4.5 ft-lb) torque.
Turn the adjustment screw (Item 1) [Figure 30-51-85] Shut loader OFF.
counterclockwise, until the other gauge registers an
increase in system pressure. Mark the position of the Remove the pressure gauges from the X1 and X2 ports
adjustment screw. on the pump. Install the plugs and tighten to 25 N•m (18
ft-lb) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See

CALIBRATION on Page 60-160-1.)

DRIVE BELT Belt Replacement
Belt Adjustment Stop the engine and open the rear door.
The drive belt does not need adjustment. The belt has a Remove the battery. (See Removal And Installation on
spring loaded idler which constantly maintains the correct Page 60-20-1.)
belt tension.
Figure 30-60-1
P-85518

Remove the drive belt shield bolt (Item 1) [Figure 30-60-
1].
Figure 30-60-2
P-90467
Do NOT loosen the drive belt shield mounting bolts (top

bolt shown) (Item 1). Slide the drive belt shield (Item 2)
toward the back of the loader to unseat the shield from
the top and bottom drive belt shield mounting bolts.
Remove the drive belt shield (Item 2) [Figure 30-60-2].

DRIVE BELT (CONT’D) Figure 30-60-5
Belt Replacement (Cont’d) Top Mounting Bolt
Figure 30-60-3
1
P-90468A
2
Bottom Mounting Bolt
P-90470
Loosen the spring loaded idler adjustment bolt (Item 1).

Insert a 12,7 mm (0.50 in). breaker bar (Item 2) [Figure
30-60-3] into the slot provided in the stop arm as shown P-90469A

and push breaker bar down to release tension on drive
belt.
Position the drive belt shield over the drive belt shield
Tighten the adjustment bolt (Item 1) [Figure 30-60-3] to mounting bolts and slide the drive belt shield toward the
hold the spring loaded idler off the drive belt. front of the loader to fully seat the shield onto the top and
bottom mounting bolts (Items 1 and 2) [Figure 30-60-5].
Remove the drive belt from the hydrostatic pump pulley
and flywheel pulley. Inspect the pulleys for wear.
Figure 30-60-6
Install new drive belt.
Loosen the spring loaded idler adjustment bolt (Item 1)
[Figure 30-60-3] and allow the idler to contact the drive
belt.
Figure 30-60-4 1
P-85518
Install the drive belt shield bolt (Item 1) [Figure 30-60-6].
Install the battery. (See Removal And Installation on

Page 60-20-1.)
P-90471

Move the breaker bar to adjust the stop arm until a gap of
3,2 mm (0.125 in) (Item 1) [Figure 30-60-4] is achieved.
Tighten the spring loaded idler adjustment bolt (Item 1)
[Figure 30-60-3] to 105 - 115 N•m (78 - 85 ft-lb) torque.

DRIVE BELT (CONT’D)
Stop Adjustment
Stop the engine and open the rear door.
Figure 30-60-7
P-90470

Loosen the spring loaded idler adjustment bolt (Item 1)
and insert a 12,7 mm (0.50 in) breaker bar (Item 2)
[Figure 30-60-7] into the slot provided in the stop arm as
shown.
Figure 30-60-8
P-90471
Move the breaker bar to adjust the stop arm until a gap of
3,2 mm (0.125 in) (Item 1) [Figure 30-60-8] is achieved.
Tighten the spring loaded idler adjustment bolt (Item 1)

[Figure 30-60-7] to 105 - 115 N•m (78 - 85 ft-lb) torque.

DRIVE BELT (CONT’D) Installation: Apply Loctite® 242 to the mounting bolts
(Item 1) [Figure 30-60-10].
Tensioner Pulley Removal And Installation
Tensioner Pulley Disassembly And Assembly
Remove the engine air cleaner. (See Housing Removal
And Installation on Page 70-40-1.) Figure 30-60-11
Remove the belt. (See Belt Replacement on Page 30-60-

1.)
1
Figure 30-60-9
1 2
2 3
P-90306
Loosen the two bolts (Item 1) [Figure 30-60-11] but do

not remove.
P-85520
Release the spring tension by allowing the adjustment
plate (Item 2) to slide past the tensioner pulley stop (Item
Loosen the spring loaded idler adjustment bolt (Item 1). 3) [Figure 30-60-11].
Insert a 12,7 mm (0.50 in) breaker bar (Item 2) [Figure
30-60-9] into the slot provided in the stop arm as shown Remove the two bolts (Item 1) and the adjustment plate
and push breaker bar down to release tension on drive (Item 2) [Figure 30-60-11].
belt.
Figure 30-60-12
Tighten adjustment bolt (Item 1) [Figure 30-60-9] to hold
the spring loaded idler off the drive belt.
Figure 30-60-10
1
2
1
P-90304
Remove the pivot sleeve (Item 1) [Figure 30-60-12].

P-85741

10].
Remove the tensioner pulley (Item 2) [Figure 30-60-10].

DRIVE BELT (CONT'D)
Tensioner Pulley Disassembly And Assembly

(Cont’d)
Figure 30-60-13
P-90303
Disassembly the tensioner pulley as shown [Figure 30-

60-13].
Check the parts for wear and replace as needed.
NOTE: The wheel and arm assembly (Item 1) [Figure

30-60-13] are not serviceable and must be
replaced as a complete assembly.


TWO-SPEED / BRAKE VALVE
Description
Figure 30-70-1
P-90507
The two-speed / brake valve (Item 1) [Figure 30-70-1] is

located on top of the chaincase in front of the hydrostatic

pump. The high range is selected by a switch located on
the right handle for manual loaders and on the left
joystick for SJC loaders.
When the high range is selected, the two-speed solenoid

is energized by the Bobcat Controller. The valve shifts
and directs charge pressure oil to the shift spool in each
motor. The charge pressure hydraulic oil shifts the spools
allowing the motors to move into high range. When low
range is selected, the solenoid is de-energized and the
shift spools are spring returned to low range.

TWO-SPEED / BRAKE VALVE (CONT'D) Figure 30-70-2
Valve Block Removal And Installation

1
DANGER
2
2
P-90437
P-90328
AVOID DEATH Remove the steering shock (Item 1) [Figure 30-70-2].

tubeline, hose, fitting, component or a part failure Mark all hydraulic hoses for proper installation.
• Keep out of this area when lift arms are raised Disconnect the five hydraulic hoses (Item 2) [Figure 30-
unless supported by an approved lift arm 70-2] from the brake / two speed valve block.

D-1009-0409 Figure 30-70-3
WARNING
Never work on a machine with the lift arms up unless 1
W-2059-0598
P-90425
WARNING
Disconnect the three hydraulic hoses (Item 1) [Figure
Put jackstands under the front axles and rear corners 30-70-3] from the brake / two speed block.
W-2017-0286

1.)

TWO-SPEED / BRAKE VALVE (CONT'D)
Valve Block Removal And Installation (Cont’d)
Figure 30-70-4
P-90444

30-70-4] from the two speed solenoid.

30-70-4] from the brake solenoid and make-up valve.
Figure 30-70-5
P-90446

5] from the valve block.

Valve Block Disassembly And Assembly
Figure 30-70-6 1
1
N-22580
Check the back-up washers (Item 1) and O-rings (Item 2)

P-90548 [Figure 30-70-8] for wear and replace as needed.
Figure 30-70-9
Mark all hydraulic hoses and fittings for proper
installation. 1

Remove the hydraulic fittings (Item 1) [Figure 30-70-6]
from the valve block.
Figure 30-70-7 4
3
1
2
P-90550
Remove the two bolts (Item 1) from the brake valve

solenoid (Item 2) [Figure 30-70-9].
Remove the electrical solenoid nut (Item 3) from the

P-90549 make-up solenoid (Item 4) [Figure 30-70-9].
Assembly: Tighten the nut to 6,78 - 9,49 N•m (60 - 84 in-

Remove the check valves (Items 1 and 2) [Figure 30-70- lb) torque.
7] from the two-speed valve.
NOTE: The check valves (Items 1 and 2) [Figure 30-

70-7] are interchangeable.

Valve Block Disassembly And Assembly (Cont'd)
Figure 30-70-10
P-90552
Remove the make-up solenoid (Item 1) [Figure 30-70-

P-90435 12] from the valve block.
Figure 30-70-13
Use a test meter and test the solenoid coils (Item 1)
[Figure 30-70-10] for resistance.

The resistance value for the solenoid coil can be found
on the electrical schematic.
Figure 30-70-11
1
N-22584
Assembly: Always install new O-rings and back-up

washers [Figure 30-70-13]. Tighten the solenoid valve to
27,1 N•m (20 ft-lb) torque.
P-90551
Use a test meter and test the solenoid coils (Item 1)

[Figure 30-70-10] for resistance.

on the electrical schematic.
Assembly: Always install new O-rings [Figure 30-70-

10].

Valve Block Disassembly And Assembly (Cont'd)
Figure 30-70-14
1
1 P-90547
Use a test meter and test the solenoid (Item 1) [Figure

P-90553 30-70-16] for resistance.

Remove the plugs (Item 1) [Figure 30-70-14] from the on the electrical schematic.
brake / two-speed valve block.

Assembly: Always install new O-rings [Figure 30-70-
Check the O-ring [Figure 30-70-14] on the plugs and 10].
replace as needed.
Figure 30-70-15
P-90554
Remove the two speed solenoid bolts (Item 1) [Figure

30-70-15].

DRAIN MANIFOLD Figure 30-80-2
Description
The drain manifold is an external assembly in the drain

circuit that returns the hydraulic oil to the reservoir.
Drain Manifold Removal And Installation
IMPORTANT 1

P-90485
damage the system. Remove the two bolts (Item 1) [Figure 30-80-2].
I-2003-0888


Figure 30-80-1
P-90484
Remove and plug all hose’s from the drain manifold (Item
1) [Figure 30-80-1].
Disconnect the wiring harness from the oil temperature

switch (Item 2) [Figure 30-80-1].


DRIVE SYSTEM
BRAKE (SINGLE SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Disc Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
BRAKE (TWO-SPEED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-11-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-11-1
DRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Axle, Sprocket And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 40-20-4
Chain Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-9
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Center Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-2
Rear Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-3


BRAKE (SINGLE SPEED) Raise the loader operator cab. (See Raising on Page 10-
30-2.)
Description
Disconnect and remove the engine speed control. (See
The brake is used to hold the machine in place. The Removal And Installation on Page 70-20-1.)
brake is operated by a switch (Item 1) [Figure 40-10-1]
located on the front accessory panel. Remove the control panel from the loader. (See Removal
And Installation on Page 50-100-2.)
The brake is applied by a spring-loaded wedge that drops
into two notched brake discs attached to the motor carrier Remove the center chaincase cover. (See Center Cover
shafts. An electric solenoid is sent power from a relay to Removal And Installation on Page 40-30-2.)
pull the wedge away from the discs. A signal from the
main Bobcat controller holds the wedge away from the Remove the traction lock assembly.
discs.
Figure 40-10-2
The hold signal will be interrupted and the wedge will
drop if the engine rpm drops below 700 rpm, the seat bar
sensor fails or if there is a break in the wires for the brake
solenoid.
1
For more information on the brake. (See TRACTION
LOCK on Page 60-120-1.)
Figure 40-10-1

1
N-19081A
The parking brake discs (Item 1) [Figure 40-10-2] are

1 located beneath the center chaincase cover.
Figure 40-10-3
P-85491
Disc Removal And Installation
WARNING 1
N-19105
support device. Failure to use an approved lift arm Inspect the traction lock guides (Item 1) [Figure 40-10-3]
support device can allow the lift arms or attachment and the brake disc for damage or wear and replace as
to fall and cause injury or death. necessary. (See Inspecting on Page 60-120-3.)
W-2059-0598

BRAKE (SINGLE SPEED) (CONT’D)
Disc Removal And Installation (Cont’d)
Figure 40-10-4
N-19082A
Figure 40-10-5

1
N-19083A
A snap ring pliers with 90° tips are necessary for

removing the parking brake disc.

end of the sprocket on the hydrostatic motor carrier.
Slide the disc (Item 2) [Figure 40-10-4] off the sprocket

(Item 1) [Figure 40-10-5] and remove the disc through
the front chaincase cover.
Reverse the removal procedure to install the disc in the

loader.

BRAKE (TWO-SPEED)
Description
Figure 40-11-1
P-85413
The brake is used to hold the machine in place. The

brake is operated by a switch (Item 1) [Figure 40-11-1]

located on the front accessory panel.
The brake is a spring applied pressure release system,

which is self contained on the end of each drive motor.
The brake block solenoid is sent power from a relay to

open the circuit which releases the charge pressure oil to
the brakes. The charge pressure oil pushes the spring
away from the brake discs allowing the drive motor to
move.
A signal from the main Bobcat controller holds the brake

solenoid open to allow constant flow of the charge
pressure oil to hold the spring away from the brake discs.
When the hold signal is interrupted the solenoid will close

the circuit and the charge oil will be shut off an the spring
will apply the brakes. This will happen if the engine rpm
drops below a set rpm, the seat bar sensor fails or if there
is a break in the wires for the brake block solenoid.
For more information on the brake. (See TWO-SPEED /

BRAKE VALVE on Page 30-70-1.)


DRIVE COMPONENTS
Description

NA1285
The drive components consist of the chaincase, drive

chains, sprockets, axleshafts, hubs, drive motor carrier
and a brake (Single speed only).
The two speed brake is part of the two speed drive motor.
The chaincase is partially filled with hydraulic fluid to

lubricate the chains and bearings.
On the bottom of the chaincase, these is a cover for

access to the fuel tank drain plug.

DRIVE COMPONENTS (CONT'D) Figure 40-20-2
Axle Seal Removal And Installation
The tools listed are needed for the following procedure:
Axle Hub Puller Tool

MEL1407 - Seal Driver Tool
MEL1242 - Power Ram (may be used if desired)

1.)
1
NOTE: If the axle and bearings are being replaced,
also loosen the sprocket mounting bolt inside
the chaincase before lifting and blocking the P4849
loader. (See Axle, Sprocket And Bearings
Install puller (Item 1) [Figure 40-20-2] on the wheel hub.
Remove the tire/wheel assembly. (See Mounting on
Page 10-160-1.)
Remove the front chaincase cover. (See Front Cover

Removal And Installation on Page 40-30-1.) WARNING

Remove the fluid from the chaincase. (See Removing NEVER STAND IN-LINE OF THE HUB WHEN
And Replacing Oil on Page 10-130-1.) REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
Figure 40-20-1 with great force and cause serious injury.
W-2186-0395
Remove the hub from the axle.

2
Figure 40-20-3
1
2
P4850
Remove the bolts (Item 1) [Figure 40-20-1] and plate.
Installation: Tighten the bolts to 240 - 260 N•m (175 -

190 ft-lb) torque. P4848
Remove the two wheel studs (Item 2) [Figure 40-20-1] Remove the key (Item 1) [Figure 40-20-3] from the axle.
across from each other.

DRIVE COMPONENTS (CONT'D)
Axle Seal Removal And Installation
Figure 40-20-4
P4817
Install a slide hammer (Item 1) [Figure 40-20-4] with a

screw tip end into the axle seal.

Remove the axle seal.
Figure 40-20-5
P4814
Installation: Place the seal with the lip facing in [Figure

40-20-5].
Installation: Use a hammer, install the new axle seal

until the tool (MEL1407) is flush with the edge of the axle
tube [Figure 40-20-5].

DRIVE COMPONENTS (CONT'D) Remove the control panel. (See Removal And Installation
on Page 50-100-2.)
Axle, Sprocket And Bearings Removal And
Installation Remove the front chaincase cover. (See Front Cover
procedure: Remove the fluid from the chaincase. (See Removing
And Replacing Oil on Page 10-130-1.)
MEL1242 - Port-a-Power
MEL1202B - Axle Bearing Service Set Figure 40-20-6
NOTE: The procedure shown for removal and

installation of the axle, sprocket and bearings
is for a front axle. This procedure will be the 2
same for the rear axle.
DANGER 1

P-68196
Remove the axle sprocket bolt (Item 1) and backing

P-90328 washer (Item 2) [Figure 40-20-6].
AVOID DEATH Installation: Tighten the axle sprocket bolt to 699 - 726
• Disconnecting or loosening any hydraulic N•m (515 - 535 ft-lb) torque.
can cause lift arms to drop. Remove the axle hub. (See Axle Seal Removal And
• Keep out of this area when lift arms are raised Installation on Page 40-20-2.)
support. Replace if damaged. Figure 40-20-7
D-1009-0409
WARNING
W-2059-0598
Raise the lift arms and install an approved lift arm support P-4158A
Lift and block the loader. (See Procedure on Page 10-10- Install a Port-a-Power ram between the two sprockets
1.) [Figure 40-20-7].

DRIVE COMPONENTS (CONT'D) NOTE: Hold the axle during removal because it will
slide freely after the bearing is removed from
Axle, Sprocket And Bearings Removal And the mounting surface.
Installation (Cont'd)
Figure 40-20-10
Figure 40-20-8
P-4171
P5406A
Press the splined end of the axle free from the bearing
Push the axle out until the ram is at the end of the stroke. [Figure 40-20-10].

Add a spacer and push the axle out again. Repeat this
procedure until the axle is out of the sprocket.
Remove the drive chain from the sprocket.
Remove the sprocket (Item 1) and inner bearing (Item 2)

[Figure 40-20-8].
Installation: Pack the inner and outer bearing with

grease before installing them.
Figure 40-20-9
P-4170
A bearing puller (Item 1) [Figure 40-20-9] is needed to

do the following procedure:
Be sure the bearing puller makes good contact with the

inner race and press the bearing off the mounting surface
of the axle [Figure 40-20-9].

DRIVE COMPONENTS (CONT'D) Use the long driver handle (Item 1) [Figure 40-20-12]
and the bearing cup removal tool to remove the inner
Axle, Sprocket And Bearings Removal And bearing cup.
The bearing cup removal tool must fall into the recess
Figure 40-20-11 behind the bearing cup, drive the cup out of the axle tube
[Figure 40-20-13].
Figure 40-20-13
Bearing Cup
Tool
P-4175
Recess
Installation: Put the spline end of the axle shaft into the
MC-2164

bearing and press the bearing onto the axle.
NOTE: Hold the axle during installation because it

will slide freely after the bearing is pressed
over the splined end of the shaft.
Put a piece of tubing over the axle (Item 1) [Figure 40-

20-11] that contacts inner race of the bearing only.
Press the bearing onto the mounting surface until the

bearing is fully seated [Figure 40-20-11].
Figure 40-20-12
P4812
Use the tools provided in the MEL1202B Axle Bearing

Service Set. A slide hammer is also needed.

DRIVE COMPONENTS (CONT'D) Figure 40-20-16

Installation (Cont'd) 2
1
Figure 40-20-14
P5468A
Use the bearing cup installation tool (Item 1) [Figure 40-

20-16] and (Item 1) [Figure 40-20-17].
P5637
Put the inner cup (Item 2) [Figure 40-20-16] in the axle
tube.
To remove the outer bearing, install a bearing cup

removal tool on the slide hammer. Install the long threaded rod (Item 2) [Figure 40-20-17]
into the axle tube and through the installation tool (Item
Install the slide hammer/tool assembly behind the 1) [Figure 40-20-16].
bearing cup [Figure 40-20-14].
Install the nut (Item 3) [Figure 40-20-16].
Figure 40-20-15
Figure 40-20-17
P4816
P4811
Use the slide hammer to remove the bearing cup from

the axle tube [Figure 40-20-15]. Install the installation tool (Item 1) [Figure 40-20-17] on
the threaded rod. Install the nut.
Hold the inside nut (Item 3) [Figure 40-20-16] with a

wrench and tighten the outside nut [Figure 40-20-17].
Tighten the nut until the bearing cup is seated.
Remove the installation tool and threaded rod.


Figure 40-20-18
P4813
To install the outer bearing cup, install the bearing cup

installation tool on the driver handle.
Install the bearing cup into the axle tube, and put the tool
into the bearing cup.
Hit the driver handle with a hammer until the bearing cup
is seated inside the axle tube [Figure 40-20-18].

DRIVE COMPONENTS (CONT'D) Remove the brake disc. (See Disc Removal And
Chain Removal And Installation
Remove the front or rear axle and sprocket. (See Axle,
Sprocket And Bearings Removal And Installation on
Page 40-20-4.)
DANGER
Figure 40-20-19
P-90328
AVOID DEATH
can cause lift arms to drop. Front Drive
Rear Drive Chain
Chain

P-68194
D-1009-0409
NOTE: It is necessary to remove the rear axle and

drive chain if the front chain has to be
WARNING removed.
Remove the motor carrier. (See Removal And Installation

Never work on a machine with the lift arms up unless on Page 30-30-2.)
W-2059-0598

1.)

on Page 50-100-2.)
Remove the front or rear chaincase cover. (See Front

Cover Removal And Installation on Page 40-30-1.)
Remove the center chaincase cover. (See Center Cover

Remove the fluid from the chaincase. (See Removing

And Replacing Oil on Page 10-130-1.)

Chain Removal And Installation (Cont’d)
Figure 40-20-20
B-13504A
The tool listed is needed for the following procedure:

MEL1246 - Chain Link Tool
Installation: If a new chain is installed, a connector link

must be used to connect the chain together.
Use MEL1246 Chain Link Tool and #120 chain adapter.
Secure the tool and place the connector link in the tool as
shown [Figure 40-20-20].
Turn the threaded rod of the tool and press the connector
link together on the chain [Figure 40-20-20]. Tighten the
threaded rod of the chain link tool to 339 N•m (250 ft-lb)
torque.
WARNING
DO NOT exceed the recommended torque. The tool
may fail under too much torque. Put cloth around the
tool to protect yourself from flying debris.
W-2233-0307

CHAINCASE Figure 40-30-1
Description
3 3
The chaincase contains the drive components.
Front Cover Removal And Installation

1
support device. (See Installing on Page 10-20-1.) 2
Raise the loader operator cab. (See Raising on Page 10-

30-2.) 3
3

on Page 50-100-2.) P-34255
Remove the front chaincase cover mounting screws

DANGER (Item 1) [Figure 40-30-1].
Remove the front chaincase cover (Item 2) [Figure 40-

30-1] from the loader.

NOTE: There are tabs (Item 3) [Figure 40-30-1] on the
side of the cover to help pry the covers off.
Installation: Apply polyurethane sealer to mating

surfaces. Polyurethane sealant should be applied to the
P-90328 screw threads to stop oil leakage. Tighten the mounting
screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
AVOID DEATH
D-1009-0409
WARNING
W-2059-0598

CHAINCASE (CONT’D) Disconnect the lift control cross bar (Item 2) [Figure 40-
30-2] from the lift spool on the main control valve.
Center Cover Removal And Installation
Disconnect the electrical connector (Item 3) [Figure 40-
Raise the loader lift arms and install an approved lift arm 30-2] from the traction lock solenoid.
Remove the crossbar mounting bolt (Item 4) [Figure 40-
Raise the loader operator cab. (See Raising on Page 10- 30-2].
30-2.)
Remove the crossbar and wire harness from the center
chaincase cover.
DANGER
WARNING
P-90328 W-2059-0598
AVOID DEATH

Figure 40-30-3
3
unless supported by an approved lift arm 1
D-1009-0409
2

on Page 50-100-2.)
Figure 40-30-2 1
4
P-90048
Remove the chaincase cover mounting screws (Item 1)

[Figure 40-30-3].
2 1
Remove the center chaincase cover (Item 2) [Figure 40-
3 30-3] from the loader.
NOTE: There are tabs (Item 3) [Figure 40-30-3] on the

Installation: Apply polyurethane sealer to mating

P-90047
surfaces. Polyurethane sealant should be applied to the
screw threads to stop oil leakage. Tighten the mounting
If loader is equipped with SJC, skip to [Figure 40-30-3]. screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
Disconnect the lift control cross bar from the lift pedal
linkage (Item 1) [Figure 40-30-2].

CHAINCASE (CONT’D) Figure 40-30-4
Rear Cover Removal And Installation
1 3
Raise the loader operator cab. (See Raising on Page 10-
30-2.) 2
DANGER 1
3
P-90056
Remove the rear chaincase cover mounting screws (Item

1) [Figure 40-30-4].
P-90328 Remove chain case cover (Item 2) [Figure 40-30-4].

AVOID DEATH NOTE: There are tabs (Item 3) [Figure 40-30-4] on the

can cause lift arms to drop. Installation: Apply polyurethane sealer to mating
• Keep out of this area when lift arms are raised surfaces. Polyurethane sealant should be applied to the
unless supported by an approved lift arm screw threads to stop oil leakage. Tighten the mounting
support. Replace if damaged. screws to 34 - 38 N•m (25 - 28 ft-lb) torque.
D-1009-0409
WARNING
W-2059-0598
If loader is equipped with two-speed, remove the two-

speed valve. (See Valve Block Removal And Installation
on Page 30-70-2.)
Remove the drain manifold. (See Drain Manifold

Disconnect the front steering linkage bars from the rear

linkage bars. (See Removal And Installation on Page 50-
100-2.)
Move the linkage bars to allow adequate space to

remove the rear chaincase cover.


MAINFRAME
SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-3
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Spring Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
Gas Spring Bracket Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-2
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Seat Belt Removal And Installation (Retractable) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1
Seat Belt And Bracket Removal And Installation (Standard) . . . . . . . . . . . . . . . . . . 50-30-2
Seat Belt Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-2
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1


Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-1
Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Lower Cushion Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-2
Lower Cushion Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-3
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-31-4
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-40-5
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
Lever And Wedge Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-4
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-41-5
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
REAR GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1


REAR DOOR (TAILGATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
Striker Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-3
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-3
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-3
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
CONTROL PEDALS AND LINKAGES (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1

Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-2
Floor Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-3
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-9
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-10
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-14
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-18
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-2

CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-1
Handle Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-4
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-5
Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-111-6
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-112-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-112-1
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-112-1
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-112-2
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1

WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1

WINDOW (SIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-4
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
LEFT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-160-1


RIGHT SIDE LOWER PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-170-1
HEADLINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-180-1

SEAT BAR Installation: Tighten the nuts to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Description
The seat bar is the secondary restraint system that has a 3.)
sensor that automatically stops the loader functions until
the seat bar is lowered. Figure 50-10-3
The seat bar is located in the operator cab.
Figure 50-10-1
1
P-90021

2 Remove the seat bar (Item 1) [Figure 50-10-3] from the
operator cab.
P-85653 P-85654 Reverse the above procedure to install the seat bar into
the operator cab.
Raise the seat bar (Item 1) [Figure 50-10-1].
Disconnect the seat bar sensor (Item 2) [Figure 50-10-1]

from the cab harness.
Lower the seat bar.
Figure 50-10-2
P-85652
Remove the seat bar mounting nuts (Item 1) [Figure 50-

10-2] (both sides).

SEAT BAR (CONT'D) Installation: Tighten the mounting bolt (Item 2) [Figure
50-10-4] and [Figure 50-10-5] to 34 - 38 N•m (25 - 28 ft-
Disassembly And Assembly lb) torque.
4 6
5 5
7 4 6
3 3
2 9 8 2 7
10
1
1
P-90022 P-90023

4 4
5 5
9 8
3 6
3 6 2
2 10 7
1
7
1
N-19219 N-19220
Assemble the parts as shown for the left side of the seat Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-4] and [Figure 50-10- bar pivot assembly [Figure 50-10-6] and [Figure 50-10-
5]. 7].
Seat Bar Mount (Item 1) Seat Bar Mount (Item 1)

Mounting Bolt (Item 2) Mounting Nut (Item 2)
Keyed Plastic Bushing (Item 3) Pivot Bushing (Item 3)
Seat Bar (Item 4) Spacer Bushing (Item 4)
Magnetic Bushing Assembly (Item 5) Seat Bar (Item 5)
Pivot Bushing (Item 6) Keyed Plastic Bushing (Item 6)
Sensor Bracket (Item 7) Mounting Bolt (Item 7)
Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9) Installation: Tighten the mounting bolt (Item 7) [Figure
Mounting Nut (Item 10) 50-10-6] and [Figure 50-10-7] to 34 - 38 N•m (25 - 28 ft-
lb) torque.
Installation: Tighten the mounting bolt (Item 9) [Figure
50-10-4] and [Figure 50-10-5] to 5,6 - 7,9 N•m (50 - 70
in-lb) torque.

SEAT BAR (CONT'D) Figure 50-10-9
Compression Spring Disassembly And Assembly

6 7
Figure 50-10-8
5
4 8
3
2
1
P-90028
Disassemble and assemble the seat bar compression

N-19222 spring and parts as shown in [Figure 50-10-9].
Bolt (Item 1)
Turn the bolt (Item 1) [Figure 50-10-8] and [Figure 50- Bushing (Item 2)
10-9] out of the clevis. Spring (Item 3)

Bushing (Item 4)
Assembly: Apply Loctite® #518 adhesive to the bolt Clevis (Item 5)
threads. Adjust the compression spring by turning the Pin (Item 6)
bolt in past the end of the clevis three turns. Bushing (Item 7)
Rue Ring (Item 8)
NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.


OPERATOR CAB Figure 50-20-2
Gas Spring Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or 1
death.
W-2113-0288
Raise the operator cab (See Raising on Page 10-30-2.)

P-85657
WARNING Remove the two bolts (Item 1) [Figure 50-20-2].
Figure 50-20-3
Attach a chain hoist to the grab handles of the

operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
W-2760-0309
2
Figure 50-20-1 1
3
1
P-85652
Remove the retaining pin (Item 1), the pin (Item 2), and
the gas spring (Item 3) [Figure 50-20-3] from the loader.
NOTE: If the loader is equipped with a second gas

spring repeat the procedure for the other side.
P-85662
Install a strap and hoist (Item 1) [Figure 50-20-1] to the

cab handles.
Lift the cab with the hoist to release the pressure on the
gas spring(s).

OPERATOR CAB (CONT’D) Removal And Installation
Gas Spring Bracket Disassembly And Assembly
Figure 50-20-4
WARNING
Attach a chain hoist to the grab handles of the
3 operator cab before removing the operator cab gas
spring(s). If the operator cab is tilted forward without
the gas spring(s) operational, the cab will fall and
could cause injury or death.
1 W-2760-0309
1
2 Remove the throttle cable from the cab. (See Cable

Remove the operator cab gas spring(s). (See Gas Spring

P-85661
Remove the clevis (Item 1) from both ends, and the outer NOTE: Use the hoist connected to the operator cab
housing (Item 2) from the gas spring (Item 3) [Figure 50- grab handles to lower or (raise) the operator
cab when the gas spring(s) are disconnected.

20-4].
Installation: Apply a small amount of thread-locker on Figure 50-20-5

the threads of the gas spring rod before installing the
clevis (Item 1) [Figure 50-20-4].
WARNING
AVOID INJURY 1
Cylinders for raising and lowering operator cab have
gas under pressure. Do not open cylinder. Only
qualified service personnel can remove the cylinder.
W-2112-0987
P-85663
Disconnect the cab harness connector screw (Item 1)

[Figure 50-20-5].
Installation: Tighten the connector screw to 3,39 - 3,96


OPERATOR CAB (CONT’D)
Figure 50-20-6
P-85658
Remove the two cab mount bolts and nuts (Item 1)

[Figure 50-20-6] from both sides of the cab.

Installation: Tighten the cab mount bolts and nuts to
24,4 - 29,8 N•m (18 - 22 ft-lb) torque.
Figure 50-20-7
P-85662
Using a strap and a hoist remove the cab from the loader.


OPERATOR SEAT Seat Belt Removal And Installation (Retractable)
Removal And Installation Figure 50-30-2
Figure 50-30-1
P-90355
P-85776
Remove the mounting nut (Item 1) [Figure 50-30-2].
Raise the operator cab. (See Raising on Page 10-30-2.) Remove the seat belt.

Remove the four seat mounting nuts (Item 1) [Figure 50- Installation: Tighten the mounting nut to 73 N•m (54 ft-
30-1] and washers from the operator seat mounting lb) torque.
studs.

3.)
Remove the seat.
NOTE: With the seat removed, the cab may raise.

OPERATOR SEAT (CONT’D) Seat Belt Bracket Removal And Installation
Seat Belt And Bracket Removal And Installation Figure 50-30-4

(Standard)
Figure 50-30-3
3 1
P101250
P101249 Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the bracket mounting bolts (Item 1) [Figure 50-

Remove the lower mounting bolt, washer and nut (Item 30-4].

1). Remove the upper mounting bolt and nut (Item 2)
[Figure 50-30-3]. Remove the bracket (Item 3) [Figure 50-30-3].
Remove the seat belt. Installation: Tighten the mounting bolts to torque.
Installation: Tighten the mounting bolts to 73 N•m (54 ft-

lb) torque.

OPERATOR SEAT (SUSPENSION) Slide Rail Removal And Installation
Figure 50-31-1
1 1
P-85769
P-85776
Remove the operator seat. (See Removal And
Remove the two slide rail mounting bolts (Item 1) [Figure

Remove the four seat mounting nuts (Item 1) [Figure 50- 50-31-2].
31-1] and washers from the operator seat mounting
studs. Figure 50-31-3

3.)
Remove the seat. 2
P-85770
Remove the two slide rails mounting bolts (Item 1)

[Figure 50-31-3].
Remove the slide rail (Item 2) [Figure 50-31-3] from the

bottom of the seat frame.

OPERATOR SEAT (SUSPENSION) (CONT’D) Lower Cushion Removal
Seat Belt Removal And Installation Figure 50-31-6
Figure 50-31-4
1 1
P-85773
P-85771
Lift up and push forward on the rear of the seat cushion
(Item 1) [Figure 50-31-6].
Remove the nut (Item 1) [Figure 50-31-4] from the seat
belt mount.

Figure 50-31-5
P-85772
Remove the nut (Item 1) [Figure 50-31-5] from the seat

belt mount.
Remove the seat belt.

OPERATOR SEAT (SUSPENSION) (CONT’D) Back Cushion Removal And Installation
Lower Cushion Installation Figure 50-31-9
Figure 50-31-7
2 1
1
2
P-85774
P-85773
P-85778
Tilt the seat all the way forward.
Insert the tab (Item 1) into the slot (Item 2) [Figure 50-31- Remove the two screws (Item 1) [Figure 50-31-9] and tilt
7]. the seat back to the upright position.

Figure 50-31-8 Remove the back cushion from the seat
1 1
P-85775
Push down on the front of the seat (Item 1) and push

back (Item 2) [Figure 50-31-8] to lock the seat into
position.

OPERATOR SEAT (SUSPENSION) (CONT’D) 3-Point Seat Belt Removal And Installation
Shock Removal And Installation Remove the operator seat. (See Removal And
Figure 50-31-10
Figure 50-31-11
1
1
2
1
P-85777
P-85785
Remove the operator seat. (See Removal And

Installation on Page 50-31-1.) Remove the mounting nut (Item 1) [Figure 50-31-11].

Remove the seat shock clips (Item 1) [Figure 50-31-10]. Remove the end release buckle (Item 2) [Figure 50-31-
(Both ends.) 11].
Remove the seat shock (Item 2) [Figure 50-31-10]. Figure 50-31-12
P-85784
Remove the mounting nut (Item 1) [Figure 50-31-12].
Remove the seat belt retractor (Item 2) [Figure 50-31-

12].

OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-31-15
3-Point Seat Belt Removal And Installation (Cont’d)

2
Figure 50-31-13
1 3
1
P-85788
Remove the nut (Item 1) [Figure 50-31-15].

P-85786
Remove the shoulder harness guide and bushing (Item
2) and hardened washer (Item 3) [Figure 50-31-15].
13].

Figure 50-31-14
P-85787
Remove the shoulder harness retractor (Item 1) [Figure

50-31-14].


BOB-TACH (HAND LEVER) Figure 50-40-2
Description 1
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Hand Lever Bob-Tach uses
two manually operated, spring assisted, locking wedge
and lever assemblies to secure the attachment the Bob-
Tach.
The Bob-Tach is located on the front of the loader

connected to the loader lift arms.
Figure 50-40-1 P-85649

P-85554
Tilt the Bob-Tach forward, so it is parallel to the floor. Put

blocks (approximately 76,2 mm (3 in)) under each side of
the Bob-Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.


40 ft-lb) torque.

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-5
Figure 50-40-3
1 P-31405
Check and replace O-ring (Item 1) [Figure 50-40-5] on

P-31402 the grease plug.
Figure 50-40-6
Bob-Tach pivot pin grease plug (both sides).

Figure 50-40-4
P-31403
1
Remove the nut (Item 1) [Figure 50-40-6] from the Bob-
P-31404 Tach pivot pin retaining bolt (both sides).
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-40-4].

BOB-TACH (HAND LEVER) (CONT'D) Lever And Wedge Disassembly And Assembly
Figure 50-40-7
P-85664
P-31406
Remove the lever mounting nut (Item 1) [Figure 50-40-
9].
Remove the retainer bolt (Item 1) [Figure 50-40-7] from
the Bob-Tach pin. Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)

torque.
Installation: Tighten the retainer nut and bolt (Item 1)
[Figure 50-40-6] and [Figure 50-40-7] to 446 N•m (330 Figure 50-40-10
ft-lb) torque.
Figure 50-40-8
2
P-85665
1
P-31407 Remove the washer and spring, (Item 1) and the lever
assembly (Item 2) [Figure 50-40-10].
With a punch (Item 1) [Figure 50-40-8] and a hammer,

drive the pivot pin out of the lift arm and Bob-Tach.

BOB-TACH (HAND LEVER) (CONT'D) Figure 50-40-13
Lever And Wedge Disassembly And Assembly

(Cont'd) 4
Figure 50-40-11
1 3 2
P-85668
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-13] are damaged, put the
P-85666 assembly in a vise.
Remove the bolt and replace the damaged parts as

Use a punch and hammer to remove the roll pin (Item 1) needed.

[Figure 50-40-11] from the Bob-Tach wedge and spring
clevis.
Remove the spring clevis assembly (Item 2) [Figure 50-

40-11].
Figure 50-40-12
P-85667
Remove the wedge (Item 1) [Figure 50-40-12] out the

bottom of the Bob-Tach.
Always replace bent or broken wedges.

BOB-TACH (HAND LEVER) (CONT'D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-14
2 1
P-85669
Remove the Bob-Tach. (See Removal And Installation on

Page 50-40-1.)

Use a seal pick to remove seal (Item 1) [Figure 50-40-
14] from the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-40-14]

with a driver tool and hammer.


BOB-TACH (POWER) Removal And Installation
The Bob-Tach is the section of the loader lift arm that

attachments mount to. The Power Bob-Tach option uses
two hydraulically operated, spring assisted, locking
wedge and lever assemblies to secure the attachment to
the Bob-Tach.
The hydraulically operated Power Bob-Tach has a

hydraulic cylinder that opens and closes both wedge and
1
lever assemblies by pressing a switch on the right switch 2 2
panel. The switch activates the Power Bob-Tach block to
allow flow into or out of the hydraulic cylinder connected
to the levers on the Bob-Tach.
The Power Bob-Tach block is located on the rear of the P-85570

gear pump.
The Bob-Tach is located on the front of the loader Tilt the Bob-Tach forward, so it is parallel to the floor. Put
connected to the loader lift arms. 2x4 blocks under each side of the Bob-Tach [Figure 50-
41-1].

Lower the Bob-Tach onto the blocks.
Mark the hoses (Item 1) [Figure 50-41-1] for correct

installation.
Remove and cap the hoses from the cylinder.
Remove the washers and bolts (Item 2) [Figure 50-41-1]

from the cylinder (both ends).

40 ft-lb) torque.
Remove the cylinder from the Bob-Tach.

BOB-TACH (POWER) (CONT'D) Figure 50-41-4
Figure 50-41-2
1 1
P-31402
Remove the snap ring (Item 1) [Figure 50-41-4] at the

P-85554 Bob-Tach pivot pin grease plug (both sides).
Figure 50-41-5

40 ft-lb) torque.
Figure 50-41-3
P-31404
Use a grease gun and pump grease into the pivot pin
forcing the grease plug out of the Bob-Tach (Item 1)
[Figure 50-41-5] (both sides).
P-85649

BOB-TACH (POWER - OPTION) (CONT’D) Figure 50-41-8
Figure 50-41-6
P-31406
1
P-31405 the Bob-Tach pivot pin (both sides).
Installation: Tighten the retainer nut and bolt (Item 1)

Check and replace the O-ring (Item 1) [Figure 50-41-6] [Figure 50-41-7] and [Figure 50-41-8] to 446 N•m (330
on the grease plug. ft-lb) torque.

1
P-31403 P-31407
Remove the nut (Item 1) [Figure 50-41-7] from the Bob- With a punch (Item 1) [Figure 50-41-9] and a hammer,
Tach pivot pin retaining bolt (both sides). drive the pivot pin out of the lift arm and Bob-Tach (both
sides).
Remove the Bob-Tach from the loader.

BOB-TACH (POWER) (CONT'D) Figure 50-41-3
Lever And Wedge Disassembly And Assembly
Figure 50-41-1
1 1 2
P-85665
Remove the washer and spring, (Item 1) and the lever

P-85570 assembly (Item 2) [Figure 50-41-3].
Figure 50-41-4
Remove the washers and bolts (Item 1) [Figure 50-41-1]
from the cylinder (both ends).

Installation: Tighten the bolts to 48 - 54 N•m (35 - 40 ft-
lb) torque.
Remove the cylinder from the lever pivots.

1
Figure 50-41-2
P-85666
1 Use a punch and hammer to remove the roll pin (Item 1)

[Figure 50-41-4] from the Bob-Tach wedge and spring
clevis.
Remove the spring clevis assembly (Item 2) [Figure 50-

41-4].
P-85664
Remove the lever mounting nut (Item 1) [Figure 50-41-

2].
Installation: Tighten the nut to 48 - 54 N•m (35 - 40 ft-lb)

torque.

BOB-TACH (POWER - OPTION) (CONT'D) Pivot Pin Bushing And Seal Removal And Installation
Lever And Wedge Disassembly And Assembly Figure 50-41-7

(Cont'd)
Figure 50-41-5
2 1
P-85669
P-85667 Remove the Power Bob-Tach. (See Removal And

Remove the wedge (Item 1) [Figure 50-41-5] out the Use a seal pick to remove seal (Item 1) [Figure 50-41-7]

bottom of the Bob-Tach. from the Bob-Tach.
Always replace bent or broken wedges. Remove and replace bushing (Item 2) [Figure 50-41-7]
with a driver tool and hammer.
Figure 50-41-6
3 2
P-85668
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-41-6] are damaged, put the
assembly in a vise.
Remove the bolt and replace the damaged parts as

needed.


LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation

1
NOTE: Remove the lift arm stabilizer bar from one
side of the loader at a time.
Figure 50-50-1
P-90591
1
2 With a slide hammer, remove the rear lift arm stabilizer
pin (Item 1) [Figure 50-50-3].
Remove the stabilizer bar from the loader.
Figure 50-50-4

P-90592A
Remove the retainer bolt (Item 1) [Figure 50-50-1] and

nut from the front stabilizer bar pivot pin.
Remove the stabilizer bar pivot pin (Item 2) [Figure 50-

50-1].
1
Figure 50-50-2
P-31595
Remove the bushings (Item 1) [Figure 50-50-4] from the

stabilizer bar (both ends).
Inspect the bushings and replace as needed.
P-90593

the stabilizer bar rear pivot pin at the lift arm.


LIFT ARMS (CONT'D) Figure 50-50-7
Link Removal And Installation

1
Figure 50-50-5
P-90594

P-90595 7] from the lift arm link pivot pin (both sides).

Install a sling and chain hoist on the lift arm link [Figure N•m (35 - 40 ft-lb) torque.
50-50-5].

Figure 50-50-8
Figure 50-50-6
1
1
P-90598
P-90597
Remove the lift arm pivot pin (Item 1) [Figure 50-50-8]

Remove the retainer bolt and nut (Item 1) [Figure 50-50- (both sides).
6] from the lift arm pivot pin (both sides).


LIFT ARMS (CONT'D) Removal And Installation
Link Removal And Installation (Cont’d) Put jackstands under the rear corners of the loader.
Figure 50-50-9 Raise the operator cab. (See Raising on Page 10-30-2.)

1 Figure 50-50-10
P-90610
Remove the lift arm link pivot pin (Item 1) [Figure 50-50-
9] (both sides).

P-90600
At the right side upright disconnect and cap the two tilt
Remove the lift arm link from the loader. cylinder hoses (Item 1) [Figure 50-50-10].
NOTE: Mark the hoses for proper installation.
Figure 50-50-11
P-90599
At the left side upright disconnect and cap the three

auxiliary hydraulic hoses (Item 1) [Figure 50-50-11].
NOTE: Mark the hoses for proper installation.

Figure 50-50-12
1
P-90611

P-85692 50-14] from the rod end of the lift cylinder (both sides).
Figure 50-50-15
Disconnect the electrical controls harness (Item 1)
[Figure 50-50-12]. (If equipped.)

Figure 50-50-13
1
1
P-90606
Install slings (Item 1) [Figure 50-50-15] on the lift arms

P-90602 and connect to a chain hoist.

50-13] from the pin on the rod end of the lift cylinder (both
sides).


Figure 50-50-16
1
2
P-90609
2
Remove the retaining bolt and nut (Item 1) and the pin
P-90604 (Item 2) [Figure 50-50-18] (both sides).

NOTE: Be sure the slings on the lift arms are in a N•m (35 - 40 ft-lb) torque.
position to balance the lift arms when being

removed. See (Item 1) [Figure 50-50-16]. Remove the lift arms from the loader.
Disconnect the stabilizer bar from both sides of the lift

arms (Item 2) [Figure 50-50-16].
Figure 50-50-17
P-90605
Position the front sling in the middle of the Bob-Tach as

shown in (Item 1) [Figure 50-50-17].
Support the lift arms with the chain hoist.


REAR GRILLE Figure 50-60-3
Figure 50-60-1
1 P-85602
Align the tabs of the two side covers into the slots in the
P-85496 loader frame and lower [Figure 50-60-3].
Figure 50-60-4
Flip up the lockable handle (Item 1) [Figure 50-60-1] and
turn the handle a quarter turn counter-clockwise. Lift and

pull the rear grille to remove it from the loader.
Figure 50-60-2
P-85604
Align the edge of the rear grille under the loader frame
and slide rear grille in while lowering [Figure 50-60-4].
P100052
Turn the lockable handle a quarter turn clockwise and
fold the handle down.
Lift and remove the two side covers (Item 1) [Figure 50-
60-2].


REAR DOOR (TAILGATE) Figure 50-70-3
Figure 50-70-1 1
3
2
P-85695
1
Remove the top and bottom door hinge mounting bolts

P-85697 and nuts (Item 1) [Figure 50-70-3].
NOTE: Install the door stop (Item 2) and the door stop
Disconnect the light harness connector (Item 1) [Figure
retainer (Item 3) in the top hinge as shown
50-70-1] from the main frame harness.
[Figure 50-70-3].

Remove both rear lights (Item 2) [Figure 50-70-1] from
the door. (See Rear Removal And Installation on Page
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-70-2
flat on the floor.
2
1 1
P-90584
Secure the chain hooks (Item 1) [Figure 50-70-2] to the

door as shown.
Connect a chain hoist (Item 2) [Figure 50-70-2] to the

lifting chain.

REAR DOOR (TAILGATE) (CONT’D) Striker (Adjusting)
Striker Removal And Installation
Figure 50-70-4 WARNING

1
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Figure 50-70-6
1
1
P-85698A
Remove the two striker mount bolts (Item 1) [Figure 50- 1

70-4].

Remove the striker assembly from the loader.
Striker Disassembly And Assembly

P-85698A
Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
2
3 Align the striker assembly in the center of the mounting
holes.
NOTE: Tighten the striker assembly, top mount bolt

only, until it will hold the striker assembly in
the center of the mounting slots.
4
1 Close the rear door. (This will align the striker assembly
to the correct position.)
Open the door.

P-31320A
Tighten both striker mount bolts (Item 1) [Figure 50-70-6]
to 125 - 135 N•m (90 - 100 ft-lb) torque.
Remove the lock nut (Item 1) [Figure 50-70-5].
Remove the rollers (Item 2) and the spacer (Item 3) from
the bolt (Item 4) [Figure 50-70-5].
Check the parts for wear and replace as needed.
Installation: Tighten the bolt (Item 4) and nut (Item 1) to

34 - 38 N•m (25 - 28 ft-lb) torque.

REAR DOOR (TAILGATE) (CONT’D) Figure 50-70-9
Latch Removal And Installation
Figure 50-70-7
1
1
P-85701
Remove the door handle (Item 1) [Figure 50-70-9] from

P-85699 the rear door.
Disconnect the spring (Item 1) [Figure 50-70-7] from the

rear door.

Remove the bolt and nut (Item 2) [Figure 50-70-7] from
the latch.
Figure 50-70-8
P-85700
Remove the spring (Item 1) [Figure 50-70-8] from the

door handle.
Remove the spring (Item 2) [Figure 50-70-8] from the

door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.


FUEL TANK Figure 50-80-3

1.)
Remove the engine / hydrostatic pump assembly from 1

2
Page 70-10-7.)
Figure 50-80-1
P-85707
Disconnect the fuel vent hose (Item 1) and remove the

two bolts (Item 2) [Figure 50-80-3].
1 Figure 50-80-4
1 4

P-85714
2 3
Remove the three mount bolts (Item 1) [Figure 50-80-1]
from the access cover at the rear of the loader frame.
Remove the access cover.
Figure 50-80-2
1
P-85708
Disconnect the two fuel lines (Item 1) [Figure 50-80-4].

1
50-80-4] from the fuel level sender.
Remove the two mounting bolts (Item 3) and remove the

bracket (Item 4) [Figure 50-80-4].
P-85713
Remove the drain plug (Item 1) [Figure 50-80-2].
Drain the fuel into a container.

FUEL TANK (CONT'D) Figure 50-80-7
Figure 50-80-5
1
1
1 1
P-85711
At the right side of the loader, remove the two main frame
P-85710 mount bolts and nuts (Item 1) [Figure 50-80-7].
Installation: Tighten the main frame mount bolts to 542 -

Remove the bolts (Item 1) [Figure 50-80-5] from the 583 N•m (400 - 430 ft-lb) torque.
battery hold down plate.

Figure 50-80-8
Remove the hold down plate from the loader.
Figure 50-80-6
1 1 1
P-85712
2
P-85709 At the left side of the loader, remove the two main frame
mount bolts and nuts (Item 1) [Figure 50-80-7].
Remove the two mounting bolts (Item 1) and the bracket Installation: Tighten the main frame mount bolts to 542 -
(Item 2) [Figure 50-80-6]. 583 N•m (400 - 430 ft-lb) torque.
Lift the fuel tank and remove it from the loader frame.
NOTE: When installing the fuel tank, avoid striking

the tank with heavy objects to prevent
damage.

FUEL TANK (CONT'D) Fuel Fill Screen Removal And Installation
Fuel Level Sender Removal And Installation Figure 50-80-11
Figure 50-80-9
1
1
P-85707
P-85708
Remove the two bolts (Item 1) and disconnect the fuel fill
50-80-9] from the fuel level sender. Figure 50-80-12

Remove the fuel level sender.
Figure 50-80-10
P-85715
Remove the fuel fill screen (Item 1) [Figure 50-80-12].

P-85716
Inspect and replace as needed.
Inspect the fuel level sender and replace if worn or

damaged.


CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
1
The control pedals and linkages are connected to the
control valve. The control pedals will mechanically move
the lift and tilt spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operators feet.
Pedal Removal And Installation
WARNING P-85675
Never work on a machine with the lift arms up unless Remove the bolt (Item 1) [Figure 50-90-1] and nut from
the lift arms are secured by an approved lift arm the pedal linkage.
support device can allow the lift arms or attachment Check the bushing in the pedal for wear and replace as
to fall and cause injury or death. needed.
W-2059-0598

Figure 50-90-2
device.(See Installing on Page 10-20-1.)
Raise the operator cab.(See Raising on Page 10-30-2.)
DANGER
1
P-85676
P-90328 Remove the two nuts (Item 1) [Figure 50-90-2] from the
pedal mounting bracket.
AVOID DEATH
• Disconnecting or loosening any hydraulic Remove the pedal assembly from the loader.
D-1009-0409

CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
1
1
2
P-85679
Remove the crossbar pivot bolt (Item 1) [Figure 50-90-

P-85678 5].
Remove the crossbar from the pivot (Item 2) [Figure 50-

Remove the bolt and nut (Item 1) [Figure 50-90-3] to 90-6].
disconnect the lift pedal linkage from the crossbar.

Figure 50-90-6
Figure 50-90-4
2
1
P-85681
P-85680
Installation: Check the nylon bushing (Item 1) [Figure

Remove the hairpin clips (Item 1) and cross-pins (Item 2) 50-90-6] for wear and replace as needed.
[Figure 50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

CONTROL PEDALS AND LINKAGES (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation (Cont’d) After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
Figure 50-90-7 spool must travel full stroke without the pedal hitting the
floor panel.
1 The pedals should be positioned at a comfortable angle

so full movement of the pedal can be reached easily
while properly sitting in the loader seat.
2
Figure 50-90-9
P-85675
Remove the bolt (Item 1) [Figure 50-90-7] and nut from

the pedal linkage.

Remove the linkage (Item 2) [Figure 50-90-7].
P-85676
Figure 50-90-8
Loosen the two mounting bolts (Item 1) [Figure 50-90-9]
from the pedal mounting bracket.
1
Figure 50-90-10
2
2
P-85675A
Remove the bolt (Item 1) [Figure 50-90-8] and nut from

the pedal linkage. P-85675
Remove the linkage (Item 2) [Figure 50-90-8]. Loosen the bolt (Item 1) [Figure 50-90-10] and nut on
the pedal linkage.
Check the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable “neutral”

angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)
[Figure 50-90-10] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And

Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-90-11

1
1
P-85859 P-85860
Figure 50-90-12
1 1
P-85858
Remove the clips (Item 1) [Figure 50-90-11] and [Figure

50-90-12] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-90-12].

CONTROL PEDALS AND LINKAGES (ACS) Figure 50-91-1
Description
1
The control pedals are connected to foot sensors located
behind the control panel. The foot sensors send an
electronic pulse to the actuators on the control valve. The
electronic pulse tells the actuators to move the lift or tilt
spools on the control valve.
The control pedals and linkages are located on the lower

mainframe at the operators feet.
Pedal Removal And Installation
P-85675
WARNING Remove the bolt (Item 1) [Figure 50-91-1] and nut from
the pedal linkage.
the lift arms are secured by an approved lift arm Check the bushing in the pedal for wear and replace as
support device. Failure to use an approved lift arm needed.

Figure 50-91-2
W-2059-0598
device.(See Installing on Page 10-20-1.)
Raise the operator cab.(See Raising on Page 10-30-2.)
DANGER 1
P-85676
Remove the two nuts (Item 1) [Figure 50-91-2] from the

pedal mounting bracket.
P-90328
Remove the pedal assembly from the loader.
AVOID DEATH
D-1009-0409

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D) Pedal (Adjusting)
Linkage Removal And Installation After installing the pedal, adjust the pedal angle so that
there is clearance under the rear of the pedal. The valve
spool must travel full stroke without the pedal hitting the
Figure 50-91-3 floor panel.
The pedals should be positioned at a comfortable angle

so full movement of the pedal can be reached easily
1 while properly sitting in the loader seat.
Figure 50-91-5
1
1
P-90979
Remove the hairpin clip and the pin (Item 1) [Figure 50-
91-3] from the foot sensor.

P-85676
Figure 50-91-4
Loosen the two mounting nuts (Item 1) [Figure 50-91-5]
from the pedal mounting bracket.
Figure 50-91-6
1 1
2
P-90981
Remove the linkage (Item 1) [Figure 50-91-4] and the

rubber boot. P-85675
Repeat for other side.

Loosen the bolt (Item 1) [Figure 50-91-6] and nut on the
pedal linkage.
Check the bushing in the pedal for wear and replace as

needed.
Tilt the pedal back and forth until an acceptable “neutral”
angle is achieved on the pedal.
Tighten the two nuts (Item 2) and pivot bolt (Item 1)

[Figure 50-91-6] on the pedal assembly to standard
torque.

CONTROL PEDALS AND LINKAGES (ACS) (CONT’D)
Floor Pan Removal And Installation

on Page 50-100-2.)
Remove the pedals. (See Pedal Removal And

Remove the access panels. (See ACCESS PANEL

(INSIDE) on Page 50-120-1.)
Figure 50-91-7

1
1
P-85859 P-85860
Figure 50-91-8
1 1
P-85858
Remove the clips (Item 1) [Figure 50-91-7] and [Figure

50-91-8] from the sides of the floor pan.
Remove the floor pan (Item 2) [Figure 50-91-8].


CONTROL PANEL
Description
Figure 50-100-1

NA1034
The steering system consists of independent steering Pintle arms are of a two-piece design that allow easy
levers the operator uses to provide steering input to the adjustment of the neutral or “creep”.
loader.
The steering system returns the levers to their starting
The steering levers are attached to pivoting bellcranks position by means of the centering spring and the
that pivot on a steering shaft and plastic bushings. returning force of the torsion bushings.
The forward travel is adjusted by drift adjustment bolts. NOTE: Torsion bushings need to be replaced if torn
or rotating in the housing. Loosen torsion
The bellcranks are attached to steering linkage bars with bushing bolts slightly before adjustments are
torsion bushings pressed into the bellcranks. Bellcranks made.
mount to the control handle assembly and mount to the
control panel. Sequence of steering adjustments:
Steering linkage bars are a two-piece design. Steering 1. Set neutral of pintle arms, “creep”
linkage bars are adjustable in length for “full travel 2. Set full travel at steering linkage bars
adjustment”. 3. Set drift at drift adjustment bolts
Steering linkage bars attach to the pintle arms where a

rubber torsion bushing is pressed into the pintle arms.

CONTROL PANEL (CONT'D) Figure 50-100-2
2
DANGER
1
P-85846
P-90328
AVOID DEATH Figure 50-100-3


D-1009-0409
WARNING
the lift arms are secured by an approved lift arm P-85847
to fall and cause injury or death. Disconnect the control harness connectors (Item 1) and
W-2059-0598 the back-up alarm wires (Item 2) [Figure 50-100-2] &
[Figure 50-100-3] from the control levers.
WARNING
W-2017-0286

1.)


CONTROL PANEL (CONT'D) Disassembly And Assembly
Removal And Installation (Cont'd) Remove Control Panel. (See Removal And Installation
on Page 50-100-2.)
Figure 50-100-4
Figure 50-100-6
2
1
1 1
2
2 2
P-90612
1 1
P-85864
Scribe a mark across the top of the steering linkage bars

(Item 1) [Figure 50-100-4] which are connected to the Remove the nuts (Item 1) and the steering stabilizers

steering shaft on the control panel. (Item 2) [Figure 50-100-6].
Remove the four steering linkage mounting bolts, nuts

and rubber isolators (Item 2) [Figure 50-100-4].
Inspect and replace any damaged parts.
Installation: Align the marks on the steering linkage

bars. Tighten the steering linkage mounting bolts to 47,5 -
54,2 N•m (35 - 40 ft-lb) torque.
Figure 50-100-5
3 2 3
3 3 P-85848
Remove the two bracket mounting bolts (Item 1) and the

knob (Item 2) [Figure 50-100-5] from the lift arm bypass
valve.
Remove the eight control panel bolts (Item 3) and the

control panel assembly (Item 4) [Figure 50-100-5].

Figure 50-100-7 2
2 2
1
3 1 3 3 P-85867
3
Remove the four bolts (Item 1) [Figure 50-100-9] from

P-85865 the control panel.
Remove the control handle assembly (Item 2) [Figure

Figure 50-100-8 50-100-9].

Figure 50-100-10
4
3
2
1
1
P-85861
P-85868
Remove the bolt and nut (Item 1), steering link, (Item 2),
and washers (Item 3) [Figure 50-100-7] and [Figure 50-
100-8]. Remove the tie straps (Item 1), the four nuts (Item 2), and
the plate (Item 3) [Figure 50-100-10].
Installation: Verify correct orientation of components
[Figure 50-100-7] and [Figure 50-100-8]. Remove the control handle (Item 4) [Figure 50-100-10].

CONTROL PANEL (CONT'D) Linkage Removal And Installation
Figure 50-100-11 WARNING

W-2059-0598
1 2 1
WARNING
P-85872
Remove the two bolts (Item 1) from the bellcrank (Item 2) fall or move and cause injury or death.
[Figure 50-100-11]. W-2017-0286

Remove the bellcrank from the bracket [Figure 50-100- Lift and block the loader. (See Procedure on Page 10-10-
11]. 1.)
Figure 50-100-12 Raise the lift arms and install an approved lift arm support

2
3
1
P-85873
Inspect the shaft (Item 1), the bellcrank (Item 2), and the
bushings (Item 3) [Figure 50-100-11] for wear and
replace as need.
Repeat the procedure for the other control handle

assembly.

Linkage Removal And Installation (Cont’d)

1
Figure 50-100-13
2
1
2
P-48631
2
Remove the nut (Item 1) from the end of the centering

P-90612 spring shoulder bolt (Item 2) [Figure 50-100-14].
Remove the bolt / spring assembly.

Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 50-100-13] which are connected to the Installation: Tighten the centering spring bolt and a

steering shaft on the control panel. NEW lock nut to 34 - 38 N•m (25 - 28 ft-lb) torque.
Remove the four steering linkage mounting bolts, nuts Figure 50-100-15
and rubber isolators (Item 2) [Figure 50-100-13].
Inspect and replace any damaged parts.

1
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 47,5 -
54,2 N•m (35 - 40 ft-lb) torque.
NOTE: After removal and installation of the linkage,

the linkage neutral adjusting procedure must
be performed. (See Linkage Neutral
(Adjusting) on Page 50-100-10.)
P-48632
Slide the centering plate (Item 1) [Figure 50-100-15] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operator’s seat.

Figure 50-100-16
2
7
6 8
3 1 4 1
1
P-48629
2
5
2 Check the wear on the centering blocks (Item 1) [Figure
P-48630 50-100-17].
If the centering blocks need replacement, remove the

The centering plate / centering spring assembly consists bolts (Item 2) [Figure 50-100-17]. Remove the centering
of the following parts: blocks.

ITEM DESCRIPTION Installation: Tighten the centering block bolts to 47,5 -
1 Bolt 54,2 N•m (35 - 40 ft-lb) torque.
2 Bushings
NOTE: The washers go between the bolts and the
3 Washer centering plate.
4 Bushing Spacer
NOTE: If the centering blocks are worn, they can be
5 Spring
removed and rotated 180 degrees and
6 Lock Nut reinstalled.
7 Centering Plate
8 Guide Bushings

Figure 50-100-18
2
2
1
P-54615
3
Loosen the bolt (Item 1) [Figure 50-100-20].

P-54617
Remove the pintle base (Item 2) [Figure 50-100-20].
Remove the bolts and washers (Item 1) [Figure 50-100- Figure 50-100-21
18] from the pintle.

Installation: Tighten the bolts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-18].
Figure 50-100-19 2
1 3
1
2 P-48659
4 NOTE: When installing the pintle base (Item 1) onto

3
the pump shaft, the cutouts on the pump shaft
will not line up with the bolt (Item 3) [Figure
2 50-100-21].
1 Installation: Install the pintle base (Item 1) onto the

P-48624 pump shaft (Item 2) [Figure 50-100-21]. The top of the
pintle base should be level with the top of the pump shaft.
Tighten the bolts to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque.
Remove the bolt and nut (Item 1) [Figure 50-100-19].
NOTE: After installing the linkage onto the
Inspect the washers (Item 2), pintle arm (Item 3) and the hydrostatic pumps the linkage neutral
steering control lever (Item 4) for damage and replace as adjusting procedure must be performed. (See
needed [Figure 50-100-19]. Linkage Neutral (Adjusting) on Page 50-100-
10.)
NOTE: The washers (Item 2) [Figure 50-100-19] are
hardened, and should only be replaced
through Bobcat Parts.

CONTROL PANEL (CONT'D) NOTE: Anti-seize should be used on the adjusting
screw to prevent corrosion and allow free
Pintle Arm Disassembly And Assembly movement while adjusting.
Figure 50-100-22 Figure 50-100-24
2
4
3 1
2
3
1 P-48619
P-54624
Using a bushing driver (Item 1) remove the torsion

Remove the nut (Item 1) from the pintle roller cams (Item bushing (Item 2) by pressing the bushing through the
2) and inspect the pintle roller cams and washers (Item 3) pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-100-24].

for damage [Figure 50-100-22].
Inspect the torsion bushing (Item 4) [Figure 50-100-22] Installation: Install the torsion bushing (Item 2) [Figure
for damage and replace as needed. 50-100-24] into the pintle arm using the same procedure
as the removal.
Installation: Tighten the nuts to 47,5 - 54,2 N•m (35 - 40
ft-lb) torque. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
Figure 50-100-23 arm should be the same.
4
2
P-54626
Remove the base pintle (Item 1) [Figure 50-100-23] from

the pump shaft.
Remove the retaining bolt (Item 2), adjusting screw (Item

3) and neoprene dampener (Item 4) from the base pintle
[Figure 50-100-23].
Inspect parts for wear and damage, replace as needed

[Figure 50-100-23].

Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following

procedure:
Kit - 6689778 Remote Start Tool (Service Tool) or 1

MEL1563 Remote Start Tool.
Connect the Remote Start Tool (Service Tool) to the

loader. (See REMOTE START TOOL KIT-MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7003031 on Page 10-61-1.)
Lift and block the loader. (See Procedure on Page 10-10- P-85845
1.)
Figure 50-100-25 Loosen the bolt / nut (Item 1) [Figure 50-100-26] only
until the tension is released from the torsion bushing.
3
Figure 50-100-27

2
1
P-48450A
Tool that may assist in the neutral adjustment [Figure 50- P-54613
100-25].
To make this tool use a locking grip C-Clamp and grind Loosen the nut (Item 1) only until the tension is released
one edge flat (Item 1) and grind the other edge (Item 2) from the torsion bushing (Item 2) [Figure 50-100-27].
[Figure 50-100-25] to a small rounded edge.
NOTE: The bolt must be loose enough to allow the
A steering centering block (Item 3) [Figure 50-100-25] is torsion bushing (Item 2) [Figure 50-100-27] to
also needed. The centering block can be placed as turn freely between the torsion bushing and
shown and welded to the C-clamp if desired. the steering linkage bar.
WARNING
W-2017-0286

CONTROL PANEL (CONT'D)
Linkage Neutral (Adjusting) (Cont’d) WARNING

Figure 50-100-28
W-2017-0286
1
loader. (See REMOTE START TOOL KIT-MEL1563 on
Page 10-60-1.) OR (See REMOTE START TOOL
(SERVICE TOOL) KIT - 7003031 on Page 10-61-1.)
Start the engine and run at low idle.
2 Move the traction lock override switch so the traction

P-54614 function is unlocked. On a standard loader the wedge
brake will unlock.
Loosen the two bolts (Item 1) holding the right centering NOTE: When the engine is started, the wheels /
block. Move the right hand centering block (Item 2) tracks may begin to move.

[Figure 50-100-28] until both pintle cams contact the
centering block. NOTE: In loaders equipped with manual steering and
hydraulic brake, the steering levers may have
NOTE: The left centering block is not adjustable. By to be moved during engine start-up to reduce
adjusting the right centering block the left the amount of creep. This reduction in creep
centering block will also become aligned will allow time for the engine to run and build
properly. up hydraulic charge pressure, which will
release the hydraulic brake.
Figure 50-100-29
Tighten bolts (Item 3) [Figure 50-100-29] to 47,5 - 54,2
N•m (35 - 40 ft-lb).
3
NOTE: Check for slack between centering blocks and
pintle cams. If there is excessive slack repeat
above steps [Figure 50-100-28] & [Figure 50-
100-29].
1
P-48451
A modified locking grip C-Clamp and steering block

shown in [Figure 50-100-25] may be used to help in
aligning the centering blocks.
Install the centering block (Item 1) on the inside of the

pintle cams and the C-Clamp (Item 2) [Figure 50-100-
29] around both centering blocks.
Lock the C-Clamp in place.

Linkage Neutral (Adjusting) (Cont’d)
Start the neutral adjustment procedure with the left

pump first and complete the neutral adjustment for
the left pump before adjusting the right pump.
Figure 50-100-30
2 1
1
P-54610
Move the engine speed control to high idle.
NOTE: The neutral range (dead-band) will vary

between the hydrostatic pumps.
P-48632 NOTE: This procedure is shown for neutral

adjustment on the left side of the loader. The
procedure is the same for the right side
Loosen the left pump pintle adjustment lock bolts neutral adjustment.
(Item 1). (The right pump pintle adjustment lock bolts are
(Item 2) [Figure 50-100-30].) Loosen the bolts enough to Turn the adjustment screw (Item 1) [Figure 50-100-31]
allow free movement between the pintle arm and the counterclockwise until forward creep is seen.
pintle base.
Turn the adjustment screw (Item 1) [Figure 50-100-31] to
NOTE: If the bolts are too loose or too tight, the a point between forward and reverse where there is zero
neutral adjustment may be affected. creep.
Stroke the left steering lever to forward and allow the

lever to return to neutral. Stroke the left steering lever to
reverse and allow the lever to return to neutral. Check
that there is zero creep when the lever returns from either
direction, on the left side. Turn the adjustment screw (if
necessary) until zero creep is obtained.

Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-32
1
2 2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-100-32] to 47,5 - 54,2 N•m (35 - 40 ft-lb).

Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-100-32] to 47,5 - 54,2 N•m (35 - 40 ft-lb).
Test both levers by moving them backward and forward

and letting them return to neutral by the return spring
force.
If the levers do not return to neutral and the wheels /

tracks do not come to a complete stop, repeat the
adjustment procedure again.
Stop the engine.
Remove one pintle adjustment bolt (Item 1) [Figure 50-

100-32] at a time and apply Loctite® #242 or equivalent
thread locker to the bolt and re-install the bolt. Torque the
bolt to 47,5 - 54,2 N•m (35 - 40 ft-lb). Repeat for the three
remaining pintle adjustment lock bolts.
NOTE: To maintain proper adjustment setting,

remove and reinstall only one bolt at a time.
New bolts can be installed with pre-applied
Loctite®.
Remove the Remote Start Tool (Service Tool).
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Linkage Travel
(Adjusting) on Page 50-100-14.)

Linkage Travel (Adjusting)
NOTE: When the linkage travel adjusting procedure

is being done as part of the loader neutral
adjusting procedure, check the torsion
bushings at the pump and at the bell cranks to 1
be sure they are not binding or too loose,
which will affect the procedure.
WARNING
P-85845
support device. Failure to use an approved lift arm Loosen the bolt / nut (Item 1) [Figure 50-100-33] only
support device can allow the lift arms or attachment until the tension is released from the torsion bushing.
W-2059-0598
Figure 50-100-34

WARNING
of the frame before running the engine for service. 2
W-2017-0286

1.)
P-54613
Loosen the nuts (Item 1) only until the tension is released
Raise the operator cab. (See Raising on Page 10-30-2.) from the torsion bushings (Item 2) [Figure 50-100-34].
Pre-load tension in the torsion bushings must be The bolts must be loose enough to allow the torsion
removed before adjusting the steering linkage. bushing (Item 2) [Figure 50-100-34] to turn freely
between the torsion bushing and the linkage bar.

Linkage Travel (Adjusting) (Cont’d)
Figure 50-100-35
2
1
1 3
P-51132
Move the right side steering lever forward and install a 24

P-85878 mm (15/16 in) thick spacer (Item 1) between the center
plate (Item 2) and the mounting plate (Item 3) [Figure 50-
100-37].
Locate the control lever drift adjustment access hole in
the front of the control panel. This will allow the pintle arms to move freely while

adjusting the steering linkage for full forward travel
Turn the control lever drift adjustment bolts (Item 1) speed.
[Figure 50-100-35] (one on each control lever) out until
they no longer contact the bellcrank. Remove the 10 mm (3/8 in) thick spacer.
Figure 50-100-36 Figure 50-100-38
3 2
2
4
1
3
1
P-51131 P-51133
Move the right side steering lever to the rear and install a Before adjusting the linkage, verify the base pintle arm
10 mm (3/8 in) thick spacer (Item 1) between the pintle mounting bolt (Item 1) and both of the upper pintle mount
arm cam (Item 2) and the centering block (Item 3) bolts (Item 2) are tightened to 48 - 54 N•m (35 - 40 ft-lb)
[Figure 50-100-36]. torque. There should be no play between the pintle arm
and the square pump shaft [Figure 50-100-38].
Verify the cam mounting nuts (Item 4) [Figure 50-100-

36] are tightened to 48 - 54 N•m (35 - 40 ft lb) torque.

Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-39
1
1
1
P-51132
Remove the spacer (Item 1) [Figure 50-100-41].

P-85844
Figure 50-100-42
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
39] on each steering linkage bar. 2

Figure 50-100-40
P-54613
Tighten the two bolts (Item 1) and nuts (Item 2) to 47,5 -

54,2 N•m (35 - 40 ft-lb) [Figure 50-100-42].
P-90615
Move the left control lever to the full forward position,

then pull forward on the left rear linkage bar until the
pintle arm is rotated to the front as far as possible
[Figure 50-100-40]. Use a locking plier, clamp the two
linkage bars together.
Installation: Tighten the nuts and bolts to 47,5 - 54,2

Check the lever movement to make sure that the pintle

arm and the control lever are both at full stroke at the
same time. This will allow for maximum forward speed.
Repeat the linkage travel adjustment procedure for the

right side linkage.

Linkage Travel (Adjusting) (Cont'd)
WARNING
1
W-2017-0286
Figure 50-100-43 P-85878
Push the control lever to full stroke and turn drift

adjustment bolt (Item 1) [Figure 50-100-44] and [Figure
50-100-45] in until it contacts the bellcrank.
1
Repeat steps on the other control lever.

Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 3 m (10 ft)

of “drift” in 30,5 m (100 ft) of travel distance.
If the drift is excessive to the left, turn the right

P-85845 adjustment bolt (Item 1) [Figure 50-100-44] and [Figure
50-100-45] in.
Tighten the two bolts and nuts (Items 1) [Figure 50-100- If the drift is excessive to the right, turn the left
43] to 47,5 - 54,2 N•m (35 - 40 ft-lb) torque at the steering adjustment bolt in.
bell cranks.
NOTE: When using the drift adjustment bolts, only
Installation: After removal, installation, and adjusting of adjust one bolt for each test drive.
the linkage, the Back-up Alarm must be inspected. (See
Inspecting on Page 60-210-1.) In addition, only move each bolt a maximum
of one turn for each test drive. This will help
Figure 50-100-44 prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Reinstall the plug in the drift bolt access hole after

adjustment.
P-85877

Shock Removal And Installation
Figure 50-100-46
1 2
P-85845
Remove the mounting nuts (Item 1) [Figure 50-100-46]

from the end of the shocks connected to the steering

linkages.
Remove the mounting nuts (Item 2) [Figure 50-100-46]

from the other end of the shocks connected to the
brackets on the control panel.
Installation: Tighten the nuts to torque.

CONTROL PANEL (SJC) Raise the lift arms and install an approved lift arm support
Description
The control panel is connected to the lower main frame
and wraps around the operator seat. There are no Figure 50-101-1
mechanical linkages connecting to the hydrostatic pumps
or the control valve. 1
WARNING
1
W-2017-0286
P-85879
Remove the three mount bolts (Item 1) [Figure 50-101-1]

DANGER

that secure the controller.
Figure 50-101-2
1
1
1
2
1
P-90328
AVOID DEATH
can cause lift arms to drop. 3
1 1
P-85881
D-1009-0409
Remove the 10 panel mount bolts (Item 1) [Figure 50-
101-2].
Remove the lift arm bypass knob and rubber washer

WARNING (Item 2) [Figure 50-101-2].
Remove the control panel (Item 3) [Figure 50-101-2].

W-2059-0598


CONTROL HANDLE / LEVER
Description
The control handles / levers are used to control the

forward and reverse travel.
The control handles / levers are mounted to the control

panel assembly.
Lever Removal And Installation
Figure 50-110-1
2
3

P-85882
Remove the tie strap and disconnect the electrical

connectors (Item 1) [Figure 50-110-1] from the control
lever.
Remove the four nuts (Item 2) and the plate (Item 3)

[Figure 50-110-1] used to mount the control lever.
Remove the control lever (Item 4) [Figure 50-110-1] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.

CONTROL HANDLE/LEVER (CONT’D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-110-2
P-85883A

Remove the rubber boot (Item 1) [Figure 50-110-2].
Install the new boot and reinstall the steering lever.

CONTROL HANDLE / LEVER (ACS) Handle Sensor Removal And Installation
Figure 50-111-1 1
P-85882
P-21879
NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
The control handles / levers are used to control the sensor, actuator or ACS Controller. (See Lift
forward and reverse travel and the lift and tilt And Tilt Calibration (ACS) on Page 60-160-11.)

functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-111-1] that are Loosen the nuts (Item 1) [Figure 50-111-2].
located in the base of the control handle / levers.
Installation: Tighten the nuts so the lever cannot be
The control handles / levers are mounted to the control moved either right or left when seated in the operator
panel. seat.

CONTROL HANDLE / LEVER (ACS) (CONT'D) Figure 50-111-5
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-3
1 P-21860
2 Remove the handle lock solenoid connector (Item 1)

P-21836 [Figure 50-111-5] from the clip.
NOTE: Pry out with a small screwdriver and push the

Disconnect the harness connector (Item 1) from the connector down.
handle sensor connector.[Figure 50-111-3].

Figure 50-111-6
Disconnect the harness connector (Item 2) [Figure 50-
111-3] from the handle lock solenoid connector. 1
Figure 50-111-4
5
1 2
4
1 P-21862
Remove one of the two mounting screws (Item 1) [Figure

P-21861 50-111-6] from the handle sensor.
Installation: Tighten screws to 3,6 - 4,3 N•m (32 - 38 in-

Remove the handle sensor connector (Item 1) [Figure lb) torque.
50-111-4] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screwdriver and push the handle sensor, remove the plastic spacer (Item 3), the
connector down. spring (Item 4) and washer (Item 5) [Figure 50-111-6].

CONTROL HANDLE / LEVER (ACS) (CONT’D) Figure 50-111-9
Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-111-7
2
P-21878
1 Figure 50-111-10
P-21880
2 3
Remove one of the two mounting screws (Item 1) [Figure
50-111-7] from the handle sensor.

Installation: Tighten bolt to 3,6 - 4,3 N•m (32 - 38 in-lb)
torque.
Figure 50-111-8
7
8
1
P-21799
1
Installation: When installing the handle sensor into the
control handle, check the routing of the switch handle
4 wire harness (Item 1) [Figure 50-111-9] and [Figure 50-
3 111-10] to assure proper return of the control handle to
7 neutral and minimize harness movement.
6
5 NOTE: Route wires (Item 2) [Figure 50-111-9] and
2 [Figure 50-111-10] as shown away from stop
P-21882
strap (Item 3) [Figure 50-111-9] and [Figure 50-
111-10] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-8]
from the handle assembly. NOTE: The calibration procedure must be followed
when replacing handle sensor, foot pedal
NOTE: The handle sensor (Item 1) [Figure 50-111-8] sensor, actuator or ACS Controller. (See Lift
can only be replaced as a complete assembly. And Tilt Calibration (ACS) on Page 60-160-11.)
Check the spacer (Item 2), screws (Item 3), mounting

pins (Item 4), spring (Item 5), washer (Item 6), bolt / nut
(Item 7), and stop strap (Item 8) [Figure 50-111-8] and
replace as needed.

CONTROL HANDLE / LEVER (ACS) (CONT'D) Figure 50-111-13
Handle Removal And Installation
Figure 50-111-11
1
1
N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

P-21879 111-13] from the handle.
Figure 50-111-14
Remove the handle sensor (Item 1) [Figure 50-111-11].
(See Handle Sensor Removal And Installation on Page

50-111-1.)
Figure 50-111-12 1
1 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the allen head screws (Item 2) [Figure
P16534 50-111-14] from the handle assembly.
Installation: Tighten the allen head screws to 4 N•m (35

Remove the switch handle (Item 1) [Figure 50-111-12]. in-lb) torque.
(See Switch Handle Removal on Page 60-130-4.)

CONTROL HANDLE / LEVER (ACS) (CONT'D) Lever Removal And Installation
Handle Disassembly And Assembly Figure 50-111-17
Figure 50-111-15 2
3
4
2
1
2
P-85882
1
N-17394
Remove the tie strap and disconnect the electrical
connectors (Item 1) [Figure 50-111-17] from the control
Remove the handle sleeve (Item 1) and bushings (Item lever.
2) [Figure 50-111-15] from the handle.

Remove the four nuts (Item 2) and the plate (Item 3)
Check all parts for wear and replace as needed. [Figure 50-111-17] used to mount the control lever.
Figure 50-111-16 Remove the control lever (Item 4) [Figure 50-111-17] by

sliding the lever through the control panel.
Installation: Tighten the four nuts to the plate so the

lever cannot be moved either right or left when seated in
the operator’s seat.
N-22796
Check the mounting bolt (Item 1) [Figure 50-111-16] that

connects the handle to the handle sensor unit for wear,
replace as needed.

CONTROL HANDLE / LEVER (ACS) (CONT'D)
Boot Removal And Installation
Remove the control handle / lever. (See Lever Removal

Figure 50-111-18
P-85883A

Remove the rubber boot (Item 1) [Figure 50-111-18].
Install the new boot and reinstall the steering lever.

CONTROL HANDLE / LEVER (SJC)
Description
The control panel has two electronic handles that control

the steering, lift, and tilt functions. There are no
mechanical connections to the hydrostatic pumps or the
control valve.
Joystick Testing
See Bobcat Advanced Troubleshooting System (B.A.T.S.)

or connect to service analyzer to check function.

CONTROL HANDLE / LEVER (SJC) (CONT'D) Figure 50-112-3
Joystick Removal And Installation

support device. (See Installing on Page 10-20-1.) 1
Figure 50-112-1
P-85891
1 Disconnect the joystick connector (Item 1) [Figure 50-

112-3] from the harness connector.
P-85890

Lift the rubber boot (Item 1) [Figure 50-112-1].
Figure 50-112-2
1
1
P-85889
Remove the four screws (Item 1) [Figure 50-112-2] and

lift the joystick control from the base.
Installation: Tighten the four screws to 4,0 - 4,5 N•m (35

- 40 in-lb) torque.

ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Remove the control pedal. (See Pedal Removal And
Remove the control pedal. (See Pedal Removal And
Installation on Page 50-90-1.) Figure 50-120-2
Figure 50-120-1
1 1
1
1
2
2
3
3
P-85677A
P-85677
Remove the top mounting screw (Item 1), washer (Item

2), and loosen the two bottom mounting screws (Item 3)
Remove the four mounting screws, (Item 1), washer (Item [Figure 50-120-2] from the front access panel.
2), and remove the left access panel (Item 3) [Figure 50-
120-1]. Remove the front access panel from the loader.
Remove the front access panel from the loader.


ACCESS PANEL (INSIDE) (SJC) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-121-3
Figure 50-121-1
2 1
1
2
P-90587
P-85887
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-3].
Remove the two mounting nuts (Item 1), and remove the
foot rest (Item 2) [Figure 50-121-1]. Figure 50-121-4

Figure 50-121-2
2
3 2
1 2
1
1
2
P-90588
P-85884
Remove the bolt and throttle pedal (Item 1), and remove
the mounting screws (Item 2) [Figure 50-121-4].
Remove the mounting screws (Item 1), and remove the
inside left access panel (Item 2) [Figure 50-121-2]. Remove the right inside access panel (Item 3) [Figure
50-121-4].


WINDOW (REAR) Disassembly And Assembly
WARNING
1
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
P-85705
Figure 50-130-1
Remove the screw (Item 1) from the latch [Figure 50-

130-2].
Installation: Tighten the screw (Item 1) [Figure 50-130-

2] to 21 - 23 N•m (180 - 200 in-lb) torque.
1 1
Figure 50-130-3
7
6
1
P-85706
5
Remove the rear window assembly by turning the two
latches (Item 1) [Figure 50-130-1] in until they disengage
from the window frame. 2
3
Push the rear window out the rear of the operator cab. 4
P-85704
NOTE: If rear window is broken, remove all glass
fragments from the rubber molding before
installing a new window. Inspect and replace any damaged parts.
Clean the area before installing the rear window The items listed below refer to [Figure 50-130-3].
assembly.
1. Latch
Reverse the procedure to install the rear window.
2. Spacer
3. Bushing
4. Washer
5. Screw
6. Rear Window
7. Seal


WINDOW (TOP)
Figure 50-131-1
1 1
P-85807
Install the bolts (Item 1) [Figure 50-131-1] through the

window grommets and through the cab holes.

Figure 50-131-2
1 1
1 1
P-85808
From inside the operator cab, install and tighten the four
nuts (Item 1) [Figure 50-131-2] on the window bolts.
Tighten the nuts (Item 1) [Figure 50-131-2] to 9 - 10 N•m



WINDOW (SIDE) Figure 50-132-3

1 1
Figure 50-132-1
1
1
1
1
2
P-90586
Support the window assembly and remove the six bolts

(Item 1) [Figure 50-132-3] from the window frame and
the operator cab.
P-85821 Installation: Tighten the six bolts (Item 1) [Figure 50-

132-3] to 9 - 10 N•m (80 - 90 in-lb) torque.

Figure 50-132-2 Remove the window assembly.
NOTE: The window assembly can only be replaced

as a complete unit.
1 3 4 5
2
P-85819
From inside the operator cab, remove the plastic cap

(Item 1), nut (Item 2), spring (Item 3), knob (Item 4), and
sleeve (Item 5) [Figure 50-132-1] and [Figure 50-132-2]
from the window assembly.
Installation: Tighten the nut (Item 2) [Figure 50-132-1]

flush to the end of the bolt.


CAB DOOR Figure 50-140-3
Description
The standard cab door is available as an option or dealer

1
installed kit.
Figure 50-140-1
P-85828
Lift the door (Item 1) [Figure 50-140-3] off the hinges.
Figure 50-140-4
2

P-85781A 1
2
Open the cab door.
Disconnect electrical connector (Item 2) and washer fluid

Figure 50-140-2
2
3
2 1
1
P-85837
P-85588A P-85589A
Remove the four bolts and nuts (Item 2) [Figure 50-140-

Rotate and pull the clip (Item 1) out of the gas spring 4] from the cab.
socket. Pull the gas spring socket (Item 3) straight off the
ball stud fitting (Item 2) [Figure 50-140-2]. Remove the hinges (Item 1) [Figure 50-140-4] from the
cab.
Installation: Install the hinges (Item 1) on the cab and

use the bolts and nuts (Item 2) [Figure 50-140-4] to
secure the hinges. Tighten to 9,6 - 10,7 N•m (85 - 90 in-
lb) torque.

CAB DOOR (CONT’D) Figure 50-140-7

2
Figure 50-140-5
4
3
1
1
1
P-85834
1 2
Remove the three bolts (Item 1) and the wiper motor

P-85829 assembly (Item 2) [Figure 50-140-7].
Figure 50-140-8
Remove the nuts (Items 1 and 2) and the wiper arms
(Item 3) [Figure 50-140-5].

2
Installation: Tighten the nut (Item 1) to 20 - 24 N•m (177
- 212 in-lb) torque and nut (Item 2) to 9 - 11 N•m (80 - 97 1
in-lb) torque.
Remove the wiper motor shaft nut (Item 4) [Figure 50-

140-5].
Installation: Tighten the nut (Item 4) to 9,9 - 14 N•m (88

4
- 124 in-lb) torque.
3
Remove the door from the loader. (See Removal And
4
Installation on Page 50-140-1.) P-85835
Figure 50-140-6
Remove the bolt (Item 1), the latch (Item 2), and spring
(Item 3) [Figure 50-140-8].
2
Remove the two nuts and bolts (Item 4) [Figure 50-140-
8].
1 Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

1 1
P-85841
Remove the three tie straps (Item 1) and the wiper motor
assembly cover (Item 2) [Figure 50-140-6].

CAB DOOR (CONT’D) Aligning
Disassembly And Assembly (Cont’d) Figure 50-140-11
Figure 50-140-9 WRONG WRONG
4
P-85832A P-85839A
3
4
P-85836
Figure 50-140-12
Remove the bolt (Item 1), the latch (Item 2), and spring CORRECT CORRECT
(Item 3) [Figure 50-140-9].

9].
Installation: Tighten the nuts (Item 4) to 31 - 34 N•m

Figure 50-140-10
1
1
3
P-85833A P-85838A
1
When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-11] between the
door and the cab or the striker and the latch.
If adjustment is needed. (See Adjusting on Page 50-140-

4.)
2 2
When the striker or latch is adjusted properly there will be
P-85830A no gap (Item 1) [Figure 50-140-12] between the door
and the cab or the striker and the latch.
Disconnect the harness (Item 1) [Figure 50-140-10]. After verifying alignment check for proper operation. (See
Checking Operation on Page 50-140-4.)
Remove the two bolts (Item 2), and the latch assembly
(Item 3) from the cab door [Figure 50-140-10].
Remove the glass from the frame.

CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-140-15
Figure 50-140-13
1
1
P-85413
P-85830
Sit in operator’s seat. Turn key ON, lower seat bar and
close the door. Press the PRESS TO OPERATE
Loosen the two bolts (Item 1) [Figure 50-140-13] and LOADER button (Item 1) [Figure 50-140-15].
adjust the latch as needed.

Open the door. The LIFT & TILT VALVE light (Item 2)
Figure 50-140-14 [Figure 50-140-15] will flash, an audible tone will sound,
and the message [DOOR] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-15] will go out and the display will return
to machine hours.
P-85831
Loosen the striker and adjust as needed (Item 1) [Figure

50-140-14].
After adjusting the striker and latch recheck the

alignment of the door sensor. (See Aligning on Page 50-
140-3.)

ARMREST
Description
The armrests are located on each side of the seat. They

are adjustable for comfort.
Figure 50-150-1
P-90837

Adjustable armrests (Item 1) [Figure 50-150-1].

ARMREST (CONT’D) Figure 50-150-4
Slide the seat and the backrest all the way forward.
1
Remove the seat belt (See Seat Belt Removal And
Figure 50-150-2
P-90845
Remove the top spacer (Item 1) and the bottom spacer

(Item 2) [Figure 50-150-4] from the seat.
1 Repeat for the other side.

P-90835

2].
Figure 50-150-3
P-90836
Remove the tie strap (Item 1) and disconnect the wire

harness connector (Item 2) [Figure 50-150-3].
Remove the armrest (Item 4) [Figure 50-150-3] from the

seat.

Remove the Joystick. (See Joystick Removal And

Remove the armrest. (See Removal And Installation on

Page 50-150-2.)
Figure 50-150-5
1
1
P-90840
Remove the two washers (Item 1) [Figure 50-150-7].
Figure 50-150-8

1
P-90838
2
Lift up on one edge and remove armrest cover (Item 1)
[Figure 50-150-5].
Figure 50-150-6
1 P-90841
2
Remove the two nuts and bolts (Item 1) and the support
tube (Item 2) [Figure 50-150-8].
1 1
P-90839
Remove the two bolts and washers (Item 1) and the

armrest shell (Item 2) [Figure 50-150-6].

Figure 50-150-9
1 1
3
2
2
P-90844
1
Remove the two nuts (Item 1) and the slide rail (Item 2)
P-90842 [Figure 50-150-11] from the armrest mount.
Repeat for the other side.

Figure 50-150-10

3
6
5 2
4 1
P-90843
Remove the nut (Item 1), washer (Item 2), and the plastic
washer (Item 3) [Figure 50-150-9] and [Figure 50-150-
10].
Remove the spacer (Item 4), plastic washer (Item 5), and
the bolt (Item 6) [Figure 50-150-10].
Installation: Tighten the nut to 21 - 23 N•m (180 - 200 in-

lb) torque.

LEFT SIDE LOWER PANEL Figure 50-160-3
Raise the operator’s cab.
Figure 50-160-1
1
1
1 1
P-90863 P-90856
1
Disconnect the wiper washer pump (Item 1) (if equipped)
1
[Figure 50-160-3] from the left side lower panel.
P-90897 Figure 50-160-4
Remove the five plastic rivets (Item 1) [Figure 50-160-1].

Remove the seat. (See Removal And Installation on
Page 50-30-1.)
1
Remove the 3-Point seat belt retractor (If equipped).
(See 3-Point Seat Belt Removal And Installation on Page 1
50-31-4.)
Lower the operator’s cab. 1
Figure 50-160-2 P-90856
Remove three plastic screws and the anchors (Item 1)

P-90867
Remove the storage compartment (Item 1) (if equipped)


LEFT SIDE LOWER PANEL (CONT’D) Figure 50-160-7
Figure 50-160-5
2
1 1
P-90858
1 Disconnect the hose (if equipped) (Item 1) and remove

P-90855 the hose (Item 2) [Figure 50-160-7] from the panel.
Figure 50-160-8
Remove the three plastic rivets and anchors (Item 1) and
the screw (Item 2) [Figure 50-160-5].

Figure 50-160-6
2 1
1
P-90852
Pull the left side lower panel (Item 1) [Figure 50-160-8]

P-90857 rear out and away from the side of the cab.
NOTE: Pull the left side lower panel away from the
Remove the two screws (Item 1) and the plastic rivet side of the cab far enough to access the wire
(Item 2) [Figure 50-160-6]. harness.

LEFT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-160-9 1
1 1
1 1
1
1
P-90860
P-90859
Press the four tabs (Item 1) [Figure 50-160-10] and
remove the HVAC control out of the left side lower panel.
Disconnect the HVAC or radio wire harnesses (Item 1)
[Figure 50-160-9] (if equipped). Figure 50-160-11

1
P-90865
NOTE: If the three clips (Item 1) [Figure 50-160-11] are

removed the cup holder will need to be
replaced.

LEFT SIDE LOWER PANEL (CONT’D)
Figure 50-160-12
1 1
1
1
P-90866

remove the speaker from the left side lower panel.

Figure 50-160-13
P-90864

and remove the washer tank from the left side lower
panel.

RIGHT SIDE LOWER PANEL Figure 50-170-3
Removal And Installation 2
Raise the operator’s cab.

1
Figure 50-170-1
1
1 1
1
P-90870
1
Remove the three plastic rivets and anchors (Item 1) and
1 the screw (Item 2) [Figure 50-170-3].
P-90897 Figure 50-170-4

Remove the five plastic rivets (Item 1) [Figure 50-170-1].
Remove the seat. (See Removal And Installation on

Page 50-30-1.)
2
1
Lower the operator’s cab.
Figure 50-170-2 1
1
1 P-90871
1
Remove the two screws (Item 1) and the plastic rivet
(Item 2) [Figure 50-170-4].
P-90869
Remove the three plastic screws and the anchors (Item

1) [Figure 50-170-2] from the right side lower panel.

RIGHT SIDE LOWER PANEL (CONT’D) Disassembly And Assembly
Figure 50-170-5
P-90879
P-90872
Remove the plastic nut and the lock washer (Item 1)
[Figure 50-170-7] from power port and remove the
Pull the right side lower panel (Item 1) [Figure 50-170-5] power port from the right side lower panel.
rear out and away from the side of the cab.

NOTE: The power port lock washer must be replaced
NOTE: Pull the right side lower panel away from the with a new when it has been removed.
side of the cab far enough to access the wire
harness. Figure 50-170-8
Figure 50-170-6
2 1
1
P-90877
2
1
P-90881
P-90873
Depress the tab (Item 1) [Figure 50-170-8] and remove
the radio from the right side lower panel.
Disconnect the wire harnesses (Item 1) and the antenna
(Item 2) [Figure 50-170-6] (if equipped with radio). Installation: Insert a screwdriver into the slot (Item 2)
[Figure 50-170-8] to lock the tab into place.
NOTE: Install the right side lower panel with the radio
removed to assist in connecting the power
port wire.

RIGHT SIDE LOWER PANEL (CONT’D)
Figure 50-170-9
P-90875
Remove the nut, washer, and cover, (Item 1) [Figure 50-

170-9] from the input.

Remove the input from the right side lower panel.
Figure 50-170-10
1
1
1
1
P-90876

remove the speaker from the right side lower panel.


HEADLINER Figure 50-180-3
Figure 50-180-1
1 1
1
P-90895
2
Remove the air duct (Item 1) [Figure 50-180-3] (if
P-90893 equipped).
Remove the cab light (if equipped). (See Cab Light

Remove the two screws (Item 1) and the rear shelf (Item Removal And Installation on Page 60-60-2.)
2) [Figure 50-180-1] (if equipped).

Figure 50-180-4
NOTE: The rear shelf has two panel clips on the
underneath side, lift vertically to disengage.
Installation: Tighten the screws to 2,3 N•m (20 in-lb)

torque.
1
1
Figure 50-180-2
1
1
2
1 P-90896
Remove the four retainers (Item 1) and remove the

headliner (Item 2) [Figure 50-180-4].
Installation: Route the cab light wire harness in the

P-90894 grove on the topside of the headliner (if equipped with
HVAC).
Remove the air duct (Item 1) [Figure 50-180-2] (if NOTE: Replace the retainers if needed.
equipped).


ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-9
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-12
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2

Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Left Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Display Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
Right Panel (Standard Key Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Right Panel (Keyless Start Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Right Panel (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Left Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Right Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-8
Left Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Right Panel (Standard Key Panel) Removal And Installation . . . . . . . . . . . . . . . . . . 60-50-9
Right Panel (Keyless Start Panel) Removal And Installation . . . . . . . . . . . . . . . . . 60-50-10
Right Panel (Deluxe Instrumentation Panel) Removal And Installation . . . . . . . . . 60-50-10
Key Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-11
Alarm Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-11
Left Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12
Right Switch Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-12

LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Cab Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
BOBCAT CONTROLLERS (GATEWAY AND AUXILIARY) . . . . . . . . . . . . . . . . . . . . . . 60-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1
Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-2
SPEED SENSORS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1

Viewing Service Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-2
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting The BICS (Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED - Key ON)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Lift Arm Bypass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) . . . . . . . . . . . . . 60-100-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-2
Bobcat Interlock Control System (BICS) Circuit Test . . . . . . . . . . . . . . . . . . . . . . . .60-110-4

TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
Handle Sensor Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . 60-130-3
Switch Handle Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Actuator Connector Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-9
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Handle Lock Solenoid Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . 60-130-10
Foot Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-130-11
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-12
Foot Sensor Lock Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 60-130-12
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2

Identification Chart ACD Group 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3
ELECTRICAL / HYDRAULIC CONTROLS (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-2
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-142-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Lift And Tilt Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-4
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-6
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-160-11
STEERING DRIFT COMPENSATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-2
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1
PASSWORD SETUP (DELUXE INSTRUMENTATION PANEL) . . . . . . . . . . . . . . . . . 60-190-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1

Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
PASSWORD SETUP (KEYLESS START PANEL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1

Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Changing The Owner Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
MAINTENANCE CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Adjusting Switch Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-3
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-4
Alarm Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
FRONT HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-220-1


CONNECTOR ASSIGNMENTS
NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C421 TILT SPOOL LOCK 3 10 FC1 FUSE CENTER 1 3
C103 TAILGATE 8 4,10,11,13 C422 LIFT SPOOL LOCK 3 10 FC2 FUSE CENTER 2 3
C104 ENGINE COOLANT SENSOR 2 6 C423 BUCKET POSITION 2 13 FRC1 FUSE RELAY CENTER 3,6,7,11,12
C105 HYD CHARGE PRESSURE 3 7 C425 BRAKE SOLENOID 3 7
C106 ENGINE SPEED SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5
C107 ENGINE OIL PRESSURE 3 6 C434-1 LEFT WORKLIGHT 1 2 11
C108 HYD TEMPERATURE SENDER 2 7 C434-2 LEFT WORKLIGHT 2 2 11 T1 BATT GROUND 4
C109 S/R ADAPTER HARNESS 2 6 C435-1 RIGHT WORKLIGHT 1 2 11 T2 BUZZER GROUND 8
C110 ALTERNATOR 2 6 C435-2 RIGHT WORKLIGHT 2 2 11 T3 FLASHER 13
C112 HYD OIL FILTER SWITCH 2 7 C437 TWO SPEED MAKEUP 2 7 T6 BATT GROUND 4
C126 HORN 2 13 C441 TWO SPEED 2 7 T8 BATT GROUND 4
C129 ACCESSORY 3 9 C446 HYDRAULIC FAN 2 7 T13 BUZZER POWER 8
C209 DOME LIGHT 3 9 C449 LEFT JOYSTICK 4 5 T14 PRE HEATER 6
C212 POWER SOCKET 2 9 C450 RIGHT JOYSTICK 4 5 T15 RIGHT REAR WORK LIGHT(+) 11
C250 DOOR SENSOR 2 9 C479 LEFT PANEL(BLACK) 12 5,8 T16 RIGHT REAR WORK LIGHT(-) 11
C251 WIPER 5 9 C480 LEFT PANEL(GRAY) 12 8 T17 LEFT REAR WORK LIGHT (+) 11
C252 WASHER 2 9 C482 SEATBAR SENSOR 3 9 T18 LEFT REAR WORK LIGHT (-) 11
C277 AIR RIDE SEAT 6 9 C483 TEMP CONTROL SWITCH 3 12 T19 BACKUP ALARM 10
C278 RIGHT SPEAKER 2 9 C486 AC COMPRESSOR 2 12 T20 BACKUP ALARM (GND) 10
C279 LEFT SPEAKER 2 9 C489 ACCESSORY 2 3,4
C308 BRAKE SOLENOID 2 7 C499 PTOL 4 8
C350 AC EVAPORATOR SWITCH 2 12 C500 RH KEY SWITCH 6 8
C355 DLX or STD FUEL HARNESS 6 6,12,13 C503 RH DLX PANEL 6 5,8
C362 REAR AUX SOLENOID 8 7 C602 LEFT REAR TAIL LIGHT 2 11
C404 BACKUP ALARM 2 3,10 C603 RIGHT REAR TAIL LIGHT 2 11
C405 AIR FILTER SWITCH 2 6 C606 POWER BOBTACH OPEN 2 13
C406 FUEL SENDER 2 6 C607 POWER BOBTACH CLOSE 2 13
C408 CAB CONNECTOR 48 3-5, 8-13 C611 BLOWER MOTOR 4 12
C409 RIGHT HANDLE 10 10 C630 THERMOSTAT 3 12 SW1 BRAKE SWITCH 9
C410 LEFT HANDLE 10 10 C635 HEATER VALVE 6 12 SW2 BEACON SWITCH 13
C411 LEFT HANDLE 5 WAY 5 10,13 C667 DOOR KIT 6 9 SW3 HAZARD SWITCH 13
C412 HANDLE(HORN) 2 10,13 C670 EXTERIOR BEACON 6 Dealer
13 Copy SW4
-- Not for Resale H/ISO SWITCH
HAND/FOOT, 9
C413 REAR ROD 2 7 C676 RADIO 6 9 SW5 POWER BOBTACH SWITCH 13
C414 REAR BASE 2 7 SW6 BUCKET POSITION SWITCH 13
C415 HIGH FLOW SOLENOID 2 7 SW8 FRONT WIPER SWITCH 9
C416 DIVERTER SOLENOID 2 7 SW9 TRAVEL CONTROL SWITCH 8
C417 REAR AUX RELIEF 2 7 J1A GATEWAY COTROLLER 34 SW10 BLOWER SWITCH 12
C418 FRONT ROD 2 7 J1B GATEWAY CONTOLLER 26 SW11 AC SWITCH 12
C419 FRONT BASE 2 7 J2A AUX CONTROLLER 34
C420 HYD LOCK 2 7 J2B AUX CONTROLLER 26
WIRE CATEGORIES FOR COLORS AND NUMBER RANGE SCHEMATIC INDEX

GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE OVERVIEW PAGE 1,2
BATT FEED, GENERAL 1000 THROUGH 1499 RED RED POWER PAGE 3
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT GROUND PAGE 4
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT CAN BUS PAGE 5
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9
LIGHTS 6000 THROUGH 6999 PINK PNK MANUAL CONTROLS PAGE 10
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 WIRING SCHEMATIC
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT (STANDARD MACHINE)
Sheet 1 of 13 Printable Version Click Here
(PRINTED JUNE 2009)
513 of 896Printed In U.S.A. 7175752
J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER)
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN B-1
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 REAR AUX (F) RETURN B-2 UNSW BATT
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5 REAR AUX (F)
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6 RELIEF SOLENOID
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 OUTPUT SPARE B-7 REAR AUX (M)
A-8 TRACTION PULL RELAY B-8 CAN LO 1 A-8 B-8 CAN LO 1
A-9 FAN 1 RELAY B-9 CAN HI 1 A-9 B-9 CAN HI 1
A-10 TILT SPOOL LOCK RETURN B-10 SPOOL LOCK SENSOR 2 A-10 REAR AUX (M) RETURN B-10
A-11 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11
A-12 SPARE DIGITAL, ECU SOURCES B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD A-13 RH RIGHT BUTTON UP B-13 FRONT AUX (F)
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 DIGITAL INPUT SPARE B-14 CAN HI 2
A-15 ENGINE SPEED B-15 GROUND P1 A-15 B-15 GROUND
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND
A-17 LIGHT 2 RELAY B-17 GROUND P3, SENSOR A-17 B-17 HANDLE POT GND
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP A-18 FRONT AUX (M) RETURN B-18 RH PVM POT SIGNAL
A-19 PTOL LED B-19 FAN 2 OUTPUT A-19 B-19 FRONT AUX (M)
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 LH FLOAT BUTTON B-20 CAN LO 2
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 HYDRAULIC DETENT B-21 RH TRIGGER
A-22 STATER RELAY FDBK B-22 RUN/ENTER A-22 LH RIGHT BUTTON DOWN B-22 SWITCHED POWER
A-23 HYD OIL FILTER SW2 B-23 SENSOR SUPPLY 8V A-23 RH CENTER BUTTON B-23 HANDLE POT POWER
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 DIGITAL INPUT SPARE B-24
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25 BUCKET POSITION (SPARE)
A-26 SPARE B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW
A-27 SPARE A-27 BUCKET POSITION(SPARE) RETURN
A-28 LIGHT 2 RELAY FDBK A-28 LH RIGHT BUTTON
A-29 FAN 1 RELAY FDBK A-29 RH RIGHT BUTTON DOWN
A-30 FUEL PULL RELAY FDBK A-30 RH LEFT UP
A-31 LIGHT 1 RELAY FDBK A-31 RH LEFT DOWN
A-32 HYD OIL TEMP A-32
A-33 SPARE ANALOG A-33
A-34 HYD OIL FILTER SW1 A-34 DIGITAL INPUT SPARE
HARNESS PART NUMBER

MAIN FRAME 7174782
STD CAB 7165991
DLX CAB 7176098
DLX FUEL 7175293
STD FUEL 7149219
DOOR 7155024
S/R 6733370
TAILGATE DOM 7175271
TAILGATE EUR 7175287
2 SPD ADP 7159366
BACKUP ALARM 7175017
BRAKE ADAPTER 7165061
WIRING SCHEMATIC
(STANDARD MACHINE)
(PRINTED JUNE 2009)
Printed
514 of 896 In U.S.A. 7175752
POWER
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
BATTERY MEGAFUSE
FC1 FUSE 2
100.0 Amps 1180/RED/WHT
BATT_CABLE 25 A J2B 2
1025/RED 1160/RED/WHT 1150/RED/WHT
J2B 3
1240/RED/WHT
FC1 FUSE 1 SHEET 8
1400/RED/WHT
25 A C408 17 SHEET 9
1070/RED 1120/RED/WHT 1450/RED/WHT 1450/RED/WHT 1420/RED/WHT
SHEET 8
1110/RED/WHT 1440/RED/WHT
SHEET 6 FC2 FUSE 4 J1B 2 SHEET 8
1130/RED/WHT
15 A J1B 3
1290/RED 1370/RED/WHT
SHEET 9
FC2 FUSE 2 1460/RED/WHT
25 A SHEET 13
SHEET 13
FC2 FUSE 1
1190/RED 25 A 1165/RED/WHT
SHEET 5
1010/RED
FRC 1 FUSE 6
1310/RED 30 A 1360/RED/WHT
SHEET 7
1050/RED FRC1 FUSE 5
30 A 1350/RED/WHT
SHEET 6
FRC1 FUSE 11
1300/RED
25 A
1140/RED/WHT Dealer Copy -- Not for Resale
SHEET 12
FRC1 FUSE 10
1340/RED 20 A 1330/RED/WHT
SHEET 11
1620/RNG/WHT
FRC1 FUSE 9 SHEET 8
1940/RNG/WHT
15 A SHEET 8
1320/RED/WHT 1930/RNG/WHT
SHEET 11 SHEET 8
1060/RED 1775/RNG/WHT
SHEET 6 SHEET 9
SHEET 6 SHEET 8
1785/RNG/WHT
SHEET 9
1950/RNG/WHT
FRC1 FUSE 4 C408 43 SHEET 8
1660/RNG/WHT 1660/RNG/WHT 1590/RNG/WHT
5A SHEET 8
1570/RNG/WHT
SHEET 10
FRC1 FUSE 2
1760/RNG/WHT 25 A 1850/RNG/WHT
SHEET 9
FRC1 FUSE 3
15 A 1550/RNG/WHT
SHEET 13
FRC1 FUSE1
25 A 1750/RNG/WHT 1780/RNG/WHT
C489 A
SWITCHED 1720/RNG/WHT
POWER
C404 B
WIRING SCHEMATIC
1050/RED 30
87
1765/RNG/WHT 1790/RNG/WHT
SHEET 12 (STANDARD MACHINE)
2055/BLK 85 86 FRC1 FUSE 7
SHEET 6
SHEET 12
2030/BLK 1795/RNG/WHT 25 A 1730/RNG/WHT
SHEET 5
FRC1 FUSE 8
25 A 1580/RNG/WHT
SHEET 9
8000/TAN
1920/RNG/WHT
J1A 4
SHEET 5
1830/RNG/WHT
C408 6 SHEET 5
(PRINTED JUNE 2009)
515 of Printed
896 In U.S.A. 7175752
GROUND
2080/BLK
SHEET 5
2070/BLK
SHEET 5 C408 32
2940/BLK 2950/BLK 2950/BLK
SHEET 8
2960/BLK 2510/BLK
SHEET 8 J1B 16
2920/BLK 2500/BLK 2110/BLK T6
SHEET 8 J1B 15 BATT GND
2250/BLK 2540/BLK
SHEET 8 J2B 16
2550/BLK 2090/BLK
J2B 15
2765/BLK
SHEET 11
2745/BLK
SHEET 12
2790/BLK T8
SHEET 9 BATT GND
2780/BLK
SHEET 13
2730/BLK
SHEET 9
2620/BLK
SHEET 11
2630/BLK 2720/BLK
SHEET 11
2650/BLK 2600/BLK C103 B C489 B Dealer Copy -- Not for Resale
2600/BLK
SHEET 10
2640/BLK 2810/BLK 2390/BLK
SHEET 11 SHEET6
2610/BLK
SHEET 11
2200/BLK
SHEET 7
2751/BLK
SHEET 13
2450/BLK
SHEET 7
2741/BLK
SHEET 13
2785/BLK 2710/BLK 2300/BLK T1
SHEET 13 SHEET 5 BATT GND
2930/BLK 2480/BLK
SHEET 9 C408 42 SHEET 7
2830/BLK 2900/BLK 2900/BLK
SHEET 13
2700/BLK 2000/BLK
SHEET 8 SHEET 11
3530/LBL
SHEET 7
3800/LBL
SHEET 6
3910/LBL
SHEET 9
3310/LBL 3010/LBL
SHEET 7 J1B 17
3410/LBL
SHEET 7
3110/LBL
SHEET 6
3510/LBL
SHEET 6
3710/LBL
SHEET 6
WIRING SCHEMATIC
(STANDARD MACHINE)
(PRINTED JUNE 2009)
CAN BUS
9160/PUR/WHT
C503 2
9260/PUR RH DLX PANEL
C503 4
9200/PUR 9270/PUR 9230/PUR C408 8 9230/PUR 9240/PUR 9250/PUR 9650/PUR 9630/PUR
GWY CTRLR J1B 8 C479 4
9100/PUR/WHT 9170/PUR/WHT 9130/PUR/WHT 9130/PUR/WHT 9140/PUR/WHT 9150/PUR/WHT 9550/PUR/WHT 9530/PUR/WHT LEFT PANEL
J1B 9 C479 3
120 OHM C408 7 120 OHM
RESISTOR RESISTOR C450
1830/RNG/WHT 1
#
SHEET 3
2070/BLK 2
SHEET 4 RIGHT
9560/PUR/WHT 3
JOYSTICK
9660/PUR 4
9220/PUR
J2B 8 AUX CTRLR C449
9120/PUR/WHT
J2B 9 1840/RNG/WHT 1 #
Dealer Copy -- Not for Resale SHEET 3
2080/BLK 2
SHEET 4
9540/PUR/WHT 3 LEFT
9640/PUR 4 JOYSTICK
C426
9500/PUR/WHT A
J1B 14
9600/PUR B
J1B 20
9400/PUR D
J1B 21
C CAN (Remote Start Tool, ACD)
1730/RNG/WHT E
SHEET 3
1165/RED/WHT F
SHEET 3
2710/BLK G
SHEET 4
# CONNECTOR DOES NOT EXIST IN 7165991
WIRING SCHEMATIC
(STANDARD MACHINE)
(PRINTED JUNE 2009)
Printed
517 of 896 In U.S.A. 7175752
ENGINE
STARTER
STARTER C109
1030/RED 30 J1A 22
8250/TAN B 8250/TAN R M
B SHEET 3
SHEET 3 87 8200/TAN A 8200/TAN S 1015/RED
C110
2005/BLK 85 86 8210/TAN B
SHEET 12 J1A 7 S 1020/RED FRC1 FUSE 12
ALTERNATOR G 15 A
L 1800/RNG/WHT 1815/RNG/WHT
SHEET 12
EXCITATION
2015/BLK
FUEL SHUTOFF
FUEL SOLENOID
PULL C101
8120/TAN D5 8100/TAN B 8100 TAN PULL 24.5 OHM
1350/RED/WHT 30 0.33 OHM
SHEET 3 87 8150/TAN J1B 4 8800/TAN A 8800 TAN HOLD
J1A 30
2810/BLK 2800/BLK C 2800 BLK
85 86 SHEET4
2025/BLK 8110/TAN
SHEET 7 J1A 3 Dealer Copy -- Not for Resale
C106 GLOW
3600/LBL A SIG PLUG
J1A 15 ENGINE SPEED SENSOR 30 8550/TAN
3610/LBL B GND 1060/RED J1A 14
SHEET 3 87 8500/TAN
3800/LBL T14 PRE HEATER
SHEET 4
3210/LBL B SIG 85 86
ENGINE COOLANT 2016/BLK 8510/TAN
3200/LBL A GND J1A 6
J1B 18 SENSOR (500-3000 OHM) 2055/BLK
SHEET 3
C104
C107
3500/LBL B +5V PWR
SHEET 9
3520/LBL C SIG ENGINE OIL PRESSURE
J1A 25
3510/LBL A GND SENDER (0.5 ~ 4.5V)
SHEET 4
C406
C355 C FUEL
3100/LBL 3100/LBL A SIG
J1B 12 SENDER
3110/LBL 3110/LBL B GND
SHEET 4
C355 D WIRING SCHEMATIC
C405
SHEET 4
3710/LBL B GND
AIR FILTER
(STANDARD MACHINE)
3700/LBL A SIG
J1A 16 SWITCH
(PRINTED JUNE 2009)
HYDRAULICS
TRACTION
LOCK C425 TRACK MACHINES
30 4150/LGN
1360/RED/WHT J1A 13
SHEET 3 87 4100/LGN B C308
BRAKE
2025/BLK 4200/LGN A 4200/RED A SOLENOID
SHEET 6 85 86 J1B 6
2035/BLK 4110/LGN 2200/BLK C 2200/BLK B 9.8 OHM
SHEET 11 J1A 8 SHEET 4
12 V
HARN BRAKE ADAPTER 7165061
C425 WHEEL MACHINES
B PULL 0.3 OHM TRACTION
A HOLD 10.9 OHM LOCK
C
C362 C414
OPTIONAL REAR AUX
4440/LGN A 4440/LGN 1 SIG DIRECTIONAL SOLENOID
J2B 5
2440/BLK B 2440/BLK 2 GND FEMALE COUPLER
J2A 2
7.5 OHM 12V C420
C413 2410/BLK B
4430/LGN C 4430/LGN 1 SIG OPTIONAL REAR AUX J1A 1 HYD LOCK SOLENOID
J2B 7 4410/LGN A
2430/BLK D 2430/BLK 2 GND DIRECTIONAL SOLENOID J1B 13 9.8 OHM 12V
J2A 10 MALE COUPLER
7.5 OHM 12V C105
C416 HYDRAULIC
3410/LBL B CHARGE
J2B 4
4450/LGN E 4450/LGN 1 SIG OPTIONAL REAR AUX Dealer Copy -- Not for Resale J1B 1
3420/LBL C PRESSURE
2450/BLK F 2450/BLK 2 GND BLEED / LOCK VALVE
SHEET 4 3400/LBL A 0.5-7.5V
SOLENOID MALE COUPLER J1B 23
7.5 OHM 12 V +8V
C417 C108
4480/LGN G 4480/LGN 1 SIG OPTIONAL REAR AUX
HYDRAULIC
J2B 6 3310/LBL B TEMPERATURE
2480/BLK H 2480/BLK 2 GND BLEED / LOCK VALVE SHEET 4
SHEET 4 3300/LBL A SENDER
SOLENOID FEMALE COUPLER J1A 32
500 - 3000 OHM
C112
C415
OPTIONAL HIGH FLOW 3430/LBL A HYDRAULIC
2460/BLK B GND J1A 34
J2A 26 SOLENOID 3530/LBL B FILTER SWITCH
4460/LGN A SIG SHEET 4
J2B 26 7.5 OHM
12 V
C418
2330/BLK 2 GND FRONT ROD SOLENOID (MALE)
J2A 18
4330/LGN 1 SIG 3.3 OHM PWM
J2B 19
C419
2340/BLK 2 GND FRONT BASE SOLENOID (FEMALE)
J2A 1
J2B 13
C437
2360/BLK 2 GND
J1A 27 TWO SPEED
4360/LGN 1 SIG MAKEUP SOLENOID
J1B 25
2350/BLK
C441
2 GND
WIRING SCHEMATIC
J1A 26
TWO SPEED SOLENOID
J1B 26
4350/LGN 1 SIG
(STANDARD MACHINE)
C446
J1A 18
2910/BLK 2 GND HYDRAULIC
FAN SOLENOID
4010/LGN 1 SIG 7.2 OHM
J1B 19
12 V (S/N A3NW11001 AND ABOVE)
(PRINTED JUNE 2009)
Printed
519 of 896 In U.S.A. 7175752
T13
BUZZER (+)
1940/RNG/WHT
SHEET 3
T2
BUZZER (-)
C500
LEFT PANEL (BLACK) RH KEY SWITCH
9360/PUR C408 4 9360/PUR 2
C479 10 J1A 24 START
9320/PUR 9350/PUR 9350/PUR 4
BUZZER J1B 22 RUN/ENTER SW
2920/BLK C479 2 C408 40
SHEET 4 GROUND 1950/RNG/WHT 5
SHEET 3 Switched Power
1440/RED/WHT C479 1 1420/RED/WHT 1
SHEET 3 Battery (+) SHEET 3 Battery (+)
2960/BLK 3
1960/RNG/WHT 1620/RNG/WHT C479 5 SHEET 4 GROUND
SHEET 3 SHEET 3 Switched Power 6
SW9 6450/PNK C479 11
SHEET 13 Left Blinker Input
TRAVEL CONTROL C479 8
SWITCH (OPTIONAL) SHEET 13
6550/PNK Dealer Copy -- Not for Resale
Right Blinker Input
5 6 4500/LGN C479 9
4 SHEET 9 Park Break Input
4730/LGN C479 7
2700/BLK 2 3 Travel Control Input
SHEET 4 1 RH DLX PANEL
1590/RNG/WHT C503 5
C480 SHEET 3 Switched Power
LEFT PANEL (GRAY) C503 1
1240/RED/WHT
4750/LGN 12 SHEET 3 Battery (+)
SHEET 9 Reserved Output 5 C503 3
9310/PUR 2 2250/BLK
SHEET 9 Park Break Output SHEET 4 GROUND
PTOL
C499
(Press To Operate Loader)
9380/PUR C408 1 9380/PUR 2
J1A 20 PTOL OUTPUT
9370/PUR 9370/PUR 4
J1A 19 PTOL LED
C408 37
1930/RNG/WHT 1
SHEET 3 SWITCH POWER
2940/BLK 3
SHEET 4 GROUND
WIRING SCHEMATIC
(STANDARD MACHINE)
CAB DISPLAY S650 (S/N A3NV11001 AND ABOVE)

(PRINTED JUNE 2009)
Printed In U.S.A. 7175752
520 of 896
GROUP DESCRIPTION
BATT FEED, GENERAL
BATT FEED, FUSED
BATT FEED, SWITCHED
GROUP NUMBER RANGE
1000 THROUGH 1499
1000 THROUGH 1499
1500 THROUGH 1999
WIRE COLOR
RED
RED/WHITE
ORANGE/WHITE
COLOR CODE
RED
RED/WHT
RNG/WHT
OVERVIEW
POWER
GROUND
CAN BUS
PAGE 1,2
PAGE 3
PAGE 4
PAGE 5
7176098 ONLY SW4
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 HAND/FOOT
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7 (ACS)
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8 H/ISO
4550/LGN C408 5
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9 (SJC, AWS)
SWITCH
1785/RNG/WHT 2 1 4275/LGN C408 3
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11 SHEET 3 3
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 2060/BLK 5 6 4235/LGN C408 2
COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13 4
C212
2795/BLK 1
+ POWER SOCKET
1375/RED/WHT 2
-
C209
C408 24
2790/BLK 2790/BLK 2010/BLK B
C408 23 SHEET 4
1370/RED/WHT 1370/RED/WHT 1390/RED/WHT A DOME LIGHT
SHEET 3
4760/LGN C
*
C676
1885/RNG/WHT 1
2885/BLK 2
C129 C279
1210/RED/WHT A
SHEET 3
1580/RNG/WHT
C408 16
1580/RNG/WHT * 1865/RNG/WHT
2820/BLK
B LEFT SPEAKER
1
2
+ 7820/WHT
7830/WHT
3
4 RADIO CONN
C -
ACCESSORY
CONN C278
2 - 7810/WHT 6
RIGHT SPEAKER 1 7800/WHT 5
+
2730/BLK C408 33 2730/BLK
SHEET 4
C277
Dealer Copy -- Not1510/RNG/WHT
for Resale 4
2210/BLK 5 AIR RIDE
SEAT SOLENOID
C482 SEATBAR
SENSOR C667 C250 SENSOR SHOWN
3910/LBL C408 45 3910/LBL A GND
SHEET 4 4750/LGN 4740/LGN 4 4740/LGN 1 WITH DOOR OPEN
SHEET 8 DOOR SENSOR
1400/RED/WHT 5 1400/RED/WHT 2 C251
3920/LBL C408 46 3920/LBL B SIG SHEET 3
J1B 11 1860/RNG/WHT D SW PWR
6 7330/WHT C PARK WIPER
3930/LBL 3900/LBL C408 44 3900/LBL C PWR MOTOR
J1B 24 1570/RNG/WHT 7300/WHT A LOW
3500/LBL
+5V SHEET 6 B GND
1850/RNG/WHT 1850/RNG/WHT 1 1850/RNG/WHT 3 E
SHEET 3
C408 27 1 2
3 7310/WHT 6
SW1 4 5
BRAKE SWITCH SW8
4500/LGN 3 2 FRONT WIPER
SHEET 8 1 2840/BLK 2 2840/BLK SWITCH C252
9310/PUR 4 5
SHEET 8 7310/WHT L
1775/RNG/WHT 6
SHEET 3 WASHER
2930/BLK
SHEET 4 2845/BLK X MOTOR
WIRING SCHEMATIC
(STANDARD MACHINE)
7165991Standard Cab Harness S650 (S/N A3NV11001 AND ABOVE)
7176098 Deluxe Cab Harness (S/N A3NW11001 AND ABOVE)
(PRINTED JUNE 2009)
Printed
521 of 896 In U.S.A. * SPLICE DOES NOT EXIST IN 7165991 7175752
MANUAL
CONTROLS
C409
K
G RIGHT HANDLE
1590/RNG/WHT A
4940/LGN H
J2A 30
4930/LGN J SKI CTRL
J2A 31
4920/LGN E DETENT FLOW
J2B 21
4910/LGN F
J2A 13 TWO SPD
4310/LGN C -
J2B 17
4320/LGN D
J2B 18 PWM
4300/LGN B +
J2B 23
C410
K
D LEFT HANDLE
Dealer Copy -- Not for 4840/LGN
Resale C
J2A 28
4830/LGN B SKI CTRL
J2A 22
4820/LGN G
J2A 12
4810/LGN F SIDE SHIFT
J2A 11
1570/RNG/WHT 1710/RNG/WHT A
SHEET 3
1560/RNG/WHT J
J2B 22
H
E
C411
E
C
A
D TURN SIGNAL
B
C412
C404 A 7100/WHT C103 C 7100/WHT T19 1 B
+ BACKUP ALARM
2650/BLK 7001923 A HORN
SHEET 4 -
T20 1
C421
2370/BLK 3
J1A 10
J1B 7
4370/LGN 1
2
TILT SPOOL LOCK SOLENOID WIRING SCHEMATIC
C422 (STANDARD MACHINE)
2380/BLK 3
J1A 2
J1B 5
4380/LGN 1 LIFT SPOOL LOCK SOLENOID S650 (S/N A3NV11001 AND ABOVE)
2
(PRINTED JUNE 2009)
Printed
522 of 896 In U.S.A. 7175752
LIGHTS
C434-1
2735/BLK B LEFT FRONT
6100/PNK A WORK LIGHT
37.00 Watts
C434-2
C408 28
2765/BLK 2765/BLK 2750/BLK B LEFT FRONT
SHEET 4
50.00 Watts
C435-1
6000/PNK C408 25 6000/PNK 6120/PNK A RIGHT FRONT
2760/BLK B WORK LIGHT
37.00 Watts
C435-2
6130/PNK A
RIGHT FRONT
50.00 Watts
FRONT
WORK
LIGHTS C603
SHEET 4
2610/BLK 2
SHEET 3
1330/RED/WHT 30
6340/PNK
Dealer Copy --C103
6310/PNK
NotA for Resale
6310/PNK 6320/PNK 1
RIGHT REAR
87 TAIL LIGHT
2000/BLK 85 86 C602
SHEET 4
2045/BLK 6330/PNK 1 LEFT REAR
6320/PNK 2640/BLK 2 TAIL LIGHT
J1A 5 SHEET 4
6330/PNK
J1A 31
2620/BLK T16 1
SHEET 4 RIGHT REAR
6210/PNK WORK LIGHT
REAR
LIGHT T15 1
1320/RED/WHT 30 C103 H
SHEET 3 6200/PNK 6200/PNK T17 1
87
2630/BLK LEFT REAR
85 86 SHEET 4 WORK LIGHT
2045/BLK T18 1
2035/BLK
SHEET 7
6210/PNK
J1A 17
6230/PNK
J1A 28
WIRING SCHEMATIC
(STANDARD MACHINE)
(PRINTED JUNE 2009)
Printed
523 of 896 In U.S.A. 7175752
HVAC
C630
7021/WHT 7020/WHT C408 34 7020/WHT B
J1A 11
7023/WHT 2570/BLK C
3320/LBL A
THERMOSTAT
C350
B C483
7024/WHT A EVAPORATOR 2560/BLK C BLK
(AC PRESS SWITCH) POTENTIOMETER
1980/RNG/WHT A DBL
C486 7220/WHT B WHT (TEMP CONTROL
C355 A SWITCH)
7024/WHT 7025/WHT 1
2 MAGNET CLUTCH C635
(COMPRESSOR)
2290/BLK 2280/BLK D SIG
SHEET 13
D4 2130/BLK C GND HEATER
1900/RNG/WHT 1910/RNG/WHT A 12V VALVE
SW10 B
BLOWER E
HVAC SWITCH F
1140/RED/WHT 30 OFF
SHEET 3 87 1500/RNG/WHT C408 21 1500/RNG/WHT 5 2
1
2030/BLK 85 86 4
SHEET 3
2005/BLK
Dealer Copy -- Not for Resale6 C611
SHEET 6 3 1970/RNG/WHT A 14.00 Amps High
1790/RNG/WHT
SHEET 3 1520/RNG/WHT B 7.50 Amps Med BLOWER
1815/RNG/WHT
SHEET 6 7320/WHT C 5.00 Amps Low MOTOR
8020/TAN
J1A 21 2580/BLK D
2745/BLK 2745/BLK
SHEET 4
C408 22
7040/WHT
SW11
AC SWITCH
1 C
2100/BLK
3
WIRING SCHEMATIC
(STANDARD MACHINE)
(PRINTED JUNE 2009)
Printed
524 of 896 In U.S.A. 7175752
OPTIONS
SW5
POWER
BOBTACH
SWITCH
C408 26 1 7000/WHT C408 9 7000/WHT
C411 1410/RED/WHT 1410/RED/WHT 1380/RED/WHT 2
C408 15 SHEET 3
B 6010/PNK 6010/PNK 1430/RED/WHT 1200/RED/WHT 3
4 7010/WHT C408 10 7010/WHT
C 6550/PNK 5
LEFT C408 36 SHEET 8 D1 X T3 6
HANDLE A 6515/PNK 6500/PNK 6500/PNK 6530/PNK FLASHER CONN SW2
5 PIN E 6540/PNK L BEACON
C408 29 D2 SWITCH PWR BOB CLOSE
D 6415/PNK 6400/PNK 6400/PNK 6430/PNK 6570/PNK
2725/BLK C607
6450/PNK 6 C355 E
SHEET 8 5 A 7010/WHT
SW3 1 4
C103 E HAZARD SWITCH 2 C670 STROBE 1 2 B 2770/BLK 2751/BLK 2751/BLK
6410/PNK (PINS 3 & 6 3 BEACON
4 6700/PNK E 3 C355 B
6510/PNK INTERNALLY 5 2290/BLK SHEET 4
2850/BLK 2420/BLK D SHEET 12
INSULATED) 6
C103 D C
LEFT C606
A
BLINKER B 2775/BLK
F
2780/BLK C408 30 2780/BLK A 7000/WHT C355 F
SHEET 4 B
6440/PNK
Dealer Copy -- Not for ResaleRIGHT
6540/PNK PWR BOB OPEN
BLINKER
1550/RNG/WHT C408 13
1550/RNG/WHT
SHEET 3
SW6
3 2 BUCKET
7022/WHT 1 POSITION
C126
SHEET 4 SHEET 4 4 SWITCH
C412 2785/BLK B 2830/BLK 5
B 7210/WHT C408 38 7210/WHT A C423
LEFT HANDLE 6 OPTIONAL
C408 35 D3 A
2 PIN A 1460/RED/WHT 7022/WHT 7030/WHT BUCKET
SHEET 3
POSITION
2741/BLK 2740/BLK B SOLENOID
SHEET 4 9.8 OHM
WIRING SCHEMATIC
(STANDARD MACHINE)
(PRINTED JUNE 2009)
Printed In U.S.A. 7175752
525 of 896
CONNECTOR ASSIGNMENTS CONNECTOR ASSIGNMENTS (ACS)
NUM OF NUM OF NUM OF NUM OF
CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET CONN DESCRIPTION SHEET
PINS PINS PINS PINS
C101 FUEL SHUTOFF SOLENOID 3 6 C421 TILT SPOOL LOCK 3 10 J1A GATEWAY COTROLLER 34 C428 TILT ACTUATOR 8 14
C103 TAILGATE 8 4,10,11,13 C422 LIFT SPOOL LOCK 3 10 J1B GATEWAY CONTOLLER 26 C429 LIFT ACTUATOR 8 14
C104 ENGINE COOLANT SENSOR 2 6 C423 BUCKET POSITION 2 13 J2A AUX CONTROLLER 34 C467 LIFT PEDAL LOCK 3 14
C105 HYD CHARGE PRESSURE 3 7 C425 BRAKE SOLENOID 3 7 J2B AUX CONTROLLER 26 C468 TILT PEDAL LOCK 3 14
C106 ENGINE SPEED SENSOR 2 6 C426 CAN (Remote Start Tool, ACD) 7 5 J1-ACS ACS CONTROLLER 8 C469 TILT HANDLE 3 14
C107 ENGINE OIL PRESSURE 3 6 C434-1 LEFT WORKLIGHT 1 2 11 J2-ACS ACS CONTROLLER 10 C470 TILT PEDAL 3 14
C108 HYD TEMPERATURE SENDER 2 7 C434-2 LEFT WORKLIGHT 2 2 11 J3-ACS ACS CONTROLLER 10 C471 LIFT PEDAL 3 14
C109 S/R ADAPTER HARNESS 2 6 C435-1 RIGHT WORKLIGHT 1 2 11 J5 DRIVE CONTROLLER 50 C472 LIFT HANDLE 3 14
C110 ALTERNATOR 2 6 C435-2 RIGHT WORKLIGHT 2 2 11
C112 HYD OIL FILTER SWITCH 2 7 C437 TWO SPEED MAKEUP 2 7
C126 HORN 2 13 C441 TWO SPEED 2 7 FC1 FUSE CENTER 1 3
C129 ACCESSORY 3 9 C446 HYDRAULIC FAN 2 7 FC2 FUSE CENTER 2 3
C209 DOME LIGHT 3 9 C449 LEFT JOYSTICK 4 5,15 FRC1 FUSE RELAY CENTER 3,6,7,11,12
C212 POWER SOCKET 2 9 C450 RIGHT JOYSTICK 4 5,15
C250 DOOR SENSOR 2 9 C459 LEFT JOYSTICK 4 15
C251 WIPER 5 9 C460 RIGHT JOYSTICK 4 15 T1 BATT GROUND 4
C252 WASHER 2 9 C479 LEFT PANEL(BLACK) 12 5,8 T2 BUZZER GROUND 8
C277 AIR RIDE SEAT 6 9 C480 LEFT PANEL(GRAY) 12 8 T3 FLASHER 13
C278 RIGHT SPEAKER 2 9 C482 SEATBAR SENSOR 3 9 T6 BATT GROUND 4
C279 LEFT SPEAKER 2 9 C483 TEMP CONTROL SWITCH 3 12 T8 BATT GROUND 4 CONNECTOR ASSIGNMENTS (SJC)
C308 BRAKE SOLENOID 2 7 C486 AC COMPRESSOR 2 12 T13 BUZZER POWER 8 NUM OF
CONN DESCRIPTION SHEET
C350 AC EVAPORATOR SWITCH 2 12 C489 ACCESSORY 2 3,4 T14 PRE HEATER 6 PINS
C355 DLX or STD FUEL HARNESS 6 6,12,13 C492 ACS/SJC/AWS 1 8 3,5,9,14,15 RIGHT REAR WORK LIGHT(+) C536 RIGHT SWASHPLATE 4 15
T15 11
C362 REAR AUX SOLENOID 8 7 C493 ACS/SJC/AWS 2 4 3,4,14,15 T16 RIGHT REAR WORK LIGHT(-) 11 C537 LEFT SWASHPLATE 4 15
C404 BACKUP ALARM 2 3,10 C497 SJC HORN/BLINKER 3 13 LEFT REAR WORK LIGHT (+) 11 C428 TILT ACTUATOR 8 15
T17
C405 AIR FILTER SWITCH 2 6 C499 PTOL 4 8 LEFT REAR WORK LIGHT (-) 11 C429 LIFT ACTUATOR 8 15
T18
C406 FUEL SENDER 2 6 C500 RH KEY SWITCH 6 8 10 C453 RIGHT QUAD A DRIVE 4 15
T19 BACKUP ALARM
C408 CAB CONNECTOR 48 3-5, 8-13 C503 RH DLX PANEL 6 5,8 T20 BACKUP ALARM (GND) 10 C454 LEFT QUAD DIRVE 4 15
C409 RIGHT HANDLE 10 10 C602 LEFT REAR TAIL LIGHT 2 11 C474 BRAKE LIGHT 1 15
C410 LEFT HANDLE 10 10 C603 RIGHT REAR TAIL LIGHT 2 11
C411 LEFT HANDLE 5 WAY 5 10,13 C606 POWER BOBTACH OPEN 2 13 SW1 BRAKE SWITCH 9 C501 A22 PUMP HARNESS 8 15
C412 HANDLE(HORN) 2 10,13 C607 POWER BOBTACH CLOSE 2 DealerSW2
13 Copy -- NotBEACON
for Resale
SWITCH 13 C544 LEFT FORWARD DRIVE 2 15
C413 REAR ROD 2 7 C611 BLOWER MOTOR 4 12 SW3 HAZARD SWITCH 13 C545 LEFT REVERSE DRIVE 2 15
C414 REAR BASE 2 7 C630 THERMOSTAT 3 12 SW4 HAND/FOOT, H/ISO SWITCH 9 C546 RIGHT FORWARD DRIVE 2 15
C415 HIGH FLOW SOLENOID 2 7 C635 HEATER VALVE 6 12 SW5 POWER BOBTACH SWITCH 13 C547 RIGHT REVERSE DRIVE 2 15
C416 DIVERTER SOLENOID 2 7 C667 DOOR KIT 6 9 SW6 BUCKET POSITION SWITCH 13 C542 LEFT SWASHPLATE 3 15
C417 REAR AUX RELIEF 2 7 C670 EXTERIOR BEACON 6 13 SW8 FRONT WIPER SWITCH 9 C543 RIGHT SWASHPLATE 3 15
C418 FRONT ROD 2 7 C676 RADIO 6 9 SW9 TRAVEL CONTROL SWITCH 8 C707 OBW STOP BRAKE LIGHT 3 15
C419 FRONT BASE 2 7 SW10 BLOWER SWITCH 12
C420 HYD LOCK 2 7 SW11 AC SWITCH 12

LIGHTS
ACCESSORIES
6000 THROUGH 6999
7000 THROUGH 7999
PINK
WHITE
PNK
WHT
MANUAL CONTROLS
LIGHTS
PAGE 10
PAGE 11
WIRING SCHEMATIC
(ACS & SJC MACHINE)
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
526 of 896 Printed In U.S.A.

J1 CONNECTOR ASSIGNMENTS(GATEWAY CONTROLLER) J2 CONNECTOR ASSIGNMENTS(AUXILLIARY CONTROLLER) J5 DRIVE CONTROLLER
PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION PIN FUNCTION
A-1 HYDRAULIC LOCK RETURN B-1 HYD CHARGE PRESS A-1 FRONT AUX (F) RETURN B-1 1 SAFETY IN
A-2 LIFT SPOOL LOCK RETURN B-2 UNSW BATT A-2 REAR AUX (F) RETURN B-2 UNSW BATT 2 TWO SPEED SWITCH
A-3 FUEL PULL RELAY B-3 UNSW BATT A-3 LEFT BLINKER RELAY B-3 UNSW BATT 3 SPARE DIGITAL INPUT 2
A-4 SWITCHED POWER OUT RELAY B-4 FUEL HOLD A-4 RIGHT BLINKER RELAY B-4 DIVERTED SOLENOID 4 H PAT SWITCH
A-5 LIGHT 1 RELAY B-5 LIFT SPOOL LOCK A-5 HORN RELAY B-5 REAR AUX (F) 5 ISO PAT SWITCH
A-6 GLOW PLUG RELAY B-6 TRACTION LOCK HOLD A-6 B-6 RELIEF SOLENOID 6 ISO LITE
A-7 STARTER RELAY B-7 TILT SPOOL LOCK A-7 OUTPUT SPARE B-7 REAR AUX (M) 7 L SWASH PLATE ANGLE
A-8 TRACTION PULL RELAY B-8 CAN LO 1 A-8 B-8 CAN LO 1 8 R SWASH PLATE ANGLE
A-9 FAN 1 RELAY B-9 CAN HI 1 A-9 B-9 CAN HI 1 9 SPARE ANALOG 4
A-10 TILT SPOOL LOCK RETURN B-10 SPOOL LOCK SENSOR 2 A-10 REAR AUX (M) RETURN B-10 10 SPARE ANALOG 5
A-11 SPARE DIGITAL, ECU SINKS B-11 SEAT BAR A-11 LH PADDLE RIGHT B-11 11 L FWD RETURN
A-12 SPARE DIGITAL, ECU SOURCES B-12 FUEL LEVEL A-12 LH PADDLE LEFT B-12 12 CAN HIGH
A-13 TRACTION PULL RELAY FDBK B-13 BICS HYD LOCK HOLD A-13 RH RIGHT BUTTON UP B-13 FRONT AUX (F) 13 LF ANGLE
A-14 GLOW PLUG RELAY FDBK B-14 CAN HI 2 A-14 DIGITAL INPUT SPARE B-14 CAN HI 2 14 RF ANGLE
A-15 ENGINE SPEED B-15 GROUND P1 A-15 B-15 GROUND 15 LR ANGLE
A-16 AIR FILTER SWITCH B-16 GROUND P2 A-16 B-16 GROUND 16 H PAT LITE
A-17 LIGHT 2 RELAY B-17 GROUND P3, SENSOR A-17 B-17 HANDLE POT GND 17 RR ANGLE
A-18 FAN 2 RELAY B-18 ENGINE COOLANT TEMP A-18 FRONT AUX (M) RETURN B-18 RH PVM POT SIGNAL 18 L JOYSTICK X
A-19 PTOL LED B-19 FAN 2 OUTPUT A-19 B-19 FRONT AUX (M) 19 L JOYSTICK Y
A-20 PTOL SWITCH B-20 CAN LO 2 A-20 LH FLOAT BUTTON B-20 CAN LO 2 20 R JOYSTICK X
A-21 SWITCHED POWER OUT RELAY FDBK B-21 REMOTE KEY A-21 HYDRAULIC DETENT B-21 RH TRIGGER 21 L FWD DRIVE
A-22 STATER RELAY FDBK B-22 RUN/ENTER A-22 LH RIGHT BUTTON DOWN B-22 SWITCHED POWER 22 CAN LOW
A-23 HYD OIL FILTER SW2 B-23 SENSOR SUPPLY 8V A-23 RH CENTER BUTTON B-23 HANDLE POT POWER 23 R QUAD A DRIVE
A-24 START ENGINE B-24 SENSOR SUPPLY 5V A-24 DIGITAL INPUT SPARE B-24 24 R QUAD B DRIVE
A-25 ENGINE OIL PRESS B-25 TWO SPEED MAKEUP A-25 B-25 BUCKET POSITION (SPARE) 25 TWO SPEED 1
A-26 SPARE B-26 TWO SPEED COIL A-26 HIGH FLOW RETURN B-26 HIGH FLOW 26 BRAKE LIGHT OUTPUT
A-27 SPARE A-27 BUCKET POSITION(SPARE) RETURN 27 GROUND
A-28 LIGHT 2 RELAY FDBK A-28 LH RIGHT BUTTON 28 GROUND
A-29 FAN 1 RELAY FDBK A-29 RH RIGHT BUTTON DOWN 29 SENSOR GROUND
A-30 FUEL PULL RELAY FDBK A-30 RH LEFT UP 30 SENSOR SUPPLY 2 +5V
A-31 LIGHT 1 RELAY FDBK A-31 RH LEFT DOWN 31 L REV DRIVE
A-32 HYD OIL TEMP A-32 32 CAN SHIELD
A-33 SPARE ANALOG A-33 Dealer Copy -- Not for Resale 33 L QUAD A DRIVE
A-34 HYD OIL FILTER SW1 A-34 DIGITAL INPUT SPARE 34 L QUAD B DRIVE
35 SAFETY OUT
36 BACKUP ALARM
ACS CONTROLLER HARNESS PART NUMBER HARNESS PART NUMBER
37 R JOYSTICK Y
CONNECTOR J1-ACS CONNECTOR J2-ACS CONNECTOR J3-ACS MAINFRAME 7175625 SJC TRACK 7159458
PIN FUNCTION PIN FUNCTION PIN FUNCTION STD CAB 7165991 A22 PUMP 7169309 38 SPARE ANALOG 1
A +5V TO SENSORS A LIFT CYLINDER SENSOR-SPARE A TILT MOTOR 1 DLX CAB 7176098 SUSP JSTK 7163706 39 SPARE PWM COIL 7
B SWITCHED POWER B FLOAT-SPARE B UNSWITCHED POWER DLX FUEL 7175293 BACKUP ALARM 7175017 40 SENSOR SUPPLY 1 +5V
C HAND/FOOT INPUT C RESPONSE SELECTOR-SPARE C UNSWITCHED POWER STD FUEL 7149219 BRAKE ADAPTER 7165061 41 L REV RETURN
D CAN HIGH D TILT CYLINDER SENSOR-SPARE D LIFT MOTOR 2 DOOR 7155024 42 R FWD RETURN
E CAN LOW E TILT ACTUATOR FEEDBACK E HANDLE ENABLE S/R 6733370 43 R FWD DRIVE
F F LIFT HANDLE F LIFT MOTOR 1 TAILGATE DOM 7175271 44 R REV DRIVE
G GROUND G TILT HANDLE G PEDAL ENABLE TAILGATE EUR 7175287 45 R REV RETURN
H GROUND H LIFT ACTUATOR FEEDBACK H GROUND 2 SPD ADP 7159366 46 TWO SPEED 2
J LIFT PEDAL J GROUND ACS 7164144 47 UNSWITCHED BATTERY
K TILT PEDAL K TILT MOTOR 2 SJC WHEEL 7159325 48 UNSWITCHED BATTERY
49 SPARE PWN COIL 6
50 SWITCHED BATTERY
WIRING SCHEMATIC
(ACS & SJC MACHINE)

POWER
FC1 FUSE 3 ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12
25 A COMMUNICATION 9000 THROUGH 9999 PURPLE PUR OPTIONS PAGE 13
C493 1 COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14
SJC CONTROL PAGE 15
FC1 FUSE 4
1280/RED 25 A 1235/RED/WHT
BATTERY MEGAFUSE
FC1 FUSE 2
C493 2
100.0 Amps 1180/RED/WHT
BATT_CABLE 25 A J2B 2
J2B 3
1240/RED/WHT
FC1 FUSE 1 SHEET 8
1400/RED/WHT
25 A C408 17 SHEET 9
1070/RED 1120/RED/WHT 1450/RED/WHT 1450/RED/WHT 1420/RED/WHT
SHEET 8
1110/RED/WHT 1440/RED/WHT
SHEET 6 FC2 FUSE 4 J1B 2 SHEET 8
1130/RED/WHT
15 A J1B 3
SHEET 9
FC2 FUSE 2 1460/RED/WHT
25 A SHEET 13
SHEET 13
FC2 FUSE 1
25 A
SHEET 5
1010/RED
FRC 1 FUSE 6
30 A
SHEET 7
1050/RED FRC1 FUSE 5
30 A 1350/RED/WHT
SHEET 6
FRC1 FUSE 11
1300/RED
25 A
1140/RED/WHT Dealer Copy -- Not for Resale
SHEET 12
FRC1 FUSE 10
1340/RED 20 A 1330/RED/WHT
SHEET 11
1620/RNG/WHT
FRC1 FUSE 9 SHEET 8
1940/RNG/WHT
15 A SHEET 8
1320/RED/WHT 1930/RNG/WHT
SHEET 11 SHEET 8
SHEET 6 SHEET 9
SHEET 6 SHEET 8
1785/RNG/WHT
SHEET 9
1950/RNG/WHT
FRC1 FUSE 4 C408 43 SHEET 8
5A SHEET 8
1570/RNG/WHT
SHEET 10
FRC1 FUSE 2
1760/RNG/WHT 25 A 1850/RNG/WHT
SHEET 9
FRC1 FUSE 3
15 A
1550/RNG/WHT
SHEET 13
FRC1 FUSE1
25 A 1780/RNG/WHT
1750/RNG/WHT C489 A
SWITCHED 1720/RNG/WHT
C404 B
POWER
1050/RED 30
WIRING SCHEMATIC
87 SHEET 12
SHEET 6
2055/BLK 85 86 FRC1 FUSE 7 (ACS & SJC MACHINE)
2030/BLK 1795/RNG/WHT 25 A 1730/RNG/WHT
SHEET 12
FRC1 FUSE 8
SHEET 5
25 A
1740/RNG/WHT
8000/TAN
C492 6
1580/RNG/WHT
SHEET 9 (S/N A3NW11001 AND ABOVE)
J1A 4
C408 6
1830/RNG/WHT
SHEET 5
SHEET 5

GROUND
SJC CONTROL PAGE 15
2080/BLK 2235/BLK
SHEET 5 C493 3
2070/BLK 2240/BLK
SHEET 5 C408 32 C493 4
2940/BLK 2950/BLK 2950/BLK
SHEET 8
2960/BLK 2510/BLK
SHEET 8 J1B 16
2920/BLK 2500/BLK 2110/BLK T6
SHEET 8 J1B 15 BATT GND
2250/BLK 2540/BLK
SHEET 8 J2B 16
2550/BLK 2090/BLK
J2B 15
2765/BLK
SHEET 11
2745/BLK
SHEET 12
2790/BLK T8
SHEET 9 BATT GND
2780/BLK
SHEET 13
2730/BLK
SHEET 9
2620/BLK
SHEET 11
2630/BLK 2720/BLK
SHEET 11 C489 B
SHEET 10
2650/BLK 2600/BLK C103 B Dealer Copy -- Not for Resale
2600/BLK
2640/BLK 2810/BLK 2390/BLK
SHEET 11 SHEET 6
2610/BLK
SHEET 11
2200/BLK
SHEET 7
2751/BLK
SHEET 13
2450/BLK
SHEET 7
2741/BLK
SHEET 13
2785/BLK 2710/BLK 2300/BLK T1
SHEET 13 SHEET 5 BATT GND
2930/BLK 2480/BLK
SHEET 9 C408 42 SHEET 7
2830/BLK 2900/BLK 2900/BLK
SHEET 13
2700/BLK 2105/BLK
SHEET 8 SHEET 11
2530/BLK 2000/BLK
SHEET 10
2520/BLK
SHEET 10
3530/LBL
SHEET 7
3800/LBL
SHEET 6
3910/LBL
SHEET 9
3310/LBL 3010/LBL
SHEET 7 J1B 17
3410/LBL
SHEET 7
3110/LBL
SHEET 6
3510/LBL
SHEET 6
3710/LBL
SHEET 6
WIRING SCHEMATIC
(ACS & SJC MACHINE)

CAN BUS
SJC CONTROL PAGE 15
9160/PUR/WHT
C503 2
9260/PUR RH DLX PANEL
C503 4
9200/PUR 9270/PUR 9210/PUR 9280/PUR 9230/PUR C408 8 9230/PUR 9240/PUR 9250/PUR 9650/PUR 9630/PUR
J1B 8 C479 4
GWY CTRLR 9100/PUR/WHT 9170/PUR/WHT 9110/PUR/WHT 9180/PUR/WHT 9130/PUR/WHT 9130/PUR/WHT 9140/PUR/WHT 9150/PUR/WHT 9550/PUR/WHT 9530/PUR/WHT LEFT PANEL
J1B 9 C479 3
120 OHM C408 7 120 OHM
RESISTOR RESISTOR C450
SHEET 3
1830/RNG/WHT 1 #
2070/BLK 2
SHEET 4 RIGHT
9560/PUR/WHT 3 JOYSTICK
9660/PUR 4
9240/PUR
C492 1
9140/PUR/WHT ACS CTRLR C449
C492 4
9290/PUR 1840/RNG/WHT 1 #
9190/PUR/WHT Dealer CopyDRIVE
-- Not
C492 7 for Resale
CTRLR
SHEET 3
2080/BLK 2
C492 8 SHEET 4 LEFT
9540/PUR/WHT 3
JOYSTICK
9640/PUR 4
9220/PUR
J2B 8 AUX CTRLR
9120/PUR/WHT
J2B 9
C426
9500/PUR/WHT A
J1B 14
9600/PUR B
J1B 20
9400/PUR D
J1B 21
C CAN (Remote Start Tool, ACD)
1730/RNG/WHT E
SHEET 3
1165/RED/WHT F
SHEET 3
2710/BLK G
SHEET 4
# CONNECTOR DOES NOT EXIST IN 7165991
WIRING SCHEMATIC
(ACS & SJC MACHINE)

ENGINE
SJC CONTROL PAGE 15
STARTER C109 STARTER
30 J1A 22
8250/TAN B 8250/TAN R M
B SHEET 3
SHEET 3 1030/RED 8200/TAN A 8200/TAN
87 S 1015/RED
C110
2005/BLK 85 86 8210/TAN B
SHEET 12 J1A 7 S 1020/RED FRC1 FUSE 12
ALTERNATOR G 15 A
L 1800/RNG/WHT 1815/RNG/WHT
SHEET 12
EXCITATION
2015/BLK
FUEL SHUTOFF
FUEL SOLENOID
PULL C101
8120/TAN D5 8100/TAN B 8100 TAN PULL
1350/RED/WHT 30 24.5 OHM
SHEET 3 87 8150/TAN J1B 4 8800/TAN A 8800 TAN HOLD 0.33 OHM
J1A 30
2810/BLK 2800/BLK C 2800 BLK
85 86 SHEET 4
2025/BLK 8110/TAN
SHEET 7 J1A 3
C106 GLOW
3600/LBL A SIG PLUG
J1A 15 ENGINE SPEED SENSOR 30 8550/TAN
3610/LBL B GND 1060/RED J1A 14
SHEET 3 87 8500/TAN
3800/LBL T14 PRE HEATER
SHEET 4
3210/LBL B SIG 85 86
ENGINE COOLANT 2016/BLK 8510/TAN
3200/LBL A GND J1A 6
J1B 18 SENSOR (500-3000 OHM) 2055/BLK
SHEET 3
C104
C107
3500/LBL B +5V PWR
SHEET 9
3520/LBL C SIG ENGINE OIL PRESSURE
J1A 25
3510/LBL A GND SENDER (0.5-4.5V)
SHEET 4
C406
C355 C
3100/LBL 3100/LBL A SIG
J1B 12 FUEL
3110/LBL 3110/LBL B GND SENDER
SHEET 4
C355 D
C405
WIRING SCHEMATIC
3710/LBL B GND
SHEET 4
J1A 16
3700/LBL A SIG
AIR FILTER
SWITCH
(ACS & SJC MACHINE)
531 of 896
Printed In U.S.A.
SJC CONTROL PAGE 15
TRACTION
LOCK C425 TRACK MACHINES
30 4150/LGN
1360/RED/WHT J1A 13
SHEET 3 87 4100/LGN B C308
BRAKE
2025/BLK 4200/LGN A 4200/RED A SOLENOID
SHEET 6 85 86 J1B 6
2035/BLK 4110/LGN 2200/BLK C 2200/BLK B 9.8 OHM
SHEET 11 J1A 8 SHEET 4
12 V
HARN BRAKE ADAPTER 7165061
C425 WHEEL MACHINES
B PULL 0.3 OHM TRACTION
A HOLD 10.9 OHM LOCK
C SOLENOID
C362 C414
OPTIONAL REAR AUX
4440/LGN A 4440/LGN 1 SIG DIRECTIONAL SOLENOID
J2B 5
2440/BLK B 2440/BLK 2 GND FEMALE COUPLER
J2A 2
7.5 OHM 12V C420
C413 2410/BLK B HYD LOCK
4430/LGN C 4430/LGN 1 SIG OPTIONAL REAR AUX J1A 1 SOLENOID
J2B 7 4410/LGN A
2430/BLK D 2430/BLK 2 GND
DIRECIONAL SOLENOID J1B 13 9.8 OHM 12V
J2A 10 MALE COUPLER
7.5 OHM 12V C105
C416 HYDRAULIC
3410/LBL B CHARGE
4450/LGN E 4450/LGN 1 SIG OPTIONAL REAR AUX 3420/LBL C
J2B 4 PRESSURE
SHEET 4
2450/BLK F 2450/BLK 2 GND BLEED / LOCK VALVE Dealer Copy -- Not for Resale J1B 1
3400/LBL A 0.5-7.5V
SOLENOID MALE COUPLER J1B 23
C417
7.5 OHM 12 V +8V
C108 HYDRAULIC
4480/LGN G 4480/LGN 1 SIG OPTIONAL REAR AUX 3310/LBL B TEMPERATURE
J2B 6 BLEED / LOCK VALVE SHEET 4
2480/BLK H 2480/BLK 2 GND 3300/LBL A SENDER
SHEET 4 SOLENOID FEMALE COUPLER J1A 32 500 - 3000 OHM
9.8 OHM 12 V
C112
C415 3430/LBL A HYDRAULIC OIL
2460/BLK B GND J1A 34
J2A 26 OPTIONAL HIGH FLOW 3530/LBL B FILTER SWITCH
4460/LGN A SIG SOLENOID SHEET 4
J2B 26 7.5 OHM 12 V
C418
2330/BLK 2 GND
J2A 18 FRONT ROD SOLENOID (MALE)
J2B 19
C419
2340/BLK 2 GND FRONT BASE SOLENOID (FEMALE)
J2A 1
J2B 13
C437
2360/BLK 2 GND
J1A 27 OPTIONAL TWO SPEED
4360/LGN 1 SIG
J1B 25 MAKEUP SOLENOID
C441
J1A 26
2350/BLK 2 GND TWO SPEED WIRING SCHEMATIC
4350/LGN 1 SIG SOLENOID
J1B 26
C446
(ACS & SJC MACHINE)
HYDRAULIC
J1A 18
2910/BLK
4010/LGN
2
1
GND
SIG
FAN SOLENOID
7.2 OHM
J1B 19
12 V

SJC CONTROL PAGE 15
C500 RH KEY SWITCH

9360/PUR C408 4 9360/PUR 2
J1A 24
9350/PUR 9350/PUR 4
J1B 22
T13 C408 40
BUZZER (+) 1950/RNG/WHT 5
SHEET 3
1940/RNG/WHT 1420/RED/WHT 1
SHEET 3 SHEET 3
2960/BLK 3
SHEET 4
6
T2
BUZZER (-)
RH DLX PANEL
LEFT PANEL (BLACK) 1590/RNG/WHT C503 5
C479 10 SHEET 3
9320/PUR C503 1
1240/RED/WHT
C479 2 SHEET 3
2920/BLK C503 3
SHEET 4 2250/BLK
SHEET 4
1440/RED/WHT C479 1
SHEET 3
1960/RNG/WHT 1620/RNG/WHT C479 5
SHEET 3 SHEET 3
SW9 6450/PNK C479 11
SHEET 13
TRAVEL CONTROL C479 8
6550/PNK
SWITCH OPTIONAL SHEET 13 Dealer Copy -- Not for Resale
5 6 4500/LGN C479 9
4 SHEET 9
4730/LGN C479 7
2700/BLK 2 3
SHEET 4 1
C480 LEFT PANEL (GRAY)

4750/LGN 12
SHEET 9
9310/PUR 2
SHEET 9
PTOL
C499 (Press To Operate Loader)
9380/PUR C408 1 9380/PUR 2
J1A 20
9370/PUR 9370/PUR 4
J1A 19
C408 37
1930/RNG/WHT 1
SHEET 3
2940/BLK 3
SHEET 4
WIRING SCHEMATIC
(ACS & SJC MACHINE)
CAB DISPLAY S650 (S/N A3NV11001 AND ABOVE)


GROUP DESCRIPTION
BATT FEED, GENERAL
BATT FEED, FUSED
BATT FEED, SWITCHED
GROUP NUMBER RANGE
1000 THROUGH 1499
1000 THROUGH 1499
1500 THROUGH 1999
WIRE COLOR
RED
RED/WHITE
ORANGE/WHITE
COLOR CODE
RED
RED/WHT
RNG/WHT
OVERVIEW
POWER
GROUND
CAN BUS
PAGE 1,2
PAGE 3
PAGE 4
PAGE 5
7176098 ONLY SW4
GROUNDING 2000 THROUGH 2999 BLACK BLK ENGINE PAGE 6 HAND/FOOT
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL HYDRAULICS PAGE 7 (ACS)
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN CAB DISPLAY PAGE 8 H/ISO
4550/LGN C408 5 4550/LGN
ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL CABIN PAGE 9 (SJC, AWS) C492 2
SWITCH
1785/RNG/WHT 2 1 4275/LGN C408 3 4275/LGN
ACCESSORIES 7000 THROUGH 7999 WHITE WHT LIGHTS PAGE 11 SHEET 3 C492 3
3
ENGINE 8000 THROUGH 8999 TAN TAN HVAC PAGE 12 2060/BLK 5 6 4235/LGN C408 2 4235/LGN 4230/LGN
4 SHEET 10
4220/LGN 4240/LGN
COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT ACS CONTROL PAGE 14 C492 5 SHEET 10
SJC CONTROL PAGE 15
C212
2795/BLK 1
+
1375/RED/WHT 2 POWER SOCKET
-
C209
2790/BLK C408 24 2790/BLK 2010/BLK B
C408 23 SHEET 4
1370/RED/WHT 1370/RED/WHT 1390/RED/WHT A DOME LIGHT
SHEET 3
4760/LGN C
*
C676
1885/RNG/WHT 1
2885/BLK 2
C129 C279
1210/RED/WHT A
SHEET 3
1580/RNG/WHT C408 16 1580/RNG/WHT
* 1865/RNG/WHT B LEFT SPEAKER
1
2
+ 7820/WHT
7830/WHT
3
4 RADIO CONN
2820/BLK C -
ACCESSORY
CONN C278
2 - 7810/WHT 6
RIGHT SPEAKER 1 7800/WHT 5
+
2730/BLK C408 33 2730/BLK
SHEET 4
C277
Dealer Copy -- Not 1510/RNG/WHT
for Resale 4
AIR RIDE
2210/BLK 5 SEAT SOLENOID
C482
SEATBAR
SENSOR C667 C250 SENSOR SHOWN
3910/LBL C408 45 3910/LBL A GND
SHEET 4 4750/LGN 4740/LGN 4 4740/LGN 1 WITH DOOR OPEN
SHEET 8
1400/RED/WHT 5 1400/RED/WHT 2 DOOR SENSOR C251
3920/LBL C408 46 3920/LBL B SIG SHEET 3
J1B 11 1860/RNG/WHT D SW PWR
6 7330/WHT C PARK
3930/LBL 3900/LBL C408 44 3900/LBL C PWR WIPER
J1B 24 1570/RNG/WHT 7300/WHT A LOW MOTOR
+5V 3500/LBL
SHEET 6 B GND
1850/RNG/WHT 1850/RNG/WHT 1 1850/RNG/WHT 3 E
SHEET 3
C408 27 1 2
3 7310/WHT 6
SW1 4 5
BRAKE SWITCH SW8
4500/LGN 3 2 FRONT WIPER
SHEET 8 1 2840/BLK 2 2840/BLK SWITCH C252
9310/PUR 4 5
SHEET 8 7310/WHT L
1775/RNG/WHT 6
SHEET 3 WASHER
2930/BLK
SHEET 4 2845/BLK X MOTOR
WIRING SCHEMATIC
(ACS & SJC MACHINE)
7165991 Standard Cab
7176098 Deluxe Cab (S/N A3NW11001 AND ABOVE)
534 of 896 Printed In U.S.A. * SPLICE DOES NOT EXIST IN 7165991

MANUAL
CONTROLS
SJC CONTROL PAGE 15
C409
RIGHT HANDLE
2530/BLK K
SHEET 4
4230/LGN G
SHEET 9
1590/RNG/WHT A
4940/LGN H
J2A 30
4930/LGN J SKI CTRL
J2A 31
4920/LGN E DETENT FLOW
J2B 21
4910/LGN F
J2A 13 TWO SPD
4310/LGN C -
J2B 17
4320/LGN D
J2B 18 PWM
4300/LGN B +
J2B 23
C410
LEFT HANDLE
K
4640/LGN D
Dealer J2A
Copy20 -- Not for Resale
4840/LGN C
J2A 28
4830/LGN B SKI CTRL
J2A 22
4820/LGN G
J2A 12
4810/LGN F SIDE SHIFT
J2A 11
1570/RNG/WHT 1710/RNG/WHT A
SHEET 3
1560/RNG/WHT J
J2B 22
4240/LGN H
SHEET 9
2520/BLK E
SHEET 4
C411
E
C
A
D TURN SIGNAL
B
C412
C404 A 7100/WHT C103 C 7100/WHT T19 1 B
+ BACKUP ALARM
2650/BLK 7001923 A HORN
SHEET 4 -
T20 1
C421
2370/BLK 3
J1A 10 TILT SPOOL LOCK SOLENOID
4370/LGN 1
J1B 7 (NOT USED WITH ACS)
2
WIRING SCHEMATIC
C422
J1A 2
2380/BLK 3
LIFT SPOOL LOCK SOLENOID
(ACS & SJC MACHINE)
4380/LGN 1 (NOT USED WITH ACS)
J1B 5
2 S650 (S/N A3NV11001 AND ABOVE)

LIGHTS
SJC CONTROL PAGE 15
C434-1
2735/BLK B LEFT FRONT
37.00 Watts
C434-2
2765/BLK C408 28 2765/BLK 2750/BLK B
SHEET 4 LEFT FRONT
50.00 Watts
C435-1
C408 25 RIGHT FRONT
6000/PNK 6000/PNK 6120/PNK A
37.00 Watts
C435-2
6130/PNK A
RIGHT FRONT
50.00 Watts
FRONT
WORK
LIGHTS C603
SHEET 4
2610/BLK 2
1330/RED/WHT 30 C103 A RIGHT REAR
SHEET 3 87 6340/PNK 6310/PNKCopy -- Not for6310/PNK
Dealer Resale 6320/PNK 1
TAIL LIGHT
2105/BLK 85 86 C602
SHEET 4
2045/BLK 6330/PNK 1
6320/PNK 2640/BLK 2 LEFT REAR
J1A 5 SHEET 4 TAIL LIGHT
6330/PNK
J1A 31
2620/BLK T16 1 RIGHT REAR

SHEET 4
6210/PNK WORK LIGHT
REAR
LIGHT T15 1
1320/RED/WHT 30 C103 H
SHEET 3 6200/PNK 6200/PNK T17 1
87 LEFT REAR
2630/BLK WORK LIGHT
85 86 SHEET 4
2045/BLK T18 1
2035/BLK
SHEET 7
6210/PNK
J1A 17
6230/PNK
J1A 28
WIRING SCHEMATIC
(ACS & SJC MACHINE)

HVAC
SJC CONTROL PAGE 15
C630
7021/WHT 7020/WHT C408 34 7020/WHT B
J1A 11
7023/WHT 2570/BLK C
3320/LBL A
THERMOSTAT
C350
B C483
7024/WHT A EVAPORATOR 2560/BLK C BLK
(AC PRESS SWITCH) POTENTIOMETER
1980/RNG/WHT A DBL
C486 7220/WHT B WHT (TEMP CONTROL
C355 A 7024/WHT SWITCH)
7025/WHT 1
2 MAGNET CLUTCH C635
(COMPRESSOR)
2290/BLK 2280/BLK D SIG
SHEET 13
D4 2130/BLK C GND HEATER
1900/RNG/WHT 1910/RNG/WHT A 12V VALVE
SW10 B
BLOWER E
HVAC SWITCH F
1140/RED/WHT 30 OFF
SHEET 3 87 1500/RNG/WHT C408 211500/RNG/WHT 5 2
1
2030/BLK 85 86 4
SHEET 3
2005/BLK Dealer Copy -- Not for Resale
6 C611
SHEET 6 3 1970/RNG/WHT A 14.00 Amps High
1790/RNG/WHT
SHEET 3 1520/RNG/WHT B 7.50 Amps Med BLOWER
1815/RNG/WHT
SHEET 6 7320/WHT C 5.00 Amps Low MOTOR
8020/TAN
J1A 21 2580/BLK D
2745/BLK 2745/BLK
SHEET 4
7040/WHT
C408 22
SW11
AC SWITCH
1 C
2100/BLK
3
WIRING SCHEMATIC
(ACS & SJC MACHINE)
537 of 896
Printed In U.S.A.
OPTIONS
SJC CONTROL PAGE 15
SW5
POWER
BOBTACH
SWITCH
C408 26 7000/WHT C408 9 7000/WHT
C411 1410/RED/WHT 1410/RED/WHT 1380/RED/WHT 2 1
C408 15 SHEET 3
B 6010/PNK 6010/PNK 1430/RED/WHT 1200/RED/WHT 3
4 7010/WHT C408 10 7010/WHT
C 6550/PNK 5
LEFT C408 36 SHEET 8 D1 X T3 6
HANDLE A 6515/PNK 6500/PNK 6500/PNK 6530/PNK FLASHER CONN SW2
5 PIN E 6540/PNK L BEACON
C408 29 D2 SWITCH PWR BOB CLOSE
D 6415/PNK 6400/PNK 6400/PNK 6430/PNK 6570/PNK
C607
6450/PNK 2725/BLK 6 C355 E
SHEET 8 SW3 5 A 7010/WHT
HAZARD SWITCH 1 4
C103 E 2 C670 STROBE B 2770/BLK 2751/BLK 2751/BLK
6410/PNK 3 1 2
(PINS 3 & 6 6700/PNK E BEACON
6510/PNK 4 3 2290/BLK C355 B SHEET 4
INTERNALLY SHEET 12
5 2850/BLK 2420/BLK D
INSULATED) 6
C103 D C
LEFT C606
A
BLINKER B 2775/BLK
F
2780/BLK C408 30 2780/BLK A 7000/WHT C355 F
SHEET 4 B
6440/PNK
PWR BOB OPEN
6540/PNK RIGHT
BLINKER
SW6
BUCKET
POSITION
1550/RNG/WHT C408 131550/RNG/WHT SWITCH
SHEET 3
3 2
7022/WHT 1
C126
SHEET 4 SHEET 4 4
C412 2785/BLK B 2830/BLK 5
B 7210/WHT C408 38 7210/WHT A 6 C423
LEFT HANDLE C408 35 D3
2 PIN A 1460/RED/WHT 7022/WHT 7030/WHT A
SHEET 3
2741/BLK 2740/BLK B
SHEET 4
C497
7200/WHT C
J2A 5 SJC
6420/PNK A HORN/BLINKER
J2A 4
6520/PNK B
J2A 3
WIRING SCHEMATIC
(ACS & SJC MACHINE)

ACS
CONTROLS
SJC CONTROL PAGE 15
J1-ACS
H 2280/BLK
2670/BLK See manual controls for harness
2770/BLK
2240/BLK
connection
MAINFRAME HARNESS 1170/RED/WHT HANDLE TILT
C409 C466
C492 HALL SENSOR
K A
G 2250/BLK 8 J3-ACS HANDLE
G B
7 B 1190/RED/WHT LOCK
A
C 4450/LGN 2 C 1180/RED/WHT H
4220/LGN 5 J SKI CTRL
4275/LGN 3 C429 LIFT ACTUATOR E DETENT
9240/PUR 1 D 4690/LGN 8 F FLOW
9140/PUR/WHT 4 7 C TWO SPD
1740/RNG/WHT 6 6 D
F 4680/LGN 5 PWM
B
C493 J 2260/BLK 4
A 4 H 2270/BLK 1 GND
3 C410
E 4670/LGN 2 SIG
2 K
D 1530/RNG/WHT 3 PWR
1 D
B FLOAT
C
C428 TILT ACTUATOR
B SKI CTRL
C472 K 4790/LGN 8
J2-ACS G
2650/BLK B B GND 7 SIDE
F
F 4650/LGN C C 6 SHIFT
1510/RNG/WHT A A
SIG HANDLE LIFT
HALL SENSOR A
4780/LGN 5
A
PWR
J C465
4
H A
1630/RNG/WHT 3 PWR HANDLE
E B
4770/LGN 2 SIG LOCK
H 2770/BLK 1 GND
C411
E
C467 E
A 2 C
B 4280/LGN 1 A
C 2510/BLK 3 LIFT D TURN SIGNAL
D SOLENOID B
C468
2 C412
C469 G 4260/LGN 4270/LGN 1 B
2750/BLK B B GND E 4220/LGN 2500/BLK 3 TILT A HORN
SOLENOID
G 4750/LGN C C SIG HANDLE TILT
1610/RNG/WHT A A PWR HALL SENSOR
C471
1520/RNG/WHT 1 PWR
J 4660/LGN 3 SIG LIFT PEDAL
2660/BLK 2 GND HALL SENSOR
1620/RNG/WHT
C470
1 PWR
WIRING SCHEMATIC
K 4760/LGN 3
2760/BLK 2
SIG
GND
TILT PEDAL
HALL SENSOR (ACS & SJC MACHINE)
1610/RNG/WHT
1510/RNG/WHT 1530/RNG/WHT S650 (S/N A3NV11001 AND ABOVE)
4275/LGN
4220/LGN
4670/LGN
4770/LGN Sheet 14 of 15 Printable Version Click Here

J5 - DRIVE CONTROLLER
29 2510/BLK 2580/BLK
1540/RNG/WHT
C454
3
1
GND
PWR
4680/LGN
C429
5
6
LIFT
ACTUATOR SJC
LEFT SPEED
CONTROLS
33 3020/LBL 2 SIG SENSOR 4690/LGN 8
34 3080/LBL 4 SIG 2630/BLK 1 GND
40 1640/RNG/WHT C453
4
1530/RNG/WHT 1 PWR 4670/LGN 2 SIG
2570/BLK 3 GND 7
23 3000/LBL 2 SIG
RIGHT SPEED 1610/RNG/WHT 3 PWR
SENSOR
24 3070/LBL 4 SIG
1500/RNG/WHT
C428 TILT ACTUATOR
2250/BLK
2770/BLK
C536 1630/RNG/WHT 3 PWR SCHEMATIC INDEX
1810/RNG/WHT 2 C543 HARNESS, A22 PUMP 7169309 OVERVIEW PAGE 1,2
4
2810/BLK 4 2810/BLK 1 GND POWER PAGE 3
4770/LGN 2 SIG
8 4720/LGN 3 4720/LGN 3 SIG RIGHT GROUND PAGE 4
6
1710/RNG/WHT 1 1710/RNG/WHT 2 PWR
SWASHPLATE CAN BUS PAGE 5
1 GND
ENGINE PAGE 6
C537
4780/LGN 5
HYDRAULICS PAGE 7
1820/RNG/WHT 2 C542 7
CAB DISPLAY PAGE 8
2860/BLK 4 2860/BLK 1 GND 4790/LGN 8
CABIN PAGE 9
7 4950/LGN 3 4950/LGN 3 LEFT
SIG MANUAL CONTROLS PAGE 10
SWASHPLATE
1770/RNG/WHT 1 1770/RNG/WHT 2 PWR K LIGHTS PAGE 11
HVAC PAGE 12
J2-ACS
C501 C546 J
E OPTIONS PAGE 13
43 4260/LGN 1 4260/LGN 1
RIGHT FORWARD DRIVE H ACS CONTROL PAGE 14
42 2660/BLK 2 2660/BLK 2
SJC CONTROL PAGE 15
F
C547
G
C WIRE CATEGORIES FOR COLORS AND NUMBER RANGE
44 4250/LGN 3 4250/LGN 1
RIGHT REVERSE DRIVE D GROUP DESCRIPTION GROUP NUMBER RANGE WIRE COLOR COLOR CODE
45 2650/BLK 4 2650/BLK 2 BATT FEED, GENERAL 1000 THROUGH 1499 RED RED
B
BATT FEED, FUSED 1000 THROUGH 1499 RED/WHITE RED/WHT
C545 A
BATT FEED, SWITCHED 1500 THROUGH 1999 ORANGE/WHITE RNG/WHT
ACS CONTROLLER
31 4280/LGN 5 4280/LGN 1 GROUNDING 2000 THROUGH 2999 BLACK BLK
41 2680/BLK 6 2680/BLK 2 LEFT REVERSE DRIVE
MONITORING 3000 THROUGH 3999 LIGHT BLUE LBL
HYDRAULIC 4000 THROUGH 4999 LIGHT GREEN LGN
C544 G ATTACHMENT CONTROLS 5000 THROUGH 5999 YELLOW YEL
J1-ACS
21 4270/LGN 7 4270/LGN 1 A LIGHTS 6000 THROUGH 6999 PINK PNK
11 2670/BLK 8 2670/BLK 2 LEFT FORWARD DRIVE ACCESSORIES 7000 THROUGH 7999 WHITE WHT
F
Dealer Copy -- Not for Resale E ENGINE 8000 THROUGH 8999 TAN TAN
D COMMUNICATION 9000 THROUGH 9999 PURPLE PUR
C474 HARNESS, OBW STOP LTS 7151696 C707 B COMMUNICATION 9000 THROUGH 9999 PURPLE/WHITE PUR/WHT
26 4210/LGN A 1730/RNG/WHT A H
6600/PNK B C HARNESS, JOYSTICK 7163706
C450 C460
87 2730/BLK C
30 1 1830/RNG/WHT +12V PWR 1
C492
4210/LGN 85 86 2 2070/BLK GND 2
12 9190/PUR/WHT 8 BRAKE RIGHT
LIGHT 4 9660/PUR CAN 4
22 9290/PUR 7 BRAKE LIGHT RELAY LOW JOYSTICK
4 4550/LGN 2
K 3 9560/PUR/WHT CAN 3
6 4220/LGN 5 HIGH
16 4275/LGN 3 A
D C449 C459
J3-ACS
9140/PUR/WHT 4
9240/PUR 1 F 1 1840/RNG/WHT +12V PWR 1
1740/RNG/WHT 6
MAINFRAME H
2 2080/BLK GND 2
50 1750/RNG/WHT HARNESS J LEFT
47 1250/RED/WHT C 4 9640/PUR CAN LOW 4
C493 JOYSTICK
48 1260/RED/WHT 1235/RED/WHT 2 B
3 9540/PUR/WHT CAN HIGH 3
27 2470/BLK 2235/BLK 3 E
28 2490/BLK 1170/RED/WHT 1 G
2240/BLK 4
1760/RNG/WHT WIRING SCHEMATIC

2280/BLK
2270/BLK
2260/BLK
(ACS & SJC MACHINE)
1180/RED/WHT
1190/RED/WHT S650 (S/N A3NV11001 AND ABOVE)
C404
C103 C
36 7100/WHT A 7100/WHT +
B
SHEET4 - Sheet 15 of 15 Printable Version Click Here
BACKUP
(CONNECTS TO BACKUP ALARM
ALARM C404 ON MFR
HARNESS)
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols

CONNECTIONS COMPONENTS
CONNECTOR - Harness - Used for GROUND - Frame - Used to
3500 A A 3500 connecting 2 harnesses together or a represent an component that is
C107
3520 C C 3520
3510 B B 3510
harness to a component. The internally grounded.
connector can vary from a single pin
to any number of pins (Example: 3 pin
connectors shown). The connector
LIGHT -
C107 pins can be numbered alphabetical
3500
A A
3500 (shown) or numerical (1, 2, 3 etc.).
C C
3520
B B
3520 The harness wires numbers are
3510 3510
called out next to the connector
(Example: 3500). SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Open
The connector number is called out
next to the connector (Example:
C107). These connector numbers are
used for schematic identification only
and do not appear on the harness or

connector. SWITCH - Single Pole - Single Throw
(ON-OFF) Normally Closed.
COMPONENTS
- + BATTERY - Used for supplying and SWITCH - Single Pole - Double

storing electrical power for the Throw (ON-OFF-ON) - This switch
machine. can be in any of three positions.
(Some switches are spring activated
to return them to a certain position
+ POSITIVE ELECTRICAL CIRCUIT -
when released.)
Indicates positive battery circuit.
SWITCH - Double Pole - Single
Throw (ON-OFF) Open and Closed
positions will be specified depending
- NEGATIVE ELECTRICAL CIRCUIT - on switch application.)
Indicates battery ground circuit.
SWITCH - Double Pole - Double
Throw (ON-OFF) Open and Closed
ALTERNATOR - Used to create the positions will be specified depending
on switch application.
G electrical current to supply voltage to
the battery and components.
POTENTIOMETER - Variable
+ - resistance - Provides variable
STARTER - Uses battery current to resistance.
M start the machine engine.
GROUND - Used to represent an

external ground connection.

ELECTRICAL SYSTEM INFORMATION (CONT’D)
Glossary Of Electrical Symbols (Cont’d)

COMPONENTS SOLENOID - Fuel and Traction Lock -
HOLD PULL
15 ohm B
Dual solenoids. (The ohm rating of
I SWITCH - Ignition - Multi position 0.5 ohm A the solenoid coils are listed next to
B
switch to activate various start the component [if available]). The pull
ST functions at different positions. solenoid is energized for a short time.
START
HORN - Audible alarm. Sound is
R U N
O FF
activated manually by a switch.
BUZZER - Audible alarm. Sounds at a

1 SWITCH - Light - Multi position switch predetermined setting to warn the
2 to activate various lights at different operator of a component condition.
3
positions.
4 5 RESISTOR - Limits current flow.
6

DIODE - Allows electrical current to
ROTARY CONTROL - Provides flow in 1 direction only.
variable voltage proportional to
position.
L MOTOR - HVAC - Multi speed motor.
M
H M
GRD
87A 87 86 RELAY - Uses a low amp switch to GRD MOTOR - Wiper - Single or multi
control a high amp component. PARK V speed motor.
30 85 M
HIGH
FUSE - Used to protect the wire MOTOR - Washer - Single speed.

M
harness from an overloaded circuit.
25A (The fuse rating is listed next to the
fuse.)
PUMP - FUEL
3
700 3
710 SPLICE (•) - Used to show when
3
110 multiple wires are connected together
on the schematic. HOURMETER - Records the time the
H
+ - engine is running.
SOLENOID - ON / OFF - Electrically
1 activated coil that controls movement
2 magnetically. (The ohm rating of the POWER PLUG - Supplies 12 volt
- +
7.7 ohm
solenoid coil is listed next to the power for customer supplied
component [if available]). accessories.
SOLENOID - VARIABLE - Electrically GAUGE - Instrument - Indicates

A G certain engine or other component
activated coil that controls movement
B conditions. (The different types of
7.5 ohm magnetically. (The ohm rating and I S
gauge are marked with a icon that
12V
voltage of the solenoid coil is listed represents what function the gauge is
next to the component [if available]). monitoring. Example: the gauge
shown is for fuel.)

Glossary Of Electrical Symbols (Cont’d)

SYMBOL DESCRIPTION
SENDERS AND SENSORS
+
A
PRESSURE SENDER - Provides a
A variable voltage proportional to
C
- C pressure. (Sender voltage rating is
B
B
0.5 - 7.5 V listed to show volts at high and low
setting.)
B
PRESSURE SWITCH - Switch opens
A or closes at a predetermined
pressure to active a function or to turn
on a warning light. (Switch is shown in
the open position.)
to TEMPERATURE SENDER - Provides

B a variable resistance (ohm) signal
A proportional to temperature. (Sender
500-3000ohm ohm rating is listed to show ohms at

high and low setting.)
A TEMPERATURE SWITCH - The

B switch opens or closes at a
predetermined temperature to active
a function or to turn on a warning
light. (Switch is shown in the closed
position.)
B FUEL SENDER - Provides a variable

resistance, based on the fuel level in
A
the tank. (Sender ohm rating is listed
30-270 ohm to show ohms at full and empty
setting.)
C HALL EFFECT SENSOR - Detects

B linear or rotary position and provides
A a proportional variable voltage.
A SPEED SENSOR - magnetic pickup -

detects RPM.
B

Standard Cab Harness Connectors
C129 C479
C480 C434-1
C434-2
C482
T13
T2

C499
C503
SW1
C435-1
C435-2
C500
C408
C126
MS2824

Deluxe Cab Harness Connectors
C209
C670 C479 C434-1

C480 C434-2
C499
T13
C482 T2
SW1
SW3
C500

C503 SW2
SW6
C435-1
C435-2
SW4
C667
C426
SW5
SW9
C611 C252
C630
C635
C126
C129 C253
C277 C279
C449 C483
C450 S3
T3
C278
C676
C212
MS2827

Mainframe Harness Connectors
C426
C405
C103 C 350
408
T11 T6
T1

T8 C355
T10 T4
C101 C105
C110 C104
C362
T12 C107
FRC1
C486 C446 FC1
C108 FC2
C423 C362
C441 C489
C415 C497
J2A
C409 J2B
C419 J1A
C420 C410 J1B
C418 C404 C411
C421 C437 C412
C422
C425
C492
C493
MS2825

Description
Figure 60-10-1
P-13849
P-85472
The loader has a 12 volt, negative ground, alternator

charging system.

The electrical system is protected by fuses located in the
operator cab (located under the operator cab in earlier
models) and a 100 ampere master fuse [Figure 60-10-1]
located under the air cleaner in the engine compartment.
The fuses will protect the electrical system when there is

an electrical overload. The reason for the overload must
be found before starting the engine again.

assistance in locating and correcting problems which are AVOID INJURY OR DEATH
most common. Many of the recommended procedures Instructions are necessary before operating or
must be done by authorized Bobcat Service Personnel servicing machine. Read and understand the
only. Operation & Maintenance Manual, Operator’s
W-2003-0807
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

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 solenoid is damaged.
9. Check the fuses.

ELECTRICAL SYSTEM INFORMATION (CONT’D) Later Models
Fuse And Relay Location / Identification Figure 60-10-4
Earlier Models
Figure 60-10-2
P100414
The fuse / relay panels are located behind an access

1 panel near the left foot pedal / footrest. Pull the panel at
each end (Item 1) [Figure 60-10-4] to remove.
P-85411

Figure 60-10-5
The electrical system is protected from overload by fuses

and relays located under three fuse panel covers (Item 1)
[Figure 60-10-2].
Figure 60-10-3
P100415
The electrical system is protected from overload by fuses

and relays located under three fuse panel covers (Item 1)
[Figure 60-10-5].
P-85412
Remove the covers to check or replace the fuses [Figure

60-10-3].
A decal is located inside the large cover to show location

and amp ratings.
A table is provided with details on amperage ratings and

circuits affected by each fuse and relay. (See Fuse And
Relay Location / Identification (Cont’d) on Page 60-10-
11.)

Fuse And Relay Location / Identification (Cont’d)
Later Models (Cont’d)
Figure 60-10-6
P100416

Remove the covers to check or replace the fuses [Figure
60-10-6].
A decal is located inside the access panel to show

location and amperage ratings.
Line up the clips on the back of the access panel with the
slots provided and push the panel into place when
finished [Figure 60-10-4]. A locating pin prevents the
panel from being installed upside down.
A table is provided with details on amperage ratings and

circuits affected by each fuse and relay. (See Fuse And
Relay Location / Identification (Cont’d) on Page 60-10-
11.)

ELECTRICAL SYSTEM (CONT’D)
Fuse And Relay Location / Identification (Cont’d)
1 13 17 21 25
5 7 9 11
2 18 22 26
14
3 15 19 27
23
6 8 10 12
4 16 20 24 28
The location and amperage ratings are shown in the table below and on the decal above. Relays are identified by the letter
“R” in the AMP column.
REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP REF ICON DESCRIPTION AMP
1 Alternator 15 11 Glow Plugs R 21 Bobcat Controller 25

2 Heater / HVAC 25 12 Fuel Shutoff R 22 ACS Controller 25
3 Front Lights 20 13 Cab Switched 5 23 Attachments 25

Power
4 Rear Lights 15 14 Bucket Position 15 24 Not Used --
5 Starter R 15 Wiper / Washer 25 25 Auxiliary 25

Controller
6 Front Lights R 16 Switched Power & 25 26 Drive Controller & 25

Back-up Alarm Back-up Alarm
(Standard/ACS) (SJC)
7 Heater / HVAC R 17 Switched Power 25 27 Accessories & 25

Front Horn
8 Rear Lights R 18 Switched Power 25 28 Power Port 15
9 Switched Power R 19 Traction 30
10 Traction R 20 Fuel Shutoff 30

Solenoid Testing
Figure 60-10-7
P9175
Use a test meter to measure coil resistance [Figure 60-

10-7]. Coil wires do not have polarity. Correct resistance

for the pressure relief (small) coil is 7 - 10 ohm and the
other coils 5 - 8 ohm.
Replace the test meter with 12 volt power. You can see
and hear the spool shift.

BATTERY Figure 60-20-2
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention P-09589 P-09590
and wash eye with clean, cool water for at least 15
minutes.
Always clean the battery terminals and cable ends when
If electrolyte is taken internally drink large quantities installing a new or used battery [Figure 60-20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. When installing the battery in the loader, do not touch any
W-2065-0807 metal parts with the battery terminals.

Connect the negative (-) cable last to prevent sparks.
Open the rear door.
Connect and tighten the battery cables.
Figure 60-20-1
Install and tighten the battery hold down.
3
2 WARNING
1 Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
Do not jump start or charge a frozen or damaged

battery. Warm battery to 60°F (16°C) before
P-85473
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
Disconnect the negative (-) cable (Item 1) [Figure 60-20- lean over battery while boosting, testing or charging.
1].
Battery gas can explode and cause serious injury.
Remove the battery hold down clamp (Item 2) [Figure W-2066-0705
60-20-1].
Disconnect the positive (+) cable (Item 3) [Figure 60-20-

1] from the battery.
Remove the battery from the loader.

BATTERY (CONT’D)
Servicing
Figure 60-20-3
P-09589 P-09590
The battery cables must be clean and tight [Figure 60-

20-3]. Check electrolyte level in the battery. Add distilled

water as needed. Remove acid or corrosion from battery
and cables with sodium bicarbonate (baking soda) and
water solution.
Put Bobcat Battery Saver or grease on the battery

terminals and cable ends to prevent corrosion.
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807

BATTERY (CONT’D) Keep cables away from moving parts. Start the engine.
Using A Booster Battery (Jump Starting) After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-4] first. Remove the cable from
If it is necessary to use a booster battery to start the the positive terminal (Item 2) [Figure 60-20-4].
engine, BE CAREFUL! There must be one person in the
operator’s seat and one person to connect and
disconnect the battery cables.
The key switch must be OFF or the STOP button must be

pressed. The booster battery must be 12 volt.
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
WARNING • 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
Keep arcs, sparks, flames and lighted tobacco away
connected wrong.
from batteries. When jumping from booster battery I-2023-1285


lean over battery while boosting, testing or charging.

W-2066-0705
Figure 60-20-4
2
4
3
P-85474
Connect the end of the first cable (Item 1) [Figure 60-20-

4] to the positive (+) terminal of the booster battery.
Connect the other end of the same cable (Item 2) [Figure
60-20-4] to the positive terminal on the loader starter.
Connect the end of the second cable (Item 3) [Figure 60-

20-4] to the negative terminal of the booster battery.
Connect the other end of the same cable (Item 4) [Figure
60-20-4] to the engine.


ALTERNATOR Figure 60-30-3
Belt Adjustment
1
The alternator belt is a special maintenance free type
that is pretensioned over the pulleys. This belt eliminates
the need for a tensioning device and does not require
periodic adjustment. Contact your Bobcat dealer for
replacement parts.
Belt Replacement

2
Remove the air conditioning belt. (See REGULAR
MAINTENANCE on Page 80-20-1.) P-90474
Figure 60-30-1
Remove the top alternator mounting bolt (Item 1) and
loosen the bottom alternator mounting bolt (Item 2)
[Figure 60-30-3].
Move the alternator toward the engine as far as it will go

and remove the belt from the pulleys. Inspect the pulleys

for wear.
2
1 Install new belt.
Figure 60-30-4
P-90472
Remove the belt shield mounting nuts and bolts (Item 1)

and remove the belt shield (Item 2) [Figure 60-30-1].
Figure 60-30-2
1
1
P-90475
Use a prybar (Item 1) [Figure 60-30-4] to move the

alternator until the top alternator mounting bolt (Item 1)
[Figure 60-30-3] can be installed.
2 Tighten the top and bottom alternator mounting bolts

(Items 1 and 2) [Figure 60-30-3].
P-90521A
Install the air conditioning belt. (See REGULAR

Remove the cable bracket mounting nut and bolts (Item MAINTENANCE on Page 80-20-1.)
1) and move the cable bracket (Item 2) [Figure 60-30-2]
up slightly. Install the cable bracket and belt shield.

ALTERNATOR (CONT’D) If the charging system malfunctions check the following:
Charging System Inspection Check the condition and tension of the alternator belt.
(See Belt Adjustment on Page 60-30-1.) Replace belt if
worn or deteriorated.
WARNING Inspect the alternator wiring harness and connectors at

alternator. Harness and connectors must be clean and
tight.
AVOID INJURY OR DEATH Check the fuse for the alternator in the fuse panel. If fuse
Batteries contain acid which burns eyes and skin on is burned, find the cause and repair / replace. If fuse is in
contact. Wear goggles, protective clothing and doubt, remove it and check for continuity.
Check the electrolyte level in the battery. Add distilled
In case of acid contact, wash immediately with water. water as needed. (Does not apply to maintenance free
In case of eye contact get prompt medical attention batteries.)
minutes. Verify the charge of the battery. Make sure battery is fully
charged.
If electrolyte is taken internally drink large quantities Disconnect the battery cables (negative first, then
of water or milk! DO NOT induce vomiting. Get positive). Inspect the cable clamps and battery posts for
prompt medical attention. corrosion. Remove acid or corrosion from the battery and
W-2065-0807
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to

prevent corrosion. Reconnect the cable to the positive
terminal.
WARNING
Keep arcs, sparks, flames and lighted tobacco away
from batteries. When jumping from booster battery

lean over battery while boosting, testing or charging.

W-2066-0705
IMPORTANT
disconnected.
• Battery cables are connected when using a fast
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

ALTERNATOR (CONT’D) Low Voltage Testing
Alternator Voltage Testing Figure 60-30-6
Figure 60-30-5
P-85914
P-85916
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-6] from the alternator.
Open rear door.
Turn the remote start tool key to the ON position.

Connect the remote start tool to the loader. (See
REMOTE START TOOL KIT-MEL1563 on Page 10-60- Figure 60-30-7
1.)
Turn the engine on with the remote start tool and run at
idle. With a voltmeter, check the voltage between the B+
terminal and ground at the starter [Figure 60-30-5].
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 21°C (70°F) (Alternator Temperature).
If the voltage is higher that 14.7 volts, proceed to the 2

following high voltage test.
If the voltage is lower than 13.5 volts, run the engine at

high idle and recheck voltage. If voltage is still below 13.5 1
volts, proceed with the following low voltage test. P-85915
Check the voltage across the “L” terminal (Item 1) and

ground (Item 2) [Figure 60-30-7]. The voltage should be
what the battery voltage is. If not, check wire harness,
relay and fuses. If the wire harness, relay and fuses are
okay remove alternator for replacement or repair.

ALTERNATOR (CONT’D)
High Voltage Testing
Figure 60-30-8
P-85917
Turn engine OFF and remove the L & S Terminal

connector (Item 1) [Figure 60-30-6] off the alternator.

Check the continuity between the “S” terminal (Item 1)
[Figure 60-30-8] and the positive (+) terminal on the
battery or starter terminal (Item 2) [Figure 60-30-8].
There should be continuity. If no continuity, replace wire
harness.
If voltage is still above 14.7 volts at 21°C (70°F)

(Alternator Temperature), then remove alternator for
replacement or repair.

ALTERNATOR (CONT’D) Figure 60-30-10
Remove the air conditioning belt. (See Compressor Drive

Belt Replacement on Page 80-20-2.)
IMPORTANT 2

disconnected.
• Battery cables are connected when using a fast P-85718
• Extra battery cables (booster cables) are Remove the alternator rain shield mounting nut and bolts
connected wrong. (Item 1) and remove the alternator rain shield (Item 2)
I-2023-1285 [Figure 60-30-10].
Figure 60-30-11
Figure 60-30-9

1
2
2
1
P-85609
P-85914
Remove the belt shield mounting nuts and bolts (Item 1)

Disconnect the negative (-) cable from the battery. and remove the belt shield (Item 2) [Figure 60-30-11].
Disconnect the red wire (Item 1) [Figure 60-30-9] from
the alternator which comes from the battery.
Disconnect the wiring harness connector (Item 2) [Figure

60-30-9] from the alternator.

ALTERNATOR (CONT'D) Parts Identification

1. Alternator 11. Bearing
Figure 60-30-12 2. Nut 12. Stator
3. Pulley 13. Bracket
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Bracket 16. Rectifier
1 7. Bolt 17. Cover
8. Bearing 18. Spacer
9. Retainer 19. Nut
10. Rotor
7
1
6
2 4 7 13 14
3 12
2
P-85611
10 11
5
Remove the top alternator mounting bolt (Item 1) and the 9
bottom alternator mounting bolt (Item 2) [Figure 60-30- 8

12].
Remove the belt and alternator from the loader. 19
18
17
16
15 C-3529B

STARTER If the starter does not turn, the starter is defective.
Testing Removal And Installation
2
Bat
S 3
M
1
Cranking
Motor
3
A-1992 P-85857
The key switch must be in the OFF position. Open the rear door.

The battery must be at full charge. Disconnect the negative (-) cable from the battery.
The cable connections on the battery must be clean and Disconnect the wires and positive (+) cable (Item 1)
tight. [Figure 60-40-3] from the starter solenoid.
Connect a jumper wire between S terminal and BAT Installation: Tighten the nut to 14,7 - 16,7 N•m (10.8 -
terminal [Figure 60-40-1]. 12.3 ft-lb) torque.
If the starter turns but does not turn the engine, the Disconnect the wire connector (Item 2) [Figure 60-40-3]
starter drive has a defect. from the two solenoid wires.
Figure 60-40-2 Remove the three mounting bolts (Item 3) [Figure 60-40-
3].
Bat Remove the starter from the engine.

S
M
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.

STARTER (CONT'D)
1. Starter 30 13. Lever

2. Shaft 14. Gear
3. Gear 15. Bracket
4. Washer 16. Spring
5. Shaft 17. Gear
6. Stop Ring 34 18. Stop
33
7. Lever 19. Stop Ring
8. Holder 13 20. Ball
9. Spring 21. Armature
10. Spring 36 22. Washer
11. Plate 8 23. Seal
11
12. Seal 9
10
31
32 7
21
15
12 37

16
14
17 20
19 18
14
6
29
1 4
3
28
2
27
24. Yoke
35 25. Holder
26. Bracket
27. Ring
22 26
28. Bolt
29. Bolt
23 25 30. Switch
31. Seal
23 32. Bolt
33. Washer
34. Nut
35. Boot
24
36. Bracket
37. Bearing
B-19824

INSTRUMENT PANELS
Left Panel
Figure 60-50-1
2 3
12
7
1
16
4 13
6 8 9 10 11 15
5 14

17
20
18 19
21 22
23
P-90726B
The left instrument panel [Figure 60-50-1] is the same The table on the facing page shows the DESCRIPTION
for Standard Key Panel, Keyless Start Panel and Deluxe and FUNCTION / OPERATION for each of the
Instrumentation Panel equipped machines. components of the left panel.

INSTRUMENT PANELS (CONT’D)
Left Panel (Cont’d)
REF.
DESCRIPTION FUNCTION / OPERATION
NO.
1 ENGINE TEMPERATURE GAUGE Shows the engine coolant temperature.
2 LEFT DIRECTION INDICATOR (Option) Indicates left flasher signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED (Option) High range selected.
5 ENGINE MALFUNCTION Engine malfunction or failure. (See Service Codes*)
6 ENGINE COOLANT TEMPERATURE Engine coolant temperature high or sensor error.
7 DISPLAY SCREEN Displays information. (See Display Screen in this manual.)
8 SEAT BELT Instructs operator to fasten seat belt. Remains lit for 45 seconds.
9 SEAT BAR The light comes on when the seat bar is UP.
10 LIFT & TILT VALVE The light comes on when the lift and tilt functions cannot be operated.
11 PARKING BRAKE The light comes on when the loader cannot be driven.
12 RIGHT DIRECTION INDICATOR (Option) Indicates right flasher signals are ON.
13 SHOULDER BELT (Option) Instructs operator to fasten shoulder belt when operating in high range.
Remains lit while in high range.
14 HYDRAULIC SYSTEM MALFUNCTION Hydraulic system malfunction or failure. (See Service Codes*)

15 FUEL Fuel level low or sensor error.
16 FUEL GAUGE Shows the amount of fuel in the tank.
17 LIGHTS Press once for FRONT work lights and REAR taillights. (Left green LED will
light.) Press a second time to add REAR work lights. (Left and right green LEDs
will light.) Press a third time to turn all lights off. (Left and right green LEDs will
be off.)
Press and hold five seconds to display software version in display screen.
18 HIGH-FLOW (Option) Press once to engage the HIGH-FLOW auxiliary hydraulics. (Left green LED
will light.) Press a second time to disengage.
19 AUXILIARY HYDRAULICS Press once to activate the auxiliary hydraulic system. (Left green LED will
light.) Press a second time to deactivate the system.
20 INFORMATION Cycles through (after each button press):
• Hourmeter (On start up)
• Engine RPM
• Battery voltage
• Maintenance clock (Press and hold for seven seconds when
displayed to reset the maintenance clock.)
• Service codes*
21 TRACTION LOCK OVERRIDE Functions only when the seat bar is raised and the engine is running. Press
once to unlock the brakes. Allows you to use the steering levers or joystick(s) to
move the loader forward or backward when using the backhoe attachment or
for service. (See TRACTION LOCK OVERRIDE in this manual.) Press a
second time to lock the brakes.
22 PRESS TO OPERATE LOADER Press to activate the BICS™ System when the seat bar is down and operator is
seated in operating position. Button will light.
Press and hold three seconds to engage Drive Response and Steering Drift
Compensation. (See DRIVE RESPONSE and STEERING DRIFT
COMPENSATION in this manual.)
23 PARKING BRAKE (Standard on all loaders) Press the top to engage the Parking Brake. Press the bottom to disengage.
(See PARKING BRAKE in this manual.)
* See SYSTEM SETUP & ANALYSIS for Service Code description. (See DIAGNOSTIC SERVICE CODES on Page 60-
90-1.)

Display Screen
The display screen can display the following information:
• Operating hours.
• Engine revolutions per minute (RPM).
• Speed management setting.
• Maintenance clock countdown.
• Battery voltage.
• Service codes.
• Engine preheat countdown.
• Steering drift compensation setting.
• Drive response setting.
Figure 60-50-2

2
3 4 5 6 7
P-76461A
The display screen is shown in [Figure 60-50-2]. The

data display will show operating hours upon startup.
1. Data Display
2. Hourmeter
3. Speed Management
4. Engine Preheat
5. Engine Revolutions Per Minute
6. Battery / Charging Voltage
7. Service

FUNCTION /
REF. DESCRIPTION
Right Panel (Standard Key Panel) OPERATION
SELECTABLE Press the top to select
Figure 60-50-3 JOYSTICK ‘ISO’ Control Pattern;
CONTROLS (SJC) bottom to select ‘H’
(Option) Control Pattern.
FOUR-WAY Press the top to turn

FLASHER LIGHTS lights ON; bottom to
(Option) turn OFF.
ROTATING BEACON Press the top to turn

(Option) light ON; bottom to
1 or turn OFF.
STROBE LIGHT
(Option)

2
P-85285
This machine may be equipped with a Standard Key

Panel [Figure 60-50-3].
The Standard Key Panel has a key switch (Item 1)

[Figure 60-50-9] used to turn the loader’s electrical
system on and off, and to start and stop the engine.
The switch location (Item 2) [Figure 60-50-3] can have

different functions depending on machine configuration.
See the following table for more information.
FUNCTION /
REF. DESCRIPTION
OPERATION
ADVANCED Press the top to select
CONTROL SYSTEM Hand Controls; bottom
(ACS) (Option) to select Foot
Controls.

INSTRUMENT PANELS (CONT’D) The switch location (Item 7) [Figure 60-50-4] can have
Right Panel (Keyless Start Panel) See the following table for more information.
Figure 60-50-4
FUNCTION /
REF. DESCRIPTION
OPERATION
1 Controls.

2 3 JOYSTICK ‘ISO’ Control Pattern;
5

6 FLASHER LIGHTS lights ON; bottom to
(Option) turn OFF.
ROTATING BEACON Press the top to turn

(Option) light ON; bottom to
P-90819B or turn OFF.
STROBE LIGHT
(Option)
1. Keypad (keys 1 through 0): Used to enter a number
code (password) to allow starting the engine. An
asterisk will show in the left panel display screen for
each key press.
2. LOCK Key: Used to lock keypad. The lock key will

display a red light to indicate a password is required
to start the loader. (See Password Lockout Feature
on Page 60-191-1.)
3. UNLOCK Key: Used to unlock keypad. The unlock

key will display a green light to indicate the loader can
be started without a password. (See Password
Lockout Feature on Page 60-191-1.)
4. START Button: Used to start the engine.
5. STOP Button: Used to stop the engine and shut

down the loaders electrical system.
6. RUN Button: Used to turn on the loaders electrical

system.

INSTRUMENT PANELS (CONT’D) 5. START Button: Used to start the engine.
Right Panel (Deluxe Instrumentation Panel) 6. STOP Button: Used to stop the engine and shut
down the loader’s electrical system.
Figure 60-50-5
7. RUN Button: Used to turn on the loader’s electrical
system.
1
The switch location (Item 8) [Figure 60-50-5] can have
2 See the following table for more information.
3 FUNCTION /
REF. DESCRIPTION
OPERATION
Controls.
4
5
6

7 JOYSTICK ‘ISO’ Control Pattern;

FLASHER LIGHTS lights ON; bottom to
P-90212A
(Option) turn OFF.
This machine may be equipped with a Deluxe

Instrumentation Panel [Figure 60-50-5].
1. Keypad (1 through 0): The keypad has two ROTATING BEACON Press the top to turn
functions: (Option) light ON; bottom to
or turn OFF.
- To enter a number code (password) to allow starting STROBE LIGHT
the engine. (Option)
- To enter a number as directed for further use of the

display screen.
2. Display Screen: The Display Screen is where all

system setup, monitoring and error conditions are
displayed.
3. Scroll Buttons: Used to scroll through display screen

choices.
4. ENTER Button: Used to make selections on the

display screen.

INSTRUMENT PANEL IDENTIFICATION (CONT’D) Enter The Password:
Right Panel (Deluxe Instrumentation Panel) (Cont’d) Use the numbers on the keypad to enter the password.
Then press the [Enter] button a symbol will appear on
Figure 60-50-6 the display screen for each number entered [Figure 60-
50-6]. The left scroll button can be used to backspace if
an incorrect number is entered.
If the correct password is not entered, [INVALID

PASSWORD TRY AGAIN] will appear on the display
screen and the password will have to be reentered.
See CONTROL PANEL SETUP for further description of

screens to setup the system for your use. (See
CONTROL PANEL SETUP on Page 60-180-1.)
NA3017
The first screen you will see on your new loader will be as
shown in [Figure 60-50-6].

When this screen is on the display you can enter the
password and start the engine or change the default
language.
NOTE: Your new loader (with Deluxe Instrumentation

Panel) will have an Owner Password. Your
dealer will provide you with this password.
Change the password to one that you will
easily remember to prevent unauthorized use
of your loader. Keep your password in a safe
place for future needs.
Change Language:
Press the left or right scroll button to cycle through the

languages. The language that is stopped on will be the
default language used for the deluxe instrumentation
panel [Figure 60-50-6].
The language can be changed at any time. (See

CONTROL PANEL SETUP on Page 60-180-1.)

INSTRUMENT PANELS (CONT’D) Right Switch Panel
Left Switch Panel Figure 60-50-8
Figure 60-50-7

3
P-85320
P-85319
This machine may be equipped with a Right Switch Panel
[Figure 60-50-8].
This machine may be equipped with a Left Switch Panel
[Figure 60-50-7].
REF
. DESCRIPTION FUNCTION / OPERATION
REF NO.
. DESCRIPTION FUNCTION / OPERATION
NO. 1 POWER Press and hold the up arrow to
BOB-TACH disengage the Bob-Tach
1 FOUR-WAY Press the top to turn lights ON; (Option) wedges. Press and hold the
FLASHER bottom to turn OFF. down arrow to engage the
LIGHTS (Option) Bob-Tach wedges into the
2 ROTATING Press the top to turn light ON; attachment mounting frame
BEACON (Option) bottom to turn OFF. holes.
or 2 NOT USED ---
STROBE LIGHT
(Option)
3 HYDRAULIC Press the top to engage
BUCKET Hydraulic Bucket Positioning;
POSITIONING bottom to disengage.
(Option)

INSTRUMENT PANELS (CONT’D) Right Panel (Standard Key Panel) Removal And
Installation
Left Panel Removal And Installation
Figure 60-50-11
Figure 60-50-9
1 1
1 1 2
2
P-85929
P-85928
Remove the two mounting bolts (Item 1) and the fastener

Remove the two mounting bolts (Item 1) and the fastener (Item 2) [Figure 60-50-11].
(Item 2) [Figure 60-50-9].

Installation: Be careful to not overtighten the instrument
Installation: Be careful to not overtighten the instrument panel mounting bolts to prevent stripping of the threaded
panel mounting bolts to prevent stripping of the threaded holes in the panels. Tighten the panel screws to 3 - 4 N•m
holes in the panels. Tighten the panel screws to 3 - 4 N•m (25 - 35 in-lb) torque.
NOTE: Inspect and replace the seal as needed (Item
NOTE: Inspect and replace the seal as needed (Item 3) [Figure 60-50-11].
3) [Figure 60-50-9].
Figure 60-50-12
Figure 60-50-10
1 P-85931
P-85930
Pull the right instrument panel down and disconnect the

Pull the right instrument panel down and disconnect the wire harness connector (Item 1) [Figure 60-50-12].
wire harness connectors (Item 1) [Figure 60-50-10] from
the panel. Remove the panel from the loader cab.
Remove the panel from the loader cab.

INSTRUMENT PANELS (CONT'D) Right Panel (Deluxe Instrumentation Panel) Removal
And Installation
Right Panel (Keyless Start Panel) Removal And
Installation Figure 60-50-15
Figure 60-50-13
3
3
1
1 1
1
2
2 P-90527
P-90819A
(Item 2) [Figure 60-50-15].

(Item 2) [Figure 60-50-13]. Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
Installation: Be careful to not overtighten the instrument holes in the panels. Tighten the panel screws to 3 - 4 N•m
panel mounting bolts to prevent stripping of the threaded (25 - 35 in-lb) torque.
holes in the panels. Tighten the panel screws to 3 - 4 N•m
(25 - 35 in-lb) torque. NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-15].
NOTE: Inspect and replace the seal as needed (Item
3) [Figure 60-50-13]. Figure 60-50-16
Figure 60-50-14
P-90530
P-90818A
wire harness connector (Item 1) [Figure 60-50-16].
wire harness connector (Item 1) [Figure 60-50-14]. Remove the panel from the loader cab.
Remove the panel from the loader cab.

INSTRUMENT PANELS (CONT'D) Alarm Disassembly And Assembly
Key Switch Disassembly And Assembly Remove the left instrument panel. (See Left Panel
Remove the right instrument panel. (See INSTRUMENT
PANELS on Page 60-50-1.) Figure 60-50-18
Disconnect the key switch wiring harness.
Figure 60-50-17
2
P-85947
Remove the left side instrument panel.

P-85948
Remove the retaining nut (Item 1) [Figure 60-50-18]
from the loader alarm.
Remove the ignition key (Item 1) from the switch.
Remove the ignition switch retaining nut (Item 2) [Figure Remove the alarm from the loader instrument panel.
60-50-17] from the switch.
Remove the ignition switch from the control panel.

INSTRUMENT PANELS (CONT'D) Right Switch Panel Removal And Installation
Left Switch Panel Removal And Installation Remove the right panel. (See Right Panel (Standard Key
Panel) on Page 60-50-4.)
Remove the left panel. (See Left Panel Removal And
Installation on Page 60-50-9.) Figure 60-50-21
Figure 60-50-19
1 2
1
P-85943
1
P-85945
Remove the two fasteners (Item 1) and the knob (item 2)

[Figure 60-50-21].
Remove the two fasteners (Item 1) [Figure 60-50-19].
Figure 60-50-22
Figure 60-50-20
1 1
P-85944
P-85946
Remove the fastener (Item 1) and the left side panel

Remove the fastener (Item 1) and the left side panel (Item 2) [Figure 60-50-22].
(Item 2) [Figure 60-50-20].

LIGHTS Figure 60-60-3
Front Removal And Installation 1
Disconnect the negative(-) cable from the battery. (See

Figure 60-60-1
1
P-85436
1
Figure 60-60-4
P-85433

Installation: Tighten the two bolts to 22 - 27 N•m (40 - 45

in-lb) torque.
Figure 60-60-2
P-85435
1
Remove the two bulbs (Item 1) [Figure 60-60-3] and
[Figure 60-60-4] from the housing by turning bulb a 1/4
1 turn.
NOTE: Two different light bulbs are used, take note

when removing to assure correct installation.
Reverse the above procedure to install the bulb.
P-85434
Disconnect the bulbs (Item 1) [Figure 60-60-2] from the

wire harness connectors.

LIGHTS (CONT’D) Cab Light Removal And Installation
Rear Removal And Installation Figure 60-60-7
Figure 60-60-5
1 2
P-85274
P-85438
Remove the screws (Items 1) [Figure 60-60-7] from the
cab light.
Remove the bulb assembly (Items 1 and 2) from the light
housing (Item 3) [Figure 60-60-5] by turning bulb NOTE: Do not pull the cab light to far away from the

assembly a 1/4 turn. headliner to prevent damage to the wires.
P-85437 P-85783
Using care press the rear light and housing from the door Disconnect the cab light (Item 1) [Figure 60-60-8].
[Figure 60-60-6].
Reverse this procedure for installation.

BOBCAT CONTROLLERS (GATEWAY AND
AUXILIARY)
Description
The Gateway controller is the main controller, it provides

information to all other controllers. All loaders have a
Gateway and Auxiliary controller.
The Gateway and Auxiliary controller are located behind

the access panel near the operators left foot.

AUXILIARY) (CONT’D)
Connector Identification
Gateway Controller
1 1
34 26
J1A J1B

Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76622
J1A J1B P-76623
P-76624

Connector Identification (Cont’d)
J1A
WIRE
PIN COLOR DESCRIPTION
NUMBER
1 2410 BLACK HYD LOCK VALVE SOLENOID GROUND
2 2380 BLACK LIFT SPOOL SOLENOID GROUND
3 8110 TAN FUEL RELAY SIGNAL
4 8000 TAN SWITCHED POWER RELAY SIGNAL
5 6320 PINK MRKR LIGHT PWR RELAY SIGNAL
6 8510 TAN GLOW PLUG RELAY SIGNAL
7 8210 TAN STARTER RELAY SIGNAL
8 4110 LGN TRACTION LOCK RELAY SIGNAL
9 OPEN NA NA
10 2370 BLACK TILT SPOOL LOCK SOLENOID GROUND
11 7023 WHITE AC SIGNAL MONITOR

12 OPEN NA NA
13 4150 LGN TRACTION LOCK RELAY FEEDBACK
14 8550 TAN GLOW PLUG RELAY FEEDBACK
15 3600 LBL ENGINE SPEED SENSOR SIGNAL
16 3700 LBL AIR FILTER SENDER SIGNAL
17 6210 PINK REAR LIGHT RELAY SIGNAL
18 2910 BLACK HYDRAULIC FAN GROUND
19 9370 PURPLE PTOL LED
20 9380 PURPLE PTOL SWITCH
21 8020 TAN SWITCHED POWER RELAY FEEDBACK
22 8250 TAN STARTER RELAY FEEDBACK
23 3440 LBL HYD FAN DIFF PRESS SWITCH SIGNAL
24 9360 PURPLE START ENGINE
25 3520 LBL ENGINE OIL PRESS SENDER POWER
26 2350 BLACK TWO SPEED GROUND
27 2360 BLACK TWO SPEED MAKEUP GROUND
28 6230 PINK REAR LIGHT RELAY FEEDBACK
29 OPEN NA NA
30 8150 TAN FUEL RELAY FEEDBACK
31 6330 PINK MRKR LIGHT PWR RELAY FEEDBACK
32 3300 LBL HYD TEMP SIGNAL
33 OPEN NA NA
34 3430 LBL HYD FILTER DIFF PRESS

J1B
WIRE
NUMBER
1 3420 LBL HYD CHARGE PRESS SENDER SIGNAL
2 1110 RED/WHT COMPUTER FUSE POWER OUT
4 8800 TAN FUEL SHUTOFF SOLENOID HOLD
5 4380 LGN LIFT SPOOL LOCK SOLENOID SIGNAL
6 4200 LGN TRACTION SOLENOID OUTPUT
7 4370 LGN TILT SPOOL LOCK SOLENOID SIGNAL
8 9210 PUR/WHT CAN LO 0
9 9110 PUR/WHT CAN HI 0
10 OPEN NA NA
11 3920 LBL SEATBAR SENSOR SIGNAL

12 3100 LBL FUEL SENDER SIGNAL
13 4410 LGN HYD LOCK SOLENOID SIGNAL
14 9500 PUR/WHT CAN HIGH 1
15 2500 BLACK COMPUTER GROUND
16 2510 BLACK COMPUTER GROUND
17 3010 LBL SENSOR GROUND
18 3200 LBL ENGINE COOLANT SENSOR SIGNAL
19 4010 LGN HYDRAULIC FAN SIGNAL
20 9600 PURPLE CAN LOW 1
21 9800 PURPLE REMOTE ATTACHMENT SIGNAL
22 9350 PURPLE RUN / ENTER
23 3400 LBL HYDRAULIC CHARGE PRESSURE
24 3930 LBL +5V SUPPLY
25 4360 LGN TWO SPEED MAKEUP
26 4350 LGN TWO SPEED SIGNAL

Auxiliary Controller
1 1
34 26
J2A J2B

Harness Connector View Harness Connector View
9 7 5 3 7 5 3
1 1
17 10 13 8
25 18 19 14
34 32 28 26 26 25 21 20
P-76647
J2A J2B P-76646
P-76645

J2A
WIRE
NUMBER
1 2340 BLACK FRONT BASE SOLENOID GROUND
2 2440 BLACK JEM BLOCK REAR BASE SOLENOID GROUND
3 6520 PINK LEFT BLINKER SIGNAL
4 6420 PINK RIGHT BLINKER SIGNAL
5 7200 WHITE HORN SIGNAL
6 OPEN NA NA
7 OPEN NA NA
8 OPEN NA NA
9 OPEN NA NA
10 2430 BLACK JEM BLOCK REAR ROD SOLENOID GROUND
11 4810 LGN LEFT HANDLE PADDLE RIGHT

12 4820 LGN LEFT HANDLE PADDLE LEFT
13 4910 LGN RIGHT HANDLE RIGHT ROCKER UP
14 OPEN NA NA
15 OPEN NA NA
16 OPEN NA NA
17 OPEN NA NA
18 2330 BLACK FRONT ROD SOLENOID GROUND
19 OPEN NA NA
20 4640 LGN FLOAT SIGNAL
21 OPEN NA NA
22 4830 LGN LEFT HANDLE RIGHT ROCKER DOWN
23 OPEN NA NA
24 OPEN NA NA
25 OPEN NA NA
26 2460 BLACK HIGH FLOW SOLENOID GROUND
27 OPEN NA NA
28 4840 LGN LEFT HANDLE RIGHT ROCKER UP
29 OPEN NA NA
30 4940 LGN RIGHT HANDLE LEFT ROCKER UP
31 4930 LGN RIGHT HANDLE LEFT ROCKER DOWN
32 OPEN NA NA
33 OPEN NA NA
34 OPEN NA NA

J2B
WIRE
NUMBER
1 OPEN NA NA
4 4450 LGN DIVERTER SOLENOID SIGNAL
5 4440 LGN REAR BASE SIGNAL
6 4480 LGN FRONT / REAR AUXILIARY SIGNAL
7 4430 LGN REAR ROD SIGNAL
8 9220 PURPLE CAN LO 0
9 9120 PUR/WHT CAN HI 0
10 OPEN NA NA
11 OPEN NA NA

12 OPEN NA NA
13 4340 LGN FRONT BASE SOLENOID SIGNAL
14 OPEN NA NA
15 2550 BLACK AUXILIARY CONTROLLER GROUND
16 2540 BLACK AUXILIARY CONTROLLER GROUND
17 4310 LBL RIGHT HANDLE PWM LOW
18 4320 LBL RIGHT HANDLE PWM SIGNAL
19 4330 LGN FRONT ROD SOLENOID SIGNAL
20 OPEN NA NA
21 4920 LGN RIGHT HANDLE TRIGGER RETURN
22 1560 RNG SWITCHED INPUT POWER
23 4300 LGN RIGHT HANDLE PWM HIGH
24 OPEN NA NA
25 OPEN NA NA
26 4460 LGN HIGH FLOW SOLENOID SIGNAL

BOBCAT CONTROLLERS (GATEWAY AND Figure 60-70-2

1 1
Lift and block the loader. (See Procedure on Page 10-10- 1 1

1.)
Remove the left inside access panel. (See Removal And

Installation (Left) on Page 50-120-1.)
P-85901
Figure 60-70-1
Remove the controller mounting bolts (Item 1) [Figure

60-70-2] from the left fender.
2
Installation: Tighten the controller mounting bolts to 16 -

Remove the Gateway and Auxiliary controllers from the
loader.
1
P-85900
Unplug the two harness connectors (Item 1) [Figure 60-

70-1] from the Gateway controller.
Unplug the two harness connectors (Item 2) [Figure 60-

70-1] from the Auxiliary controller.
NOTE: The connectors are keyed and will only plug

in one way.

BOBCAT CONTROLLER (ACS)
Description
The ACS controller is on loaders equipped with the ACS

or the SJC option. This controller processes information
for the lift and tilt functions.
The ACS controller is housed in a grey colored plastic

shell with black potting. The ACS controller
communicates with the Bobcat Gateway Controller by
CAN communication wires. The ACS controller is
capable of receiving upgrades to the software.

BOBCAT CONTROLLER (ACS) (CONT’D)
Connector And Wire Identification
G H
J J1 J3
F K
E A
D B
J3 C H
G
F J
K J2
F E
G D A
E H B
C
A J2
B
D
J1
C
J3
J1 J2

P-21843
P/N PIN DESCRIPTION P/N PIN DESCRIPTION

J1 CONNECTOR, METRI-PACK J3 CONNECTOR, METRI-PACK
Orange A 5V HALL EFFECT SUPPLY Red A TILT ACTUATOR FORWARD
Orange B SWITCHED ACS POWER Red/White B UNSWITCHED ACS POWER
Green C HAND/FOOT INPUT Red/White C UNSWITCHED ACS POWER
Purple D CAN SIGNAL HIGH ACS Black D LIFT ACTUATOR REVERSE
Purple E CAN SIGNAL LOW ACS Green E HANDLE LOCK POWER
Purple F CAN SHIELD ACS Red F LIFT ACTUATOR FORWARD
Black G ACS GROUND Green G PEDAL LOCK POWER
Black H ACS GROUND Black H ACS GROUND
J2 CONNECTOR, METRI-PACK Black J ACS GROUND
A OPEN Black K TILT ACTUATOR REVERSE
B OPEN
C OPEN
D OPEN
Green E TILT SPOOL SIGNAL
Green F LIFT HANDLE SIGNAL
Green G TILT HANDLE SIGNAL
Green H LIFT SPOOL SIGNAL
Green J LIFT PEDAL SIGNAL
Green K TILT PEDAL SIGNAL

BOBCAT CONTROLLER (ACS) (CONT’D) Figure 60-71-2

1
1.)
Figure 60-71-1
1 P-85902

2] from the controller.
Remove the controller from the loader.
1 NOTE: The calibration procedure must be followed

when replacing a controller. (See Lift And Tilt
Calibration (ACS) on Page 60-160-11.)
P-85903
Unplug the harness connectors (Item 1) [Figure 60-71-1]

from the controller.
NOTE: The connectors are keyed and will only plug

in one way.


BOBCAT CONTROLLER (SJC) (DRIVE) The SJC system uses electronic joysticks to control both
of the workgroups (lift and tilt) and the drive functions of
Description the loader. The control can be switched from ISO and H-
Pattern drive control layouts.
The drive controller is only on loaders equipped with the
SJC option. This controller processes information for the The workgroup actuators are the same as those used on
drive functions. the ACS system.
The drive controller is located behind the right side The hydrostatic drive pump is a Rexroth A22 unit. It has
access panel near the operator’s right foot. two electromagnetic coils on each of the two pumps to
control the drive of the loader. The coils will direct the
The drive controller monitors the position of the left forward and reverse outputs of the pump to the drive
joystick, pump swash plate angles and the output of the motors. The Rexroth pump is equipped with position
wheel speed sensors. sensors mounted to the bottom of the swash plates to
provide feedback to the controllers to sense
The drive controller works along with the ACS controller uncommanded swash plate movement.
and communicates with the main Bobcat controller in an
SJC system. All these controllers are capable of software
upgrades.
RIGHT
HAND DRIVE HYDRAULIC
PANEL CONTROL MOTOR

ACS
CONTROL SPEED
LIFT / TILT SENSOR
ACTUATORS
GEAR ENGINE
INTERNAL CAN BUS
PUMP
SERIAL TT BUS
RIGHT
JOYSTICK
FWD / REV
ISO SWASH PLATE
SWITCH LEFT
JOYSTICK SENSORS
AUXILIARY DRIVE
CONTROL PUMP
LEFT SPEED
HAND SENSOR
PANEL
ACD HYDRAULIC
EXTERNAL CONTROL MOTOR
CAN BUS
GATEWAY
CONTROL
NA1208

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
P-64295

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification (Cont'd)
P-64296

BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D) Figure 60-72-3
Figure 60-72-1
1
1
P-64325
1
Installation: Note the keyed hole in the controller socket.
(Item 1) [Figure 60-72-3]. The keyed hole matches a tab
on the connector on the wire harness.
P-85879
Figure 60-72-4

Remove the three bolts (Item 1) [Figure 60-72-1] that
secure the controller.

Figure 60-72-2
J S
P-64325
Remove the drive controller [Figure 60-72-4].

1
P-64324
Remove the screw and wire harness (Item 1) [Figure 60-

72-2].
Installation: Tighten the connector screw to 3,39 - 3,96

N•m (30 - 35 in-lb) torque. DO NOT OVERTIGHTEN!

SPEED SENSORS (SJC) Testing
Figure 60-80-1
1
P-28302
P-64765
procedure:
On SJC equipped loaders, the speed sensor [Figure 60-
80-1] is used by the loader’s controllers to sense if the MEL1609-Wheel Speed Sensor Test Harness

drive motor is rotating. The end of the sensor is magnetic [Figure 60-80-2]
and counts the magnetic pulses as a rotating disc,
attached to the motor carrier shaft, rotates by the sensor MEL1563 or 7003031-Remote Start Tool Kit
end.
Multimeter
The speed sensor is sealed with an O-ring (Item 1)
[Figure 60-80-1] to keep hydraulic oil inside the motor Raise the lift arms and install an approved lift arm support
carrier and dirt out. device. (See Installing on Page 10-20-1.)

REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.) or (See REMOTE START TOOL (SERVICE TOOL)
KIT - 7003031 on Page 10-61-1.)

SPEED SENSORS (SJC) (CONT'D) Figure 60-80-4
Testing (Cont’d)
Figure 60-80-3
3
2
1
2
1
P-64976
Connect the speed sensor test harness (Item 1) [Figure

P-64762 60-80-4] in line, between the loader wiring harness and
the speed sensor harness.
Locate the speed sensor (Item 1) [Figure 60-80-3] on the Turn the remote start key to ON position without starting
top of the right or left hydrostatic motor carrier. the loader.

Remove the transmission cover screw (Item 2) [Figure Take a voltage reading, with the multimeter, at the speed
60-80-3], to loosen the connector clamp. sensor test harness, between pin 1 and pin 3 (Item 2)
[Figure 60-80-4].
Installation: Tighten screw to 20 - 27 N•m (15 - 20 ft-lb)
torque. The voltage should be approximately 5 volts.
Disconnect the speed sensor wire connector (Item 3) Repeat the procedure for the opposite side speed
[Figure 60-80-3] from the loader harness wire connector. sensor. (If needed.)

Figure 60-80-5 1
1 P-64764
Lift the speed sensor (Item 1) [Figure 60-80-7] out from

P-64762 the motor carrier. DO NOT pull on the wires, gently pry up
with a screwdriver if necessary.
Raise the lift arms and install an approved lift arm support Figure 60-80-8

Remove the two, speed sensor mount bolts (Item 1)

[Figure 60-80-5] from the top of the hydrostatic motor
carrier.
Remove the mount plate (Item 2) [Figure 60-80-5].
Figure 60-80-6
2
P-64765
1
Remove the speed sensor [Figure 60-80-8].
P-64762
Remove the transmission cover screw (Item 1) [Figure

60-80-6], to loosen the connector clamp.
Installation: Tighten screw to 20 - 27 N•m (15 - 20 ft-lb)

torque.
Disconnect the speed sensor electrical harness


Figure 60-80-9
1
1
P-26292
Installation: Be sure to install the speed sensor (Item 1)

P-26293 [Figure 60-80-11] pointing toward the transmission case.
Figure 60-80-12
The electrical connector can be replaced.

Remove the connector wedge (Item 1) [Figure 60-80-9].
Figure 60-80-10
2
4 1
1
3 2 P-26295
Installation: The alignment pin (Item 1) at the bottom of

the speed sensor must be installed in the hole (Item 2)
P-26294 [Figure 60-80-12] in the motor carrier.
With a thin screwdriver lift the tabs and remove the wires
from the connector [Figure 60-80-10].
Wire Code
1 Red
2 White
3 Black
4 Blue

DIAGNOSTIC SERVICE CODES Deluxe Instrumentation Panel
Viewing Service Codes The optional Deluxe Instrumentation Panel offers an

additional view of service codes that includes a brief
The Service Codes will aid your dealer in diagnosing description.
conditions which can damage your machine.
The last 40 codes stored in history can also be viewed
Figure 60-90-1 using the Deluxe Instrumentation Panel.
Figure 60-90-2
Press a scroll button
2 (Item 1) repeatedly until
the Active Warnings
screen icon (Inset) is
highlighted.
1 1
The ACTIVE WARNINGS
screen displays active
1 service codes. Press [9]
P-76455G
to view the next service
code if more than one is
present. Press [4] to
Press the INFORMATION button (Item 1) to cycle the display a history of

DATA DISPLAY (Item 2) [Figure 60-90-1] until the service codes.
service code screen is displayed. If more than one
SERVICE CODE is present, the codes will scroll on the The WARNINGS
DATA DISPLAY. HISTORY screen will list
the Service Code
NOTE: Corroded or loose grounds can cause Number (CODE),
Hourmeter reading when
multiple service codes and / or abnormal the error occurred
symptoms. All instrument panel lights (HOUR), and the User
flashing, alarm sounding, headlights and (USER) who was logged
taillights flashing, could indicate a bad in to operate the machine
ground. The same symptoms could apply if when the error occurred.
the voltage is low, such as loose or corroded Press [9] to view the next eight Service Codes.
battery cables. If you observe these
symptoms, check grounds and positive leads A total of 40 Codes can be stored. When more than 40
first. codes occur, the oldest code will disappear and the
newest code will be in the number 1 position.
Press the list number

next to the service code
for more detail.
Press left scroll button to

back up one screen.
P-90378 / NA3025 / NA3000 / NA3038 / NA3035

DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List
Figure 60-90-3 The following word errors may be displayed:
2 [REPLY] One or both instrument panel(s) not

1
communicating with the controller.
[CODE] The controller is asking for a password.

(Keyless Start and Deluxe Instrumentation Panels
only.)
[ERROR] The wrong password was entered.

(Keyless Start and Deluxe Instrumentation Panels
P-76461H only.)
P-76461P
P-76455G
[SHTDN] A shutdown condition exists.
Service Codes may be either a word (Item 1) or a number [DOOR] Operator cab door is open. (Lift and Tilt
(Item 2) [Figure 60-90-3]. functions will not operate.)
CODE DESCRIPTION CODE DESCRIPTION

A3623 ACD not programmed A8503 ACD output ‘F’ error OFF

A8002 ACD output ‘A’ error ON A8505 ACD output ‘F’ short to battery
A8003 ACD output ‘A’ error OFF A8506 ACD output ‘F’ short to ground
A8005 ACD output ‘A’ short to battery A8507 ACD output ‘F’ open circuit
A8006 ACD output ‘A’ short to ground A8532 ACD output ‘F’ overcurrent
A8007 ACD output ‘A’ open circuit A8602 ACD output ‘G’ error ON
A8032 ACD output ‘A’ overcurrent A8603 ACD output ‘G’ error OFF
A8102 ACD output ‘B’ error ON A8605 ACD output ‘G’ short to battery
A8103 ACD output ‘B’ error OFF A8606 ACD output ‘G’ short to ground
A8105 ACD output ‘B’ short to battery A8607 ACD output ‘G’ open circuit
A8106 ACD output ‘B’ short to ground A8702 ACD output ‘H’ error ON
A8107 ACD output ‘B’ open circuit A8703 ACD output ‘H’ error OFF
A8132 ACD output ‘B’ overcurrent A8705 ACD output ‘H’ short to battery
A8202 ACD output ‘C’ error ON A8706 ACD output ‘H’ short to ground
A8203 ACD output ‘C’ error OFF A8707 ACD output ‘H’ open circuit
A8205 ACD output ‘C’ short to battery
A8206 ACD output ‘C’ short to ground D3905 Left joystick X-axis not in neutral
A8207 ACD output ‘C’ open circuit D3907 Left joystick Y-axis not in neutral
A8232 ACD output ‘C’ overcurrent D4007 Right joystick Y-axis not in neutral
A8302 ACD output ‘D’ error ON D7501 CAN joystick communication error
A8303 ACD output ‘D’ error OFF D7504 No communication from drive controller
A8305 ACD output ‘D’ short to battery D7505 Left joystick X-axis not in neutral
A8306 ACD output ‘D’ short to ground D7507 Left joystick Y-axis not in neutral
A8307 ACD output ‘D’ open circuit D7508 Right joystick Y-axis not in neutral
A8332 ACD output ‘D’ overcurrent D7509 Operating mode switch short to ground or battery
A8402 ACD output ‘E’ error ON D7513 Right front wheel angle sensor unresponsive
A8403 ACD output ‘E’ error OFF D7514 Left front wheel angle sensor unresponsive
A8405 ACD output ‘E’ short to battery D7515 Right rear wheel angle sensor unresponsive
A8406 ACD output ‘E’ short to ground D7516 Left rear wheel angle sensor unresponsive
A8407 ACD output ‘E’ open circuit D7517 Left swash plate not in neutral
A8432 ACD output ‘E’ overcurrent D7518 Right swash plate not in neutral
A8502 ACD output ‘F’ error ON D7519 Left joystick X-axis out of range high

Service Codes List (Cont’d)

D7521 Left joystick Y-axis out of range high D7572 Drive pump not calibrated
D7522 Right joystick Y-axis out of range high D7573 Operating mode switch flipped while operating
D7523 Right front wheel angle sensor out of range high D7574 Right wheel speed uncommanded motion
D7524 Left front wheel angle sensor out of range high D7575 Left wheel speed uncommanded motion
D7525 Right rear wheel angle sensor out of range high D7576 No communication from ACS controller
D7526 Left rear wheel angle sensor out of range high D7577 Left speed sensor out of range high
D7527 Left swash plate out of position D7578 Right speed sensor out of range high
D7528 Right swash plate out of position D7579 Left speed sensor out of range low
D7529 Left joystick X-axis out of range low D7580 Right speed sensor out of range low
D7531 Left joystick Y-axis out of range low D7581 Right front steer retract short to battery
D7532 Right joystick Y-axis out of range low D7582 Left front steer retract short to battery
D7533 Right front wheel angle sensor out of range low D7583 Right rear steer retract short to battery
D7534 Left front wheel angle sensor out of range low D7584 Left rear steer retract short to battery
D7535 Right rear wheel angle sensor out of range low D7585 Sensor supply 1 out of range high
D7536 Left rear wheel angle sensor out of range low D7586 Sensor supply 2 out of range high
D7537 Sensor supply 1 out of range low D7587 Software update required
D7538 Sensor supply 2 out of range low D7588 Switched power stuck ON
D7539 Left swash plate sensor out of range high D7589 Switched power error OFF

D7540 Left swash plate sensor out of range low D7591 Left swash plate sensor reversed
D7541 Right swash plate sensor out of range high D7592 Right swash plate sensor reversed
D7542 Right swash plate sensor out of range low D7593 Right speed sensor unresponsive
D7543 Left forward drive solenoid error ON D7594 Left speed sensor unresponsive
D7544 Left reverse drive solenoid error ON D7595 Left speed sensor reversed
D7545 Right forward drive solenoid error ON D7596 Right speed sensor reversed
D7546 Right reverse drive solenoid error ON D7597 Controller programmed
D7547 Right front steer extend short to battery D7598 In drive calibration mode
D7548 Left front steer extend short to battery D7599 In angle calibration mode
D7549 Right rear steer extend short to battery
D7550 Left rear steer extend short to battery H1221 Right Primary out of range high
D7551 Steer pressure short to battery H1222 Right Primary out of range low
D7552 Back-up alarm error ON H1224 Right Primary not in neutral
D7553 Left forward drive solenoid error OFF H1321 Left Primary out of range high
D7554 Left reverse drive solenoid error OFF H1322 Left Primary out of range low
D7555 Right forward drive solenoid error OFF H1324 Left Primary not in neutral
D7556 Right reverse drive solenoid error OFF H2005 Boost solenoid short to battery
D7557 Right front steer extend short to ground H2006 Boost solenoid short to ground
D7558 Right front steer retract short to ground H2007 Boost solenoid open circuit
D7559 Left front steer extend short to ground H2032 Boost solenoid overcurrent
D7560 Left front steer retract short to ground H2205 Pressure control solenoid short to battery
D7561 Right rear steer extend short to ground H2206 Pressure control solenoid short to ground
D7562 Right rear steer retract short to ground H2207 Pressure control solenoid open circuit
D7563 Left rear steer extend short to ground H2232 Pressure control solenoid overcurrent
D7564 Left rear steer retract short to ground H2305 Rear base solenoid short to battery
D7565 Steer pressure short to ground H2306 Rear base solenoid short to ground
D7566 Back-up alarm error OFF H2307 Rear base solenoid open circuit
D7567 No communication from Gateway controller H2332 Rear base solenoid overcurrent
D7568 Angle sensors not calibrated H2405 Rear rod solenoid short to battery
D7569 Battery voltage out of range high H2406 Rear rod solenoid short to ground
D7570 Interrupted power H2407 Rear rod solenoid open circuit
D7571 Battery voltage out of range low H2432 Rear rod solenoid overcurrent


H2505 Rear aux relief short to battery M0116 Air filter not connected
H2506 Rear aux relief short to ground M0117 Air filter plugged
H2507 Rear aux relief open circuit M0216 Hydraulic/Hydrostatic filter not connected
H2605 Front base solenoid short to battery M0217 Hydraulic/Hydrostatic filter plugged
H2606 Front base solenoid short to ground M0309 Battery voltage low
H2607 Front base solenoid open circuit M0310 Battery voltage high
H2632 Front base solenoid overcurrent M0311 Battery voltage extremely high
H2705 Front rod solenoid short to battery M0314 Battery voltage extremely low
H2706 Front rod solenoid short to ground M0322 Battery voltage out of range low
H2707 Front rod solenoid open circuit M0409 Engine oil pressure low
H2732 Front rod solenoid overcurrent M0414 Engine oil pressure extremely low
H2805 Diverter rod solenoid short to battery M0415 Engine oil pressure shutdown
H2806 Diverter rod solenoid short to ground M0421 Engine oil pressure out of range high
H2807 Diverter rod solenoid open circuit M0422 Engine oil pressure out of range low
H2905 High-flow solenoid short to battery M0509 Hydraulic charge pressure low
H2906 High-flow solenoid short to ground M0510 Hydraulic charge pressure high
H2907 High-flow solenoid open circuit M0511 Hydraulic charge pressure extremely high
H2932 High-flow solenoid overcurrent M0514 Hydraulic charge pressure extremely low

H3028 Controller memory failure M0515 Hydraulic charge pressure shutdown
H3128 Interrupted power failure M0521 Hydraulic charge pressure out of range high
H3648 ACD multiple M0522 Hydraulic charge pressure out of range low
H3913 Left joystick grip no communication M0610 Engine speed high
H3916 Left joystick not connected M0611 Engine speed extremely high
H3928 Left joystick failure M0613 Engine speed no signal
H3948 Left joystick multiple M0615 Engine speed shutdown
H4013 Right joystick grip no communication M0618 Engine speed out of range
H4016 Right joystick not connected M0710 Hydraulic oil temperature high
H4028 Right joystick failure M0711 Hydraulic oil temperature extremely high
H4048 Right joystick multiple M0715 Hydraulic oil temperature shutdown
H4302 Horn error ON M0721 Hydraulic oil temperature out of range high
H4303 Horn error OFF M0722 Hydraulic oil temperature out of range low
H4423 Auxiliary not programmed M0810 Engine coolant temperature high
H4502 Right signal error ON M0811 Engine coolant temperature extremely high
H4503 Right signal error OFF M0815 Engine coolant temperature shutdown
H4602 Left signal error ON M0821 Engine coolant temperature out of range high
H4603 Left signal error OFF M0822 Engine coolant temperature out of range low
H4721 Sensor supply 1 out of range high M0909 Fuel level low
H4722 Sensor supply 1 out of range low M0921 Fuel level out of range high
H7314 Remote control failure M0922 Fuel level out of range low
H7328 Remote control no signal M1016 Hydraulic charge filter not connected
H7404 Main controller no communication M1017 Hydraulic charge filter plugged
H7604 Left hand panel no communication M1121 Seat bar sensor out of range high
M1122 Seat bar sensor out of range low
L0102 Left panel button 1 error ON M1305 Fuel hold solenoid short to battery
L0202 Left panel button 2 error ON M1306 Fuel hold solenoid short to ground
L0302 Left panel button 3 error ON M1307 Fuel hold solenoid open circuit
L0402 Left panel button 4 error ON M1402 Fuel pull output error ON
L7404 Left panel main controller no communication M1403 Fuel pull output error OFF
L7672 Left panel programming error M1407 Fuel pull output open circuit
M1428 Fuel pull output failure


M1502 Traction lock pull output error ON M3805 Auxiliary hydraulic lock short to battery
M1503 Traction lock pull output error OFF M3806 Auxiliary hydraulic lock short to ground
M1507 Traction lock pull output open circuit M3807 Auxiliary hydraulic lock open circuit
M1528 Traction lock pull output failure M3832 Auxiliary hydraulic lock overcurrent
M1605 Traction lock hold solenoid short to battery M4109 Alternator low
M1606 Traction lock hold solenoid short to ground M4110 Alternator high
M1607 Traction lock hold solenoid open circuit M4304 Keyless panel no communication
M1705 Hydraulic lock valve solenoid short to battery M4404 Auxiliary no communication
M1706 Hydraulic lock valve solenoid short to ground M4621 5 volt sensor supply out of range high
M1707 Hydraulic lock valve solenoid open circuit M4622 5 volt sensor supply out of range low
M1732 Hydraulic lock valve solenoid overcurrent M4721 8 volt sensor supply out of range high
M1805 Lift spool lock short to battery M4722 8 volt sensor supply out of range low
M1806 Lift spool lock short to ground M4802 Front light relay error ON
M1807 Lift spool lock open circuit M4803 Front light relay error OFF
M1832 Lift spool lock overcurrent M4807 Front light relay open circuit
M2005 Two-speed primary short to battery M4902 Rear light relay error ON
M2006 Two-speed primary short to ground M4903 Rear light relay error OFF
M2007 Two-speed primary open circuit M4907 Rear light relay open circuit

M2032 Two-speed primary overcurrent M5002 Front light output error ON
M2102 Glow plug output error ON M5003 Front light output error OFF
M2103 Glow plug output error OFF M5007 Front light output open circuit
M2107 Glow plug output open circuit M5028 Front light output failure
M2128 Glow plug output failure M5102 Rear light output error ON
M2202 Starter output error ON M5103 Rear light output error OFF
M2203 Starter output error OFF M5107 Rear light output open circuit
M2207 Starter output open circuit M5128 Rear light output failure
M2228 Starter output failure M5202 PTOL switch error ON
M2302 Starter relay error ON M5221 PTOL switch out of range high
M2303 Starter relay error OFF M5222 PTOL switch out of range low
M2402 Fuel pull relay error ON M5305 PTOL LED short to battery
M2403 Fuel pull relay error OFF M5306 PTOL LED short to ground
M2502 Traction pull relay error ON M5405 Tilt spool lock short to battery
M2503 Traction pull relay error OFF M5406 Tilt spool lock short to ground
M2602 Glow plug relay error ON M5407 Tilt spool lock open circuit
M2603 Glow plug relay error OFF M5432 Tilt spool lock overcurrent
M2721 Throttle primary out of range high M6402 Switched power relay error ON
M2722 Throttle primary out of range low M6403 Switched power relay error OFF
M2821 Throttle secondary out of range high M6505 EEC power short to battery
M2822 Throttle secondary out of range low M6506 EEC power short to ground
M3128 Interrupted power failure M6507 EEC power open circuit
M3204 Workgroup no communication M6604 EEC power no communications
M3304 Deluxe panel no communication M7002 Switched power output error ON
M3505 Hydraulic fan short to battery M7003 Switched power output error OFF
M3506 Hydraulic fan short to ground M7007 Switched power output open circuit
M3507 Hydraulic fan open circuit M7028 Switched power output failure
M3532 Hydraulic fan overcurrent M7102 Electric fan 1 output error ON
M3705 Two-speed secondary short to battery M7103 Electric fan 1 output error OFF
M3706 Two-speed secondary short to ground M7128 Electric fan 1 output failure
M3707 Two-speed secondary open circuit M7202 Electric fan 1 relay error ON
M3732 Two-speed secondary overcurrent M7203 Electric fan 1 relay error OFF


M7207 Electric fan 1 relay open circuit W3251 Lift actuator short to battery
M7304 Remote control no communication W3252 Tilt actuator short to battery
M7316 Remote control no signal from transmitter W3253 Lift handle / pedal short to ground
M7423 Main controller not programmed W3254 Tilt handle / pedal short to ground
M7472 Main controller in boot code W3255 Lift handle / pedal short to battery
M7497 Main controller software updated W3256 Tilt handle / pedal short to battery
M7504 Drive no communication W3257 Lift actuator reduced performance
M7604 Left display panel no communication W3258 Tilt actuator reduced performance
M7748 Key switch multiple W3259 Lift actuator wrong direction
M7839 Hourmeter changed W3260 Tilt actuator wrong direction
M7974 Door open W3261 Handle lock short to ground
W3262 Handle lock short to battery
W3223 ACS calibration required W3263 Pedal lock short to ground
W3224 ACS calibration failed W3264 Pedal lock short to battery
W3231 Tilt actuator fault W3265 Sensor supply voltage out of range
W3232 Tilt actuator wiring fault W3266 Battery voltage out of range
W3233 Tilt handle wiring fault W3267 Handle/pedal switch flipped while operating
W3234 Tilt actuator not in neutral W3268 Lift handle information error

W3235 Tilt handle / pedal not in neutral W3270 Right hand drive short to ground
W3236 Lift actuator fault W3271 Right hand drive short to battery
W3237 Lift actuator wiring fault W3274 Left joystick X-axis out of range
W3238 Lift handle wiring fault W3275 Interrupted unswitched power
W3239 Lift actuator not in neutral W3276 CAN joystick information error
W3240 Lift handle / pedal not in neutral W3277 Remote control information error
W3241 No communication W3905 Left joystick X-axis not in neutral
W3249 Lift actuator short to ground W4005 Right joystick X-axis not in neutral
W3250 Tilt actuator short to ground W4007 Right joystick Y-axis not in neutral

BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
Description
Figure 60-100-1
1 2 3
4
3
P-85413C
The Bobcat Interlock Control System is an electronic

system that is used to protect the operator. The system

consists of the traction lock, seat bar sensor and the lift
and tilt lockouts solenoid.
These all have indicator lights on the left panel (Items 1,

2, 3) [Figure 60-100-1] of the loader cab.
The Press To Operate button (Items 4) [Figure 60-100-1]

activates the system and allows the operator to function
the loader.

BOBCAT INTERLOCK CONTROL SYSTEM (BICS) Inspecting The Traction Lock (Engine RUNNING)
(CONT'D)
6. Fasten seat belt, disengage parking brake, press the
Inspecting The BICS (Engine STOPPED - Key ON) PRESS TO OPERATE LOADER button and raise
seat bar fully. Move steering levers or joystick(s)
Figure 60-100-2 slowly forward and backward. The TRACTION lock
must be engaged. Lower the seat bar. Press the
1 PRESS TO OPERATE LOADER button.
2 3
7. Engage parking brake and move steering levers or
joystick(s) slowly forward and backward. The
TRACTION lock must be engaged.
4 NOTE: The PARKING BRAKE light on the left

instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
LOADER button is pressed and the parking
5
brake is disengaged.
6 Inspecting The Lift Arm Bypass Control

P-85413C
8. Raise the lift arms 2 m (6 ft) off the ground. Stop
engine. Turn lift arm bypass control knob clockwise 1/
1. Sit in operator’s seat. Turn key to RUN or press RUN
4 turn. Pull up and hold lift arm bypass control knob
button. Lower seat bar and disengage parking brake.

until lift arms slowly lower.
Press the PRESS TO OPERATE LOADER button
(Item 6). Two BICS™ lights (Items 1 and 2) [Figure
Inspecting Deactivation Of Lift And Tilt Functions
60-100-2] [SEAT BAR AND LIFT & TILT VALVE] on
(ACS And SJC)
left instrument panel must be OFF. The PRESS TO
OPERATE LOADER button will light.
9. Sit in operator’s seat and fasten seat belt. Lower seat
bar, start engine and press the PRESS TO OPERATE
2. Raise seat bar fully. All three BICS™ lights (Items 1,
LOADER button.
2 and 3) [Figure 60-100-2] [SEAT BAR, LIFT & TILT
VALVE and PARKING BRAKE] on left instrument
10. Raise lift arms about 2 m (6 ft) off the ground.
panel must be ON. The PRESS TO OPERATE
LOADER button light will turn OFF.
11. Turn key OFF or press STOP button and wait for the
engine to come to a complete stop.
Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED - Key ON)
12. Turn key ON or press RUN button. Press the PRESS
TO OPERATE LOADER button, move the control
3. Sit in operator’s seat, lower seat bar and press the
(foot pedal, hand control or joystick) to lower the lift
PRESS TO OPERATE LOADER button (Item 6).
arms. Lift arms must not lower.
Press the auxiliary hydraulics button (Item 5). The
auxiliary hydraulics light will be ON (Item 4) [Figure
13. Move the control (foot pedal, hand control or joystick)
60-100-2]. Raise the seat bar. The light must be OFF.
to tilt the bucket (or attachment) forward. The bucket
(or attachment) must not tilt forward.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in operator’s seat, lower seat bar, engage parking

brake and fasten seat belt. WARNING
5. Start engine and operate at low idle. Press the
PRESS TO OPERATE LOADER button. While raising AVOID INJURY OR DEATH
the lift arms, raise the seat bar fully. The lift arms must The Bobcat Interlock Control System (BICS) must
stop. Repeat using the tilt function. deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
modify the system.
W-2151-0394

BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
(CONT'D)
Troubleshooting
WARNING
The following troubleshooting guide is provided for Check for correct function after adjustments, repairs
assistance in locating and correcting BICS system or service. Failure to make correct repairs or
problems. It is recommended that these procedures be adjustments can cause injury or death.
done by authorized Bobcat Service Personnel only. W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
SOLUTION SUGGESTIONS
1. Refer to BICS troubleshooting chart.
2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.

4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.


SEAT BAR SENSOR Troubleshooting
Description The following troubleshooting chart is provided for

assistance in locating and correcting BICS system
The seat bar sensor is part of the BICS system. The seat problems. It is recommended that these procedures be
bar sensor sends a signal that indicates whether the seat done by authorized Bobcat Service Personnel only.
bar is in the down or up position.
The sensor is located on the left side of seat bar.

WARNING
Check for correct function after adjustments, repairs
or service. Failure to make correct repairs or
adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
1. Check sensor wire connection.

2. Use the BICS sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.

SEAT BAR SENSOR (CONT'D) Figure 60-110-3
Testing
Figure 60-110-1
1
P-4698
If there is no power light (Item 1) [Figure 60-110-3] on

P-85653 the sensor tester, check the tester or wiring harness.
Figure 60-110-4
Use Sensor Tester (MEL1428) and seat bar sensor tester
adapter (MEL1567) for the following procedure:

Connect the seat bar adapter sensor leads (MEL1567) to
the sensor tester.
1
Disconnect the seat bar sensor connector (Item 1)
[Figure 60-110-1].
Figure 60-110-2
P-4699
Lower the seat bar. The Sensor Test light (Item 1)

1 [Figure 60-110-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
60-110-4] should go off.
If the above test fails, there is a problem with the seat bar
P-85925 sensor.
Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-110-2]
inline, to the seat bar sensor connectors. [Figure 60-110- Replace the Seat Bar Sensor. (See Removal And
2]. Installation on Page 60-110-3.)
Turn the key to the ON position. DO NOT START THE If the above test passes, run the seat bar sensor BICS
ENGINE. circuit test. (See Bobcat Interlock Control System (BICS)
Circuit Test on Page 60-110-4.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.


2
Remove the seat bar from the loader. (See Removal And 1
Installation on Page 50-10-1.) 3
Figure 60-110-5
3
N-19383
Remove the keyed plastic bushing (Item 1) magnetic

1 bushing assembly (Item 2) and sensor bracket (Item 3)
[Figure 60-110-6].

2 IMPORTANT
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Installation: Be sure the tabs on the pivot bushing are

positioned in the slotted hole (Item 1) [Figure 60-110-6]
of the seat bar.
N-19219
Inspect all parts for damage and wear and replace if
Remove the mounting bolt (Item 1) from the seat bar necessary.
mount (Item 2) [Figure 60-110-5].
Reverse the removal procedure to install the seat bar
Installation: Tighten the mounting bolt to 5,6 - 7,9 N•m sensor.
Remove the sensor mounting bolt (Item 3) [Figure 60-

110-5] and nut.

Bobcat Interlock Control System (BICS) Circuit Test
Figure 60-110-7
3
1
1
P-4703
Connect Sensor Tester (Item 1) [Figure 60-110-8] inline

P-85653 to the seat bar sensor connectors.
Turn the key to the ON position. DO NOT START THE

Use Sensor Testers (MEL1428) and seat bar sensor ENGINE.
tester adapter (MEL1567) for the following procedure:

If there is no power light on the sensor tester, check the
Connect the seat bar sensor tester adapter MEL1567 to tester or wiring harness.
the sensor tester.
When the power light is illuminated, move the toggle
Disconnect the seat bar sensor connector (Item 1) switch (Item 2) [Figure 60-110-8] on the sensor tester to
[Figure 60-110-7]. the Present position.
NOTE: The sensor test light (Item 3) [Figure 60-110-8]

is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.

SEAT BAR SENSOR (CONT'D)
Bobcat Interlock Control System (BICS) Circuit Test

(Cont’d)
Figure 60-110-9
P-85413
The BICS seat bar indicator light (Item 1) [Figure 60-110-

9] should illuminate.
Figure 60-110-10
P-4699
Move the toggle switch (Item 1) [Figure 60-110-10] on

the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-110-9] should go

off.
If the above test fails, there is a problem with the Bobcat

controller or the wiring harness.


TRACTION LOCK
Description
The Traction Lock Control System will lock the traction

drive system when the engine stops. The Traction Lock
Control System is incorporated into the Bobcat Interlock
Control System (BICS).

TRACTION LOCK (CONT'D)
assistance in locating and correcting BICS system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION #
Brake stays engaged. 1, 2, 3, 4, 5, 6, 7,11
Intermittent activation of brake. 8, 9, 10,11
1. Make sure brake switch is not engaged.
2. Check the display for an error code.
3. If all lights indicate the brake should be released, but it doesn’t, check the brake 30 amp fuse.
4. When checking fuse, also check other fuses. Check the fuse block for correct orientation and location of fuses.
(See Electrical System, Information Page 60-01.)
5. To test the solenoid, the coil should be about 9.8 ohm.

6. Check brake solenoid wiring voltage, solenoid wiring should read 12 volts.
7. Check the brake solenoid mounting nut for correct torque.
8. Check wire connections for loose connector body.
9. Check for loose or bent pins in connectors.
10. Check for loose spade connectors in fuse holder.
11. Check the flywheel RPM sensor and wiring.

TRACTION LOCK (CONT'D) Figure 60-120-2
Inspecting
Figure 60-120-1
P-85923
1
Check the wire connections at the engine speed sensor
P-85413 (Item 1) [Figure 60-120-2].
Check the adjustment of the flywheel speed sensor and

Fasten the seat belt, disengage the parking brake button, replace the speed sensor if needed. (See Adjustment on
press the PRESS TO OPERATE LOADER Button (Item Page 60-170-2.)

1) and raise the Seat Bar fully. Move the steering levers
slowly forward and backward. The TRACTION lock (Item NOTE: When the Traction Lock Override Button is
4) should be engaged. Lower the Seat Bar. Press the activated, the Traction Lock Override Control
PRESS TO OPERATE LOADER Button (Item 1) [Figure System will NOT engage the Traction Lock if
60-120-1]. the engine stops.
Engage the parking brake pedal and move the steering

levers slowly forward and backward. The TRACTION
lock should be engaged.
NOTE: The TRACTION light on the left instrument

panel will remain ON until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.


CONTROL SYSTEM (ACS)
Description
The ACS option allows the operator to quickly switch

between foot and hand control modes. It uses the electric
actuators to control the lift and tilt spools, foot sensors,
handle sensors and a specially designed control handle.

CONTROL SYSTEM (ACS) (CONT'D)
Troubleshooting
The Advanced Control System (ACS) has a built-in diagnostic function to indicate the condition of the ACS controller. The
ACS controller continually monitors the lift handle sensor, lift actuator, tilt handle sensor, and the tilt actuator. The controller
also records alarm condition(s) as service code(s).
To see what error occurred. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)

CONTROL SYSTEM (ACS) (CONT'D) Figure 60-130-3
Handle Sensor Connector Disassembly And

Assembly
Figure 60-130-1
1
3
2
1 P13733
With a pointed tool, lift the tab (Item 1) [Figure 60-130-3]

and pull the wire from the connector.
P16578
Installation: Install the wires into the connector as listed
below [Figure 60-130-3]:
The wire connector (Item 1) [Figure 60-130-1] can be

removed from the handle sensor wires, use the following 1-Terminal - Red
procedure. 2-Terminal - Black
3-Terminal - Green
Figure 60-130-2
1 1
1 1
P13725
P13725 P13732
Remove the wedge (Item 1) [Figure 60-130-2] from the

connector.

Switch Handle Removal
Figure 60-130-4
3 1
2
P13735
2 1
Using a pointed tool, press down on the tab (Item 1)

P-21879 [Figure 60-130-6] and pull the wire from the connector.
Figure 60-130-7
NOTE: Switch handle can be removed and installed
while in loader.

130-4] from the handle sensor connector.

130-4] from the handle lock solenoid connector.
1
Figure 60-130-5
P13725 P13732

harness connector (Black) that connects to the handle
1 lock solenoid connector.
P13725 P13732

harness connector (Gray) that connects to the handle
sensor connector.

Switch Handle Removal (Cont'd)
Figure 60-130-8
1
1
3 1
2
P-90994
1
Disconnect the left switch handle connectors (Item 1)
P13735 [Figure 60-130-10] from the loader wiring harness
connectors.
Use a pointed tool, press down on the tab (Item 1) Figure 60-130-11
[Figure 60-130-8] and pull the wire from the connector.

Figure 60-130-9
2 2
1
N-22783
P-90995 Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Disconnect the right switch handle connectors (Item 1) Using a small screwdriver, lift the handle tabs (Item 2)
[Figure 60-130-9] from the loader wiring harness [Figure 60-130-11] and slightly rotate the switch handle.
connectors.

CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation
Switch Handle Removal (Cont'd) Figure 60-130-14
Figure 60-130-12
2
Tape back 1/2 of Wires Tape 1/2 of Wires
P-24233
P-21699
N-22784
When installing the new switch handle, tape the wire
terminals together.
Pull the switch handle and wiring harness assembly (Item
1) [Figure 60-130-12] from the control lever. The switch handle comes with a 6 inch piece of heat

shrink tube side on the end of the wires. Remove the
Cut the wires (Item 2) [Figure 60-130-12] below the heat shrink tube from the end of the wires before routing
switch handle and remove switch handle. through handle and control lever tube.
NOTE: Only cut the wires if the switch handle is bad NOTE: Leave all the other heat shrink tube on the
and needs replacement. If the switch handle is wires for protection.
good and just needs to be removed for control
handle or lever replacement, then remove the Tape half of the wires back and half forward [Figure 60-
connectors on the end of the harness and pull 130-14] to keep the harness small enough to route
switch handle up out of lever tube. through the control lever tube.
Figure 60-130-13
P-90996
Pull harness (Item 1) [Figure 60-130-13] out the bottom

of the control lever tube.

CONTROL SYSTEM (ACS) (CONT'D) Install the wires into the connectors as listed below:
Switch Handle Installation (Cont’d) Right Switch Handle
Figure 60-130-15 Ten-Pin Connector

A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
1 F-Terminal - White/Lt. Green
G-Terminal - Yellow/Red
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Orange/Black
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
P-21700 C-Terminal - Purple/White
Left Switch Handle

Install the new switch handle and wires from the top of
the control lever. Ten-Pin Connector

A-Terminal - Orange
Route wire (Item 1) [Figure 60-130-15] through the B-Terminal - Dk. Blue
casting, along side the handle sensor and into the control C-Terminal - White
lever tube. D-Terminal - Purple
E-Terminal - Yellow/Red
NOTE: Do not pull the wire harness tight, allow a F-Terminal - Tan
small amount of slack or slight bend at the G-Terminal - Pink
handle pivot area. Verify the control handle H-Terminal - Orange/Black
returns to neutral position. J-Terminal - Blank
K-Terminal - Blank
Figure 60-130-16
Three-Pin Connector
A-Terminal - Red/White
B-Terminal - Black/White
C-Terminal - Purple/White
2
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
1
Five-Pin Connector
A-Terminal - Dk. Green
B-Terminal - Brown
C-Terminal - Blank
D-Terminal - Yellow
P-21695 E-Terminal - Blank
Remove tape from wires for installation and install the 6

inches of heat shrink tube (Item 1) [Figure 60-130-16]
approximately 3 inches into the control lever. Apply heat
to the exposed heat shrink tube.
Inspect the wire terminal tabs (Item 2) [Figure 60-130-

16] and re-bend tabs if necessary.

Switch Handle Installation (Cont'd)
Figure 60-130-17
3 1
2
1 P13735
Install the wires into the connectors as listed below:

P-90995
Left and Right Control Lever Switch Handle [Figure 60-
130-19]
Figure 60-130-18 1-Terminal - Red/White
2-Terminal - Black/White

3-Terminal - Purple/White
Figure 60-130-20
1
1
1
3
P-90994 2
Connect the handle harness connectors (Item 1) [Figure

60-130-17] and [Figure 60-130-18] to the loader harness
P13735
connectors.
Left and Right Control Lever Switch Handle [Figure 60-

130-20]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black

Switch Handle Installation (Cont'd)
Figure 60-130-21
N-17741
Installation: Install the wires into the connector as listed

P-21804 below. The terminal numbers are written on the back of
the connector (Item 1) [Figure 60-130-23].
Connect the handle harness connectors to the sensor Lift and Tilt Actuator
and lock solenoid connectors [Figure 60-130-21]. 1. Terminal-Black/Green-Larger diameter wire (16

gauge)
Actuator Connector Disassembly And Assembly 2. Terminal-Green-Larger diameter wire (16 gauge)
3. Terminal-Red/Green-Larger diameter wire (16
NOTE: Actuator shown removed for clarity. Not gauge)
necessary for procedure. 4. Terminal-Open
5. Terminal-Red-Smaller diameter wire (18 gauge)
Figure 60-130-22 6. Terminal-Open
7. Terminal-Open
8. Terminal-Black-Smaller diameter wire (18 gauge)
1
P-66842
Check the actuator wiring harness connector (Item 1)

[Figure 60-130-22] and replace if broken.

CONTROL SYSTEM (ACS) (CONT'D) Handle Lock Solenoid Disassembly And Assembly
Handle Lock Solenoid Removal And Installation Figure 60-130-26
Figure 60-130-24
1
2
1 P-21878A
P-21836
Remove solenoid (Item 1) from the solenoid mount (Item
2) [Figure 60-130-26].
130-24] from the handle sensor connector. Installation: Apply a drop of oil to the solenoid threads

and tighten solenoid to 47 - 54 N•m (35 - 40 ft-lb) torque.
130-24] from the handle lock solenoid connector. Figure 60-130-27
Figure 60-130-25
P-21789
1
P-21832
Check the O-ring (Item 1) [Figure 60-130-27] for
damage. Replace as necessary.
Remove the two screws (Item 1) [Figure 60-130-25]
holding the handle lock solenoid to the handle.
Installation: Tighten the screws to 3,6 - 4,3 N•m (32 - 38

in-lb) torque.
Remove handle lock solenoid assembly from handle.

Foot Sensor Removal And Installation
Figure 60-130-28
2‘
1
1
1 P-90980
Remove the two bolts (Item 1) and the foot sensor (Item
P-90979 2) [Figure 60-130-30].

Remove the hairpin clip and the pin (Item 1) [Figure 60-
130-28] from the foot sensor.

Figure 60-130-29
P-90982
Disconnect the wire harness (Item 1) [Figure 60-130-29]

from the foot sensor.

CONTROL SYSTEM (ACS) (CONT'D) Foot Sensor Lock Solenoid Removal And Installation
Foot Sensor Disassembly And Assembly Figure 60-130-33
Figure 60-130-31
1 1
P-90992
1
P-24269
Disconnect the wire harness (Item 1) [Figure 60-130-33]
from the foot sensor shield lock solenoid.
Remove the two bolts (Item 1) [Figure 60-130-31] from
the end of the foot sensor. Remove foot lock solenoid (Item 2) [Figure 60-130-33].

Installation: Tighten the bolts to 10,2 N•m (90 in-lb) Installation: Apply a drop of oil on the solenoid threads
torque. Apply Loctite® #242 to the threads. and tighten the solenoid to 47 - 54 N•m (35 - 40 ft-lb)
torque.
Figure 60-130-32
Figure 60-130-34
5
4
3 1
2
1 P-24270
P-21790
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3) and O-ring (Item 4) [Figure 60-130- Check the O-ring (Item 1) [Figure 60-130-34] for
32]. damage. Replace as necessary.
NOTE: Do not disassemble the sensor assembly

(Item 5) [Figure 60-130-32]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.

ELECTRICAL / HYDRAULIC CONTROLS
1 2 3 10 11 12
5
6
7 8
13
9
4
B-15781F / NA1014A / B-15781E
REF. NO. DESCRIPTION

1 TURN SIGNALS (Option)
2 REAR AUXILIARY HYDRAULICS (Option)

Also: ATTACHMENT FUNCTION CONTROL
3 ATTACHMENT FUNCTION CONTROL
4 FRONT HORN
5 ENGINE SPEED CONTROL
6 STEERING LEVERS
7 LIFT ARM PEDAL
8 TILT PEDAL
9 LIFT ARM BYPASS CONTROL
11 FRONT AUXILIARY HYDRAULICS
12 NOT USED
13 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS

ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Description
The Attachment Control Device (ACD) uses a 7 or 14 pin

connector to communicate between the loader and the
attachment.
Attachments with a 14 pin connector use four different

groups to control operations and hydraulic flow. Use
service Analyzer to determine what group is being used
and to troubleshoot the attachment / loader functions. If
service analyzer is not available use a Ohmmeter to
check for jumpers on the attachment harness.
Group 0 = No Jumpers
Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D
Refer to the Identification Chart ACD Group 0,1,2, or 3 for

more detailed information.

Identification Chart ACD Group 0
Attachment Attachment
Switch Solenoid Number Harness Harness
Left side Control Number Activated Terminal Connector RIght Side Control
Handle Switches Activated Handle Switches
STD RH HFH RH / HFH Fourteen Pin

1 1 1 1, 7 1,7 K Connector
Viewed
2 2 2 2 2 K from front
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
12, 13,

B-16447 14 B-16448
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
RH / HFH - Loaders with Rear Hydraulics and High
Flow Hydraulics Option.
3
Terminal K is activated with Key switch ON.
6 4
NOTE: For diagnostics and troubleshooting connect
the Service PC (See SERVICE PC (LAPTOP 2
1
COMPUTER) on Page 60-150-1.) 7
5
The ACD (Attachment Control Device)
automatically recognizes the use of the seven
or fourteen pin connector when connected.
Pressing the auxiliary hydraulics button and

moving the rear auxiliary hydraulic switch to NA1892
the right and left several times activates
solenoid numbers 3,4,5, and 6 at the diverter
valve. Solenoid Hydraulic Coupler Wiring
Number Number
Front Auxiliary Pressure Release is 1 Front Male (Rod) 4330
accomplished by manually pushing the male 2 Front Female (Base) 4340
and female couplers in at the front auxiliary 3 Diverter Rear (Rod) 4430
block.
4 Diverter Rear (Base) 4440
The High Flow Button in the left side 5 Bleed / Lock Valve (Base) 4480
instrument panel must be pushed ON to 6 Bleed / Lock Valve (Rod) 4450
activate solenoid number seven at the gear 7 High Flow on Pump 4460
pump.


1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
12, 13,

B-16447 14 B-16448
3
6 4
1
5

Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
Viewed
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
12, 13,

B-16447 14 B-16448
3
6 4
1
5

Number Number
block.
pump.


1 1 1 - - K Connector
Viewed
2 2 2 - - K from front
(pin side of
3 1 1 - - K connector)
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
12, 13,

B-16447 14 B-16448
3
6 4
1
5

Number Number
block.
pump.

ELECTRICAL / HYDRAULIC CONTROLS (ACS)
1 2 3 11 12 13
6
8 9
4
14
5 10
B-15781D / NA1164A / B-15781E

4 FLOAT CONTROL
5 FRONT HORN
6 ENGINE SPEED CONTROL
7 STEERING LEVERS AND LIFT / TILT HANDLES
8 LIFT ARM PEDAL
9 TILT PEDAL
13 NOT USED

ELECTRICAL / HYDRAULIC CONTROLS (ACS) (CONT’D)
Description

attachment.

Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D



13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
2 2 2 2 2 K from front 11
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
8 1 4,5,6 1 4,5,6 K,G
3
14 9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-90898 12, 13, P-90899

P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.


13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
8 1 1 1 1 K,M,G
3
14 9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-90898 12, 13, P-90899

P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.


13 6
1 1 1 1, 7 1,7 K Connector 8 10
4 5 Viewed 2 1
12 7 (pin side of 9
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-90898 12, 13, P-90899

P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.


13 6
1 1 1 - - K Connector 8 10
4 5 Viewed 2 1
2 2 2 - - K from front 11
12 7 (pin side of 9
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
8 - - - - K,G
3
14 9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-90898 12, 13, P-90899

P-90900 14 P-90900A
3
6 4
1
5

Number Number
block.
pump.

ELECTRICAL / HYDRAULIC CONTROLS (SJC)
1 2 3 4 5 13 14 15 16 17
8
9
10
11
18
6 7 19
12
B-19873A / NA1165A / B-19874A

1 SPEED MANAGEMENT
2 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
4 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
6 SPEED MANAGEMENT
7 FRONT HORN
8 ENGINE SPEED CONTROL (HAND)
9 JOYSTICKS
10 FOOTRESTS
11 ENGINE SPEED CONTROL (FOOT)
14 NOT USED
16 NOT USED
18 FLOAT CONTROL

ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
Description

attachment.

Group 1 = Pins K,L
Group 2 = Pins K,P
Group 3 = Pins C,D



1 1 1 1, 7 1,7 K Connector
8
13 6 Viewed 2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 3,5,6 2 3,5,6 K,A,D
5 1 4,5,6 1 4,5,6 K,A,C
6 1 4,5,6 1 4,5,6 K,E
7 1 4,5,6 1 4,5,6 K,F
14 8 1 4,5,6 1 4,5,6 K,G
3
9 1 4,5,6 1 4,5,6 K,H
10, 11, - -- -- K No Jumpers
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
8
13
4
6 Viewed 2 1
10
12
5
7 2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 1 1 1 1 K,M,D
5 1 1 1 1 K,M,C
6 1 1 1 1 K,M,E
7 1 1 1 1 K,M,F
14 8 1 1 1 1 K,M,G
3
9 1 1 1 1 K,M,H
10, 11, - -- -- K Jumpers K,L
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.


1 1 1 1, 7 1,7 K Connector
13 6 Viewed 8
2 1
10
4
12
5
7
2 2 2 2 2 K from front 9 11
(pin side of
3 1 1 1, 7 1,7 K connector)
of loader.
4 2 2 2 2 K,A
5 1 1 1,7 1,7 K,A
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers K,P
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.


1 1 1 - - K Connector
13 6 Viewed 8
2 1
10
4 5
2 2 2 - - K from front 9 11
12 7
(pin side of
of loader.
4 - - - - K,A,D
5 - - - - K,A,C
6 - - - - K,E
7 - - - - K,F
14 8 - - - - K,G
3
9 - - - - K,H
10, 11, - -- -- K Jumpers C,D
P-24820A 12, 13, P-24802A

P-28316A 14 P-28316A
3
6 4
1
5

Number Number
block.
pump.

SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)
Connecting Remote Start Tool Figure 60-150-2
Figure 60-150-1
1 2
2
3
1
P-76450
P16119
procedure:
procedure: Order from Bobcat Parts P/N: 7003031 - Remote Start

Tool (Service Tool) Kit
MEL1565 - Service Tool Harness Control Kit Includes:
MEL1566 - Service Tool Harness Communicator
(Computer Interface) 7003030 - Remote Start Tool (Service Tool)
NOTE: Make all connections with the key in the OFF 6689747 - Loader Service Tool Harness
position. 6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
The Service PC (Item 1) with the Remote Start Tool (Item NOTE: Make all connections with the key in the OFF
2) [Figure 60-150-1]. When connected to the loader, the position.
Service PC is used to monitor, conduct diagnostics, and
upgrade software. The Service PC (Item 1) with the Remote Start Tool
(Service Tool) (Item 2) [Figure 60-150-2]. When
Connect the Service Tool Harness Communicator connected to the loader, the Service PC is used to
(MEL1566) (Item 3) [Figure 60-150-1] to the designated monitor, conduct diagnostics, and upgrade software.
serial port on the Service PC.
Connect the Remote Start Tool (Service Tool) Computer
NOTE: The recommended serial cable length should Service Tool Harness (Item 3) [Figure 60-150-2] to the
not exceed 15 feet. A serial cable longer than designated serial port on the Service PC.
15 feet will create a degraded signal causing
communication errors. NOTE: The recommended serial cable length should
not exceed 15 feet. A serial cable longer than
Connect the other end to the connector on the Remote 15 feet will create a degraded signal causing
Start Tool. communication errors.
Connect the remote start tool to the loader. (See Connect the other end to the connector on the Remote
REMOTE START TOOL KIT-MEL1563 on Page 10-60- Start Tool (Service Tool).
1.)
NOTE: Refer to BobcatNET for PC requirements and loader. (See REMOTE START TOOL (SERVICE TOOL)
the latest Service Analyzer software. KIT - 7003031 on Page 10-61-1.)
NOTE: Refer to BobcatNET for PC requirements and

the latest Service Analyzer software.


CALIBRATION Actuator Testing
Calibration procedures must be followed when replacing

a hydraulic control valve, actuator, Drive / Drive+
Controller, ACS Controller, pump controller, hydrostatic
pump, or hydrostatic motor. Failure to calibrate after
component replacement may result in poor performance
or reduced life of actuator(s).
The Actuator Test is performed with the Service PC. The

Actuator Test should be used if reduced performance
codes are present or when replacing a controller or
actuator.
NOTE: The Actuator Test should be used as the

preferred method of actuator and valve spool CONTROL VALVE ACTUATORS
P-54336
calibration.
The Lift and Tilt Calibration (ACS) provides set points to [Figure 60-160-1] Excessive actuator loading can occur
the ACS controller to actuate the lift and tilt valve. The Lift if the actuator and valve spool components are
and Tilt Calibration (ACS) should be used if reduced misaligned. Misalignment may reduce spool stroke
performance codes are present or when replacing a performance and reduce the life of the actuator. Starting

controller or actuator. with software version 36, the Bobcat Service Analyzer
will be able to perform tests to diagnose actuator and
The Lift and Tilt Calibration (SJC) provides set points to valve spool misalignment.
the ACS controller to actuate the lift and tilt valve. The Lift
and Tilt Calibration (SJC) should be used if reduced Connect the Service PC. (See SERVICE PC (LAPTOP
performance codes are present or when replacing a COMPUTER) on Page 60-150-1.)
controller or actuator.
If a Service PC is not available, (See Lift And Tilt
The Hydrostatic Pump Calibration (SJC) provides set Calibration (SJC) on Page 60-160-4.) or (See Lift And Tilt
points to the Drive controller to actuate the hydrostatic Calibration (ACS) on Page 60-160-11.).
controller that directs flow to a servo piston. Hydrostatic
Pump Calibration (SJC) should be performed when a NOTE: Warm the hydraulic oil to room temperature
desired travel path cannot be attained or replacing the 22°C (72°F), stop the engine and clear all
hydrostatic pump, hydrostatic motor, or controller. After active service codes before running the test.
Performing a Hydrostatic Pump Calibration (SJC),
Steering Drift Compensation can be used to fine tune the Once the test is initiated, an automatic calibration
hydrostatic pump control. sequence will start. When calibration is complete, the test
will be performed and the results can be viewed on the
For more information on Steering Drift Compensation Service PC (Laptop) monitor.
(See STEERING DRIFT COMPENSATION on Page 60-
161-1.)
NOTE: The Actuator Test is the only test that uses a

Service PC. The Lift and Tilt Calibration (ACS
or SJC) does not need to be performed if the
Actuator Testing is being performed with the
Service PC. The Hydrostatic Pump Calibration
does not need to be performed with the
Actuator Test or Lift and Tilt Calibration (SJC).

CALIBRATION (CONT’D) If the Actuator Test fails after the hydraulic oil is warmed,
go to the next step and loosen the bolts that mount the
Actuator Testing (Cont’d) actuator to the control valve. Loosen the bolts just
enough so the actuator can be moved slightly up / down
This test will engage both actuators to fully stroke the or side / side.
spools then allow the centering springs to return the
spools to neutral. Next, both actuators are engaged to Rerun the Actuator Test, if the test passes, check the
move the spools just past the neutral points then allow following probable causes in Column 1 [Figure 60-160-
the centering springs to return the spools to neutral. 2]. Check the probable causes in the order they are
listed. Repairing one cause may be all that is required.
When complete, the Actuator Test will show a pass mode Re-run the test to verify.
or fail mode. The pass mode indicates that no problems
were detected. The fail mode indicates one or a NOTE: Actuator and spool misalignment. Re-tighten
combination of three problems below. the two bolts evenly, turn the first bolt one
turn, then turn the other bolt one turn until
• Actuator slow return to neutral. The spool returns to both bolts are tight.
neutral too slowly.
If the Actuator Test failed due to a slow return to neutral
• Actuator did not fully extend / retract. During the test, after checking the probable causes in Column 1 [Figure
the spool was not able to fully stroke in both 60-160-2], check the following probable causes in
directions. Column 2 [Figure 60-160-2].
• Actuator out of neutral. The spool did not return to the • Contamination in the spool.
neutral window during the test.

• The spool end cap may be defective or the centering
NOTE: A time out will occur if the test cannot be spring may be broken. Inspect the end cap and the
completed within 8 seconds. If this happens, centering spring, replace if necessary.
retry the test.
• The wire harness or connectors may have an
Figure 60-160-2 intermittent short. Check the connections and wire
Run Actuator Test harnesses.
• The controller may be defective, replace the

Pass Fail controller.
Retest With Warm Hydraulic Oil
Pass Fail
Loosen Actuator
Pass Fail
Column 1 Column 2
Probable Cause Probable Cause
• Misaligned Assembly • Actuator
• Pin • End Cap / Center Spring
• Contamination in Spool • Wire Harness
• Controller
• Contamination in Spool
[Figure 60-160-2] If the initial Actuator Test results in a

fail mode due to a slow return to neutral, follow the
troubleshooting tree to pinpoint the probable cause.

CALIBRATION (CONT’D)
Actuator Testing (Cont’d)
If the initial Actuator Test results in the fail mode actuator

did not fully extend / retract, check the following.
• The actuator connectors may be reversed between

the lift and tilt actuator. Reverse the connectors and
rerun the Actuator Test.
• The actuator may be weak, replace the actuator.

spring may be broken. Inspect the end cap and the
centering spring, replace if necessary.
• Contamination in the spool.
If the initial Actuator Test results in the fail mode actuator

out of neutral, check the following.
• The actuator may be defective, replace the actuator.

spring may be broken. Inspect the end cap and the
centering spring, replace if necessary.
• Contamination in the spool.

CALIBRATION (CONT’D) Figure 60-160-4
Lift And Tilt Calibration (SJC)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.
NOTE: The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-160-1.)
NOTE: This calibration procedure must be followed

when replacing the hydraulic control valve, lift P-85958 P-85958
or tilt actuator. Failure to calibrate after
component replacement may result in poor
performance or reduced life of actuator(s). Move the right joystick to the forward-right corner position
[Figure 60-160-4] and hold in position.
Figure 60-160-3
SJC

1
P-85307
With an operator in the seat and the seat bar down.
Close the cab door. (If loader is equipped.)
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-3] in the ISO position.

Lift And Tilt Calibration (SJC) (Cont’d)
Figure 60-160-5
P-85413C
P-85493A
At the left panel, press the PRESS TO OPERATE Button

With the seat bar down, turn the ignition key ON [Figure (Item 1) [Figure 60-160-7] while holding the right joystick
60-160-5]. in position.
NOTE: Do not start the engine. Release the joystick.

Figure 60-160-6 NOTE: During the calibration cycle, the system will
beep three times. Once the calibration is
SJC complete, code W3224 (Calibration
Performed) will be generated.
The ACS controller will cycle the actuators.
The lift and tilt calibration is complete.
P-85307
The loader Control Pattern Switch (Item 1) [Figure 60-

160-6] will start flashing and will continue to flash until the
calibration procedure is completed.

Hydrostatic Pump Calibration (SJC)
WARNING
W-2017-0286 P-85493A

With the seat bar down, turn the ignition key ON [Figure
10-10-1.)
60-160-9].
Operator must be in the seat and the seat bar down.
NOTE: Do not start the engine.
Figure 60-160-8
Figure 60-160-10
SJC
SJC

1
1
P-85307
P-85307
Close the cab door. (If loader is so equipped.)

The Control Pattern ISO Switch (Item 1) [Figure 60-160-
10] will start flashing.
Place the loader Control Pattern Switch (Item 1) [Figure
60-160-8] in the ISO position.
Verify the parking brake.

CALIBRATION (CONT'D) Figure 60-160-13
Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-11
B-19873
P-85960
B-19873 Move the left joystick to the reverse-right corner position

P-85959 [Figure 60-160-13] and hold in position.
Figure 60-160-14
Move the left joystick to the forward-left corner position
[Figure 60-160-11] and hold in position.

Figure 60-160-12
P-85413C
1
Press the PRESS TO OPERATE LOADER Button (Item
P-85413C 1) [Figure 60-160-14] while holding the left joystick in
position.
Press the PRESS TO OPERATE LOADER Button (Item Three audible beeps will sound.
1) [Figure 60-160-12] while holding the left joystick in
position.
Three audible beeps will sound.

Hydrostatic Pump Calibration (SJC) (Cont'd) SJC
Figure 60-160-15
P-85307
The Control Pattern ISO Switch (Item 1) [Figure 60-160-

P-85961 17] will stop flashing, and will remain ON for the rest of
the calibration procedure.
Allow the left joystick to go to the neutral position [Figure Figure 60-160-18
60-160-15].

Figure 60-160-16
P-85760A
1
P-85413C Move the throttle (Item 1) [Figure 60-160-18] to high idle.
NOTE: If at any time, during calibration, the operator

Press the PRESS TO OPERATE LOADER Button (Item needs to stop the loader, turn the key OFF, lift
1) [Figure 60-160-16]. the seat bar, or return the joystick to the
neutral position.
Three audible beeps will sound.
The calibration procedure will stop.
Start the engine from the RUN, RUN / ENTER position.
DO NOT TURN TO OFF POSITION. This would cancel To return to calibration mode, the operator
the calibration mode and the procedure would have to be must start the complete procedure from the
repeated. beginning.

Hydrostatic Pump Calibration (SJC) (Cont'd)
1 2
WARNING
W-2017-0286
Figure 60-160-19 P-64321
The loader speed will “ramp up” quickly (Item 1)

[Figure 60-160-20] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)

[Figure 60-160-20] until it reaches full speed and then
come to a stop.

Continue to hold the left joystick in the forward position
until the loader wheels or tracks come to a stop and an
audible beep is heard.
B-19873 Forward calibration is complete.

P-85962
NOTE: If the wheels or tracks do not stop moving in
Full Speed Forward in 2 minutes or less, there
Move and hold the left joystick to the forward position was an error in the calibration procedure. The
[Figure 60-160-19] until the forward calibration is operator must shut the loader OFF, and start
completed. the calibration procedure from the beginning.

CALIBRATION (CONT'D) NOTE: If the wheels or tracks do not stop moving in
Full Speed Reverse in 2 minutes or less, there
Hydrostatic Pump Calibration (SJC) (Cont'd) was an error in the calibration procedure. The
operator must shut the loader OFF, and start
Figure 60-160-21 the calibration procedure from the beginning.
There will be an audible beep, the PRESS TO OPERATE

LOADER button light will remain on. The TRACTION
light will illuminate, the SEAT BAR, and LIFT AND TILT
lights will be off. The D7598 error code will clear. There
should be no other codes in the display area.
Allow the joystick to go to the neutral position.
Once the calibration procedure is complete the Steering

Drift Compensation values will be reset to [S----] or
neutral.
B-19873 Press the PRESS TO OPERATE LOADER button. Move

P-85963 the left joystick to forward position [Figure 60-160-19]
and check for normal forward wheel or track rotation.
Move and hold the left joystick to the reverse position Move the left joystick to the reverse position [Figure 60-
[Figure 60-160-21] until the reverse calibration is 160-21] and check for normal reverse wheel or track

completed. rotation.
Figure 60-160-22 Stop the engine, and remove the loader from jackstands.
The calibration procedure is completed.
1 2 After calibration is complete, use Steering Drift

Compensation for fine tuning or if an acceptable line of
drift cannot be achieved. (See STEERING DRIFT
COMPENSATION on Page 60-161-1.)
If loader does not maintain a desired travel path with

Steering Drift Compensation at maximum setting [S-R10]
or [S-L10], see the electrical and hydrostatic
troubleshooting. (See Troubleshooting on Page 30-10-1.)
or (See Troubleshooting on Page 60-10-8.)
P-64321
The loader speed will “ramp up” quickly (Item 1)

[Figure 60-160-22] and slow down 3 times in a row.
The loader will then “stair step” the speed (Item 2)

[Figure 60-160-22] until it reaches full speed and then
come to a stop.
Continue to hold the left joystick in the reverse position

until the loader wheels or tracks come to a stop and an
audible beep is heard.
Reverse calibration is complete.

Lift And Tilt Calibration (ACS)
The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
stroke (full flow) while preventing over stroke (loading) of
the actuator and resets the calibration points in the
controller.
NOTE: The Actuator Test is the preferred method to

calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-160-1.)
P-85493A
NOTE: This calibration procedure must be followed

when replacing a hydraulic control valve, Close the cab door. (If loader is equipped.)
actuator or ACS controller. Failure to calibrate
after component replacement may result in With the seat bar down, turn the ignition key ON (Deluxe
poor performance or reduced life of Instrumentation Panel press RUN / ENTER) (Item 1)
actuator(s). [Figure 60-160-24].
Figure 60-160-23 NOTE: Do not start the engine.
ACS
Figure 60-160-25

1
P-85307B 1
Update the loader service software to the latest version. P-85413C
Place the rocker switch (Item 1) [Figure 60-160-23] in

Push the PRESS TO OPERATE button (Item 1) [Figure
the hand control mode.
60-160-25] to unlock the hand controls.

CALIBRATION (CONT’D) NOTE: During the calibration cycle, the system will
beep three times. Once the calibration is
Lift And Tilt Calibration (ACS) (Cont’d) complete, code W3224 (Calibration
Performed) will be generated.
Figure 60-160-26
Release the control handles.
Calibration is complete.
Stroke Both Handles Fully In and Hold Them
B-16628
Fully stroke both control handles in toward the center of

the cab and hold the handles [Figure 60-160-26].

Lift the seat bar, high enough for the PRESS TO
OPERATE light (Item 1) [Figure 60-160-27] to go OFF.
Lower the seat bar.
Figure 60-160-27
P-85413C
Push the PRESS TO OPERATE button (Item 1) [Figure

60-160-27] to begin calibration.
NOTE: The ACS icon will light up and if you listen

closely the cycling of the actuators can be
heard. The ACS icon will stay lit until the
ignition key is cycled or the loader is started
and a function is operated.

STEERING DRIFT COMPENSATION Operation
Steering Drift Compensation is available on SJC NOTE: Changes CANNOT be performed until the seat
equipped machines. bar is lowered, the engine is started and the
PRESS TO OPERATE LOADER button is
Description pressed to activate the BICS.
Steering Drift Compensation can be used to reduce Perform pre-starting and starting procedures:
steering drift to maintain a desired travel path in both
forward and reverse directions. 1. Fasten seat belt.
Examples of applications where this feature can be used: 2. Lower seat bar.
• To compensate for normal variations such as tire 3. Place joysticks in neutral position.
inflation pressure, track tension, tire wear and track
wear. 4. Start the engine.
• Using side shift attachments such as trenchers, 5. Press the PRESS TO OPERATE LOADER button.
planers and silt fence installers.
6. Current drive response setting will be displayed briefly
• Driving on uneven terrain such as crowned road in the data display.
surfaces.
NOTE: Raising the seat bar or changing control
Figure 60-161-1 mode (ISO / H) will cause the machine to

disengage from steering drift compensation.
STEERING DRIFT COMPENSATION The last displayed setting will remain in effect
until the machine is turned OFF.
B-23580C
Steering drift compensation contains a total of 21

settings. Steering drift compensation can be set to any
point from neutral to [S-L10] left and from neutral to [S-
R10] right. [S----] is displayed when set for neutral
[Figure 60-161-1].

STEERING DRIFT COMPENSATION (CONT’D) Press the upper right button (Item 7) on the left joystick to
adjust back toward center. The display will decrease
Operation (Cont’d) down to neutral displayed as [S----] (Item 4). Another
press of the upper right button will cause [S-R01] (Item 5)
Figure 60-161-2 to appear in the data display (Item 2) [Figure 60-161-2].
The number will increase by one each time you press the
button up to a maximum of [S-R10]. The higher the
number, the greater the amount of steering drift
compensation to the right. Adjustments to steering drift
compensation will be effective immediately.
Figure 60-161-3
2
1
NA1011
3 4 5
P-76461L 2
P-76461N
1

P-76461M
NA1011
Left Joystick Right Joystick
3 4
P-76461K
P-76461O
6 7
P-24820C P-24802C Saving The Steering Drift Compensation Setting:
The current steering drift compensation setting can be

Press and hold the PRESS TO OPERATE LOADER
saved by pressing and holding the PRESS TO OPERATE
button (Item 1) for three seconds to enter the drive
LOADER button (Item 1) for three seconds. [SET] (Item
response adjustment menu. Press the PRESS TO
3) will appear in the data display (Item 2) [Figure 60-161-
OPERATE LOADER button (Item 1) again to adjust the
3] and the machine will exit from the steering drift
loader’s steering drift compensation setting. The current
compensation adjustment menu.
steering drift compensation setting will appear in the data
display (Item 2) [Figure 60-161-2].
OR
Press the upper left button (Item 6) on the left joystick to
Press the PRESS TO OPERATE LOADER button to exit
adjust the machine left. [S-L01] (Item 3) through a
from the steering drift compensation adjustment menu
maximum of [S-L10] will appear in the data display (Item
without saving the current setting. [DONE] (Item 4) will
2) [Figure 60-161-2]. The number will increase by one
appear in the data display (Item 2) [Figure 60-161-3] and
each time you press the button. The higher the number,
the upper left and upper right buttons on the left joystick
the greater the amount of steering drift compensation to
will no longer make changes to steering drift
the left. Adjustments to steering drift compensation will
compensation.
be effective immediately.
NOTE: The last displayed steering drift
compensation setting will remain in effect
until the machine is turned OFF. The machine
will revert back to the last saved setting the
next time it is started.

FLYWHEEL RPM SENSOR
Description
The flywheel rpm sensor has a magnet located on the

end of the sensor which senses breaks between the ring
gear teeth, the sensor relays this information back to the
controller which registers the rpm of the engine.
The flywheel rpm sensor is located just above the starter

on the left side of the engine.

FLYWHEEL RPM SENSOR (CONT’D) Figure 60-170-2
Adjustment
1
Figure 60-170-1
1
2
2
P-85921
Turn the RPM sensor and the jam nut out from the
P-85922 flywheel. Set a clearance of 1,27 mm (0.050 in) between
the jam nut and the housing with a feeler gauge (Item 1)
[Figure 60-170-2].
When reinstalling the rpm sensor, turn the rpm sensor
(Item 1) [Figure 60-170-1] in until it makes contact with Remove the feeler gauge.

the engine flywheel.
Tighten the jam nut (Item 2) [Figure 60-170-2] to 16 - 23
Turn the jam nut (Item 2) [Figure 60-170-1] until it N•m (12 - 17 ft-lb) torque.
contacts the flywheel housing. The jam nut should not be
tightened, it needs to turn with the rpm sensor when the NOTE: New rpm sensors have a plastic tip which is
sensor is turned back out for adjustment. used as a gauge during installation. The
plastic tip is designed to come off after the
engine is started.

CONTROL PANEL SETUP Languages
Right Panel Setup (Deluxe Instrumentation Panel) Figure 60-180-2
Icon Identification Press a scroll button

(Item 1) repeatedly until
the Display screen icon
Figure 60-180-1 (Inset) is highlighted.
1 1
Select
[2. LANGUAGES].
Select the desired

language.
NA3025

ICON DESCRIPTION
DATE / TIME
P-90385 / NA3025 / NA3012 / NA3023

USER / HOURMETER
CURRENT JOB HOURS
ACTIVE WARNINGS screen icon
VITALS screen icon
SERVICE screen icon
MAIN screen icon
ATTACHMENTS screen icon
SECURITY screen icon
DISPLAY screen icon
LEFT SCROLL button
RIGHT SCROLL button
ENTER button
Example

CONTROL PANEL SETUP (CONT’D) The Deluxe Instrumentation Panel is easy to use.
Continue to set your own preferences for running /
Right Panel Setup (Deluxe Instrumentation Panel) monitoring your Bobcat loader.
(Cont’d)
More Examples
Clocks
Select …
DISPLAY screen icon
[1. CLOCKS]
SET TIME AND DATE

Select [1. TIME]
Use the keypad to enter date.
Press ENTER to continue.
Use the keypad to enter time.
Select AM / PM / 24hr.
RESET JOB CLOCK

(Owner password required if Job Clock is locked.)
Select [2. JOB CLOCK]

Press [4] to cycle between lock and unlock.
Press [9] to reset.
SET ALARM
Select [3. ALARM CLOCK]
Select alarm 1, 2 or 3.
Press [1] to cycle between ON and OFF.
Press [2] and use the keypad to enter alarm time.
Select AM / PM / 24hr.
Press [3] to cycle between ONCE, DAILY and
WEEKLY.
Selecting WEEKLY will prompt for a day selection
using number [4].
Vitals (Monitor the engine, hydraulic / hydrostatic,

electrical functions when engine is running.)
Select …
VITALS screen icon
Press [6] to cycle between METRIC or ENGLISH (M /
E) readouts.
You can monitor real-time readouts of:

Engine Speed
Engine Oil Pressure
Engine Coolant Temperature
System Voltage
Hydraulic Charge Pressure
Hydraulic Oil Temperature

PASSWORD SETUP (DELUXE INSTRUMENTATION Changing The Owner Password
PANEL)
Figure 60-190-1
Password Setup is available on machines with a Deluxe
Press a scroll button (Item
Instrumentation Panel. 1) repeatedly until the
Security screen icon
Password Description (Inset) is highlighted.
All new machines with a Deluxe Instrumentation Panel

arrive at Bobcat dealerships with the keypad in locked
1 1
mode. This means that a password must be used to start
the engine. Enter owner password and
press [ENTER].
For security purposes, your dealer may change the
password and also set it in the locked mode. Your dealer
will provide you with the password.
Master Password:
Select [1. USER
A permanent, randomly selected password set at the SETTINGS].
factory which cannot be changed. This password is
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner
password.

Owner Password:
Select [1. OWNER].
Allows for full use of the loader and to setup the
Deluxe Instrumentation Panel. There is only one
owner password. It must be used to change the owner
or user passwords. Owner should change the
password as soon as possible for security of the
loader.
Select [2. CHANGE
User Password: PASSWORD].
Allows starting and operating the loader; cannot

change password or any of the other setup features.
For the procedures to change passwords (See Changing

The Owner Password on Page 60-190-1.) and (See
Enter new owner
Changing The User Passwords on Page 60-190-2.) password and press
[ENTER].
You will be prompted to

reenter the new owner
password.
Press [ENTER].
P-90399/NA3025/NA3016/NA3031/NA3033/NA3028/NA3015/NA3027

PASSWORD SETUP (DELUXE INSTRUMENTATION Password Lockout Feature
PANEL) (CONT’D)
Changing The User Passwords This feature allows the owner to unlock the password
feature so that a password does not need to be used
Figure 60-190-2 every time the engine is started.
Press a scroll button (Item
2) repeatedly until the Figure 60-190-3
Security screen icon
(Inset) is highlighted. Press a scroll button
(Item 2) repeatedly until
the Security screen icon
(Inset) is highlighted.
1 1
Enter owner password and
press [ENTER].
1 1
Enter owner password
and press [ENTER].
Select [1. USER

SETTINGS].
Select [2. MACHINE

LOCK].
Select user.
P-90399 / NA3025 / NA3016 / NA3031
NOTE: The procedure above can be followed to reset

Select [2. CHANGE the machine lock so that the machine requires
PASSWORD]. a password to start the engine.
Enter new user password

and press [ENTER].
Press [ENTER].
P-90399/NA3025/NA3016/NA3031/NA3033/NA3026/NA3010/NA3027

PASSWORD SETUP (KEYLESS START PANEL) Password Lockout Feature
Password Description This feature allows the owner to unlock the password
feature so that a password does not need to be used
Master Password: every time the engine is started.
A permanent, randomly selected password set at the Press the RUN button to turn on the loaders electrical
factory which cannot be changed. This password is system.
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner Enter the five digit owner password using the number
password. keys (1 through 0).
Owner Password: Figure 60-191-2
Allows for full use of the loader. It must be used to

change the owner password.
Changing The Owner Password
Press the RUN button to turn on the loaders electrical

system.
Enter the five digit owner password using the number

keys (1 through 0) if locked.

1 2
Figure 60-191-1
P-90805
Press the unlock key (Item 2) [Figure 60-191-2].
The left panel display screen will show [CODE].

keys (1 through 0). The unlock key green light will flash,
then become solid.
1 2
The loader can now be started without using a password.
P-90805 NOTE: Use the following procedure to reset the

machine lock so that the loader requires a
password to start the engine.
Press and hold the lock (Item 1) and unlock (Item 2)
[Figure 60-191-1] keys for two seconds. Press the RUN button to turn on the loaders electrical
system.
The lock key red light will flash and the left panel display
screen will show [ENTER]. Press the lock key (Item 1) [Figure 60-191-2].
Enter a new five digit password using the number keys (1 The lock key red light will flash and the left panel display
through 0). An asterisk will show in the left panel display screen will show [CODE].
screen for each key press.
The left panel display screen will show [AGAIN]. keys (1 through 0). The unlock key green light will flash,
then the lock key red light will become solid.
Enter the new five digit password again.
You must now enter the password every time to start the
The lock key red light will become solid. loader.


MAINTENANCE CLOCK This message will remain for 10 seconds and will appear
for 10 seconds every time the machine is started until the
Description maintenance clock is reset.
The Maintenance Clock alerts the operator when the next Figure 60-200-3
service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 500 hour interval as a reminder for
the next 500 hour planned maintenance.
Figure 60-200-1
1
1
3 NA3040
P-76461R
The Deluxe Instrumentation Panel, if equipped, will
display a bar (Item 1) [Figure 60-200-3] showing time
During machine operation, a two beep alarm will sound remaining until next service. This bar will turn red when
when there are less than 10 hours until the next planned service is past due. NEXT MAINTENANCE DUE will

maintenance. change to MAINTENANCE PAST DUE and display the
number of hours past due.
The remaining hours before maintenance is required will
appear in the data display (Item 1) for five seconds while Keys [4] and [9] can be used to adjust the service
the service icon (Item 3) and hourmeter icon (Item 2) interval when the owner is logged in [Figure 60-200-3].
[Figure 60-200-1] flash.
NOTE: Loaders equipped with a Standard Key Panel
NOTE: The display will show negative numbers after or Keyless Start Panel will not display the
counting down to zero. BobCARE PMSM message or NEXT
MAINTENANCE TYPE on the right panel.
The display will then revert back to the previous display
and will appear for five seconds every time the machine
is started until the maintenance clock is reset.
Figure 60-200-2
NA3034
The Deluxe Instrumentation Panel, if equipped, will

display a message (Item 1) [Figure 60-200-2] alerting
the operator to service the machine.

MAINTENANCE CLOCK (CONT’D) Figure 60-200-6
Setup
Figure 60-200-4
P-76110
P-64243A
Select Install (Item 1) [Figure 60-200-6] to begin sending

The first analyzer screen has an added bar for the the dealer information to the controller.
Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-200-4] to Figure 60-200-7
view the next analyzer screen.

Figure 60-200-5
1
1
P-76113
3 Click SEND TO MACHINE (Item 1) [Figure 60-200-7] to

P-76110
send the dealer information to the machine controller.
Click Options (Item 1) and add your dealer name and NOTE: Verify that all correct option and kits are
phone number (Item 2). Click Save Options (Item 3) selected before clicking SEND TO MACHINE.
[Figure 60-200-5] the information is now stored.

Setup (Cont’d)
Figure 60-200-8
P-76112
1
Click the right arrow (Item 1) [Figure 60-200-10] to scroll
P-76114 through the tabs.
Figure 60-200-11
A green COMPLETE (Item 1) [Figure 60-200-8]

message will be displayed when the dealer information
has been transferred to the machine controller. 1
Click Back (Item 2) [Figure 60-200-8] to return to the

Bobcat Service Analyzer screen.
3
Figure 60-200-9 4 2
P-76111
Click the Maintenance tab (Item 1) [Figure 60-200-11] to

view the maintenance clock screen.
Click ON/OFF (Item 2) to turn the maintenance clock on

or off [Figure 60-200-11].
P-76110
The default Interval (Item 3) is 250 hours, it can also be
changed by placing the cursor in the box and typing the
Select Warnings (Item 1) [Figure 60-200-9]. new interval. Click SET/RESET (Item 4) [Figure 60-200-
11] to reset and set the maintenance clock.

Setup (Cont’d)
Figure 60-200-12
1
2
P-76110
Select Program / Update (Item 1) [Figure 60-200-14] to

P-76111 view the maintenance clock.
Figure 60-200-15
The current maintenance clock Length (Interval) and

Time Reset will be displayed (Item 1). This screen will 1
also store the most recent 20 entries of history. Once an
entry is added, it cannot be changed. If an entry is made
and the interval is not correct, make another entry and
click SET/RESET (Item 2) [Figure 60-200-12].
NOTE: If the interval is set to 10 hours or less, the

maintenance clock will reset and log a reset
time but the wrench icon, hour interval and
service icon will NOT be removed from the left
display screen.
P-64244A
Figure 60-200-13
After the maintenance clock has been activated, the first

analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-15]. If past
1 the interval, the number will reflect negative hours.
P-76111
Select Back (Item 1) [Figure 60-200-13] to return to the

main menu.

MAINTENANCE CLOCK (CONT’D)
Reset
Figure 60-200-16
P-76455H
Press the information button (Item 2) until the display

screen (Item 1) [Figure 60-200-16] shows the
maintenance clock.

Press and hold the information button (Item 2) for seven
seconds until [RESET] (Inset) appears in the display
screen (Item 1) [Figure 60-200-16].


BACK-UP ALARM SYSTEM Figure 60-210-2
Description
The back-up alarm will sound when the operator moves

both steering levers or joystick(s) into the reverse
position. Slight movement of the steering levers into the 1
reverse position is required with hydrostatic
transmissions, before the back-up alarm will sound.
Inspecting
Figure 60-210-1
2
P-90531A
Inspect the back-up alarm electrical connections (Item 1)

[Figure 60-210-2], wire harness (Item 2) [Figure 60-210-
2] and back-up alarm switches (if equipped) (Item 1)
[Figure 60-210-3] for tightness and damage. Repair or
1 replace any damaged components.

If the back-up alarm switches require adjustment, (See
P-85994 Adjusting Switch Position on Page 60-210-2.)
Inspect for damaged or missing back-up alarm decal

(Item 1) [Figure 60-210-1]. Replace if required.
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
button. Disengage the parking brake.
Move both steering levers or joystick(s) into the reverse

position. The back-up alarm must sound when all wheels
or both tracks are moving in reverse.
The back-up alarm is located on the inside of the rear

door.

BACK-UP ALARM SYSTEM (CONT’D) Figure 60-210-4
Adjusting Switch Position

1
NOTE: Joystick equipped machines do not have
back-up alarm switches and cannot be
adjusted. See your Bobcat dealer for service if
your back-up alarm does not sound. 2
Standard Controls and ACS (If Equipped) 3
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Place the steering levers in the neutral position.

P-85723A
Figure 60-210-3
Loosen the screws (Item 3) [Figure 60-210-4] securing

1
the back-up alarm switch. (Left side shown)
Position the back-up alarm switch so that the roller (Item

1) just makes contact with the bellcrank (Item 2) [Figure
60-210-4] without compressing the switch spring.

Torque the screws (Item 3) [Figure 60-210-4] securing
the switch to the bracket to 1,6 - 2,1 N•m (14 - 19 in-lb).
Repeat adjustment procedure for the other switch.

P-85722 3.)
Inspect back-up alarm system for proper function. (See

The back-up alarm switches (Item 1) [Figure 60-210-3] Inspecting on Page 60-210-1.)
are located alongside the steering bellcranks. Both
switches must be adjusted properly for the back-up alarm
to operate correctly.

BACK-UP ALARM SYSTEM (CONT’D)
Troubleshooting (Standard And ACS) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves both steering levers into the 1, 2, 3, 4, 5, 6, 7
reverse position.
Back-up alarm sounds when steering levers in neutral / forward position. 2, 6, 7

2. The back-up alarm switches are damaged.
3. The alarm is damaged.
4. The back-up alarm or switch wires are disconnected.
5. Check the fuses.
6. The wiring is damaged.
7. The back-up alarm switches need adjusting.

BACK-UP ALARM SYSTEM (CONT’D)
Troubleshooting (Joystick) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) into the reverse 1, 2, 3, 4, 5, 6
position.
Back-up alarm sounds when joystick(s) in neutral / forward position. 5, 6

2. The alarm is damaged.
3. The alarm wires are disconnected.
4. Check the fuses.
5. The wiring is damaged.
6. The joystick controller is not working correctly.

BACK-UP ALARM SYSTEM (CONT’D) Figure 60-210-6
Alarm Removal And Installation

2
Figure 60-210-5
2
1
P-85723A
1 Place the steering levers in the neutral position.
P-85280 Loosen the screws (Item 1) securing the back-up alarm

switches. Slide the switch (Item 2) [Figure 60-210-6] off
the mounting bracket.
Disconnect the alarm connector (Item 1) [Figure 60-210-

5] from the alarm. Mark the wires for ease of assembly and disconnect
them from the switch.
Remove the two nuts (Item 2) [Figure 60-210-5].
Remove the alarm and bracket from the loader.
Installation: Slide the alarm switches onto the mounting
Switch Removal And Installation bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
NOTE: Joystick equipped machines do not have installation of switches, adjust the switches (See
back-up alarm switches. Adjusting Switch Position on Page 60-210-2.) and
inspect back-up alarm operation (See Inspecting on
Standard Controls and ACS (If Equipped) Page 60-210-1.) are required.
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)


FRONT HORN Figure 60-220-3
NOTE: Two different style horns are used.
Remove the left side lower panel. (See Removal And

Figure 60-220-1
1
1
1
P-90886
1
Remove the two bolts and nuts (Item 1) [Figure 60-220-

2 3].
2
3
Remove the front horn from the bracket.
P-90885 P-90901

Figure 60-220-2
2
3
1 3
P-90903 P-90902
Disconnect wire harness (Item 1) [Figure 60-220-1] and

[Figure 60-220-2] from the front horn.
Remove the two bolts and nuts (Item 2) [Figure 60-220-

1] and [Figure 60-220-2].
Remove the front horn and bracket from the loader (Item
3) [Figure 60-220-2].


ENGINE SERVICE
ENGINE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-5
Engine Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-7
Engine Mount Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-14
Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-15
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

Cable Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-2
ENGINE SPEED CONTROL (SJC) S/N A3NV12469 AND BELOW & S/N A3NW11130 AND
BELOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21-1

ENGINE SPEED CONTROL (SJC) S/N A3NV12470 AND ABOVE & S/N A3NW11131 AND
ABOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-22-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
Housing Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-2
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Radiator Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Hydraulic Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-3
Hydraulic Fan Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
Lower Fan Duct Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-5
Blower Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-5
Hydraulic Fan Motor Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . 70-50-6
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-6
Hydraulic Fan Motor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-7
Water Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-8
Water Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-8
Thermostat Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-9
Thermostat - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-10

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1
Relief Valve - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Pump Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Filter Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-3
Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-4
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1

Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-2
Fuel Injection Pump Assembly Removal And Installation . . . . . . . . . . . . . . . . . . . . . 70-70-3
Governor Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
Governor Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Fuel Injection Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-14
Fuel Injector Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-15
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-17
Nozzle Spray Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-18

Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-18
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Glow Plugs - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
Valve Timing - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-3
Cylinder Head Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-4
Cylinder Head Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Guide - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Guide Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Reconditioning The Valve And Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-9
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-80-11
Valve Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12
Rocker Arm And Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Bridge Arm And Bridge Arm Shaft - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-13
Bridge Arm Shaft - Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-14
Push Rod Alignment - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-15
CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

Piston And Connecting Rod Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 70-90-1
Piston And Connecting Rod - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-2
Cylinder Bore - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5
Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-6
Crankshaft Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-6
Crankshaft And Bearings Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-7
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-9

CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Timing Gearcase Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1
Timing Gearcase Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Timing Gears Backlash - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Idler Gear And Camshaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-6
Idler Gear And Shaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-7
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1
FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-3
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-3
EXHAUST GAS RECIRCULATION (EGR) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-130-2



ENGINE INFORMATION
Description
The S650 has a Kubota direct injected V3307-DI-T turbo

diesel engine with a displacement of 3,3 L (203 in3). The
engine is rated at an SAE Gross 55,4 kW (74.3 hp) and
has a closed breather system [Figure 70-10-1].
The engine has 4 cylinders and the rotation is counter-

clockwise (viewed from the flywheel side). It is equipped
with glow plugs for assisting in cold starts. Engine block
heaters are also available from Bobcat Parts.
To meet emission regulations it is also equipped with an

Exhaust Gas Recirculation (EGR) system to reduce
Nitrogen Oxide (NOx).
The engine serial number is stamped on the engine and

is located near the injection pump. The model number is
located on the valve cover. Use these numbers to obtain
the correct service parts.
The engine is liquid cooled with a propylene glycol/water

mixture in a radiator. Coolant flow is controlled by a
thermostat. The cooling fan is driven by a hydraulic
motor. The speed of the fan is determined by the engine
coolant temperature sensor and the hydraulic/hydrostatic
fluid temperature sensor.
Figure 70-10-1
P-85028

ENGINE INFORMATION (CONT’D)
Specifications
All dimensions are shown in millimeters. Respective imperial dimensions are given in inches enclosed by
parentheses.
Valve Springs
Free Length (Intake and Exhaust) 35,1 - 35,6 (1.39 - 1.40)
Allowable Limit 34,6(1.36)
Fitted Length (Intake and Exhaust) 31,5 (1.24)
Setting Load/ Setting Length (Intake and Exhaust) 63,5 N/31,5mm (14.3 lb./1.24in)
Allowable Limit 45,9 N/31,5mm (10.3 lb./1.24in)
Tilt Allowable Limit (Intake and Exhaust) 1,0 (0.039)
Valve Timing
Intake Valve (Open) 14 degrees B.T.D.C.
(Close) 40 degrees A.B.D.C.
Exhaust Valve (Open) 50 degrees B.B.D.C.
(Close) 14 degrees A.T.D.C.
Rocker Arms

O.D. of Rocker Arm Shaft 14,973 - 14,984 (0.58949 - 0.58992)
I.D. of Rocker Arm Bushings 15,000 - 15,018 (0.59056 - 0.59125)
Oil Clearance Between Rocker Arm & Bushing 0,016 - 0,045 (0.00063 - 0.0017)
Allowable Limit 0,15 (0.0059)
Camshaft
Journal O.D. 1 34.934 - 34,950 (1.3754 - 1.3759)
Bearing I.D. 1 35,0 - 35,025 (1.3780 - 1.3789)
Journal O.D. 2 43,934 - 43,950 (1.7297 - 1.7303)
Bearing I.D. 2 44,000 - 44,025 (1.7323 - 1.7332)
Oil Clearance 0,050 - 0,091 (0.002 - 0.0035)
Alignment Allowable Limit 0,01 (0.0004)
Cam Lobe Height (Intake) 37,50 (1.476)
Allowable Limit (Intake) 37,00 (1.457)
Cam Lobe Height (Exhaust) 37,90 (1.492)
Allowable Limit (Exhaust) 37,40 (1.472)
Side Clearance Allowable Limit 0,10 (0.0039)
Tappet
Oil Clearance Between Tappet & Guide 0,020 - 0,050 (0.0079 - 0.0019)
Tappet O.D. 9,965 - 9,980 (0.3924 - 0.3929)
Tappet Guide I.D. 10,000 - 10,015 (0.39370 - 0.39429)

Specifications (Cont’d)
parentheses.
Cylinder Liner
Cylinder Bore I.D. 94,000 - 94,022 (3.7008 - 3.7016)
Oversized Cylinder Liner (Bore) I.D. 94,500 - 94,522 (3.7205 - 3.7213)
Piston Rings
Ring Gap (Top Ring) 0,25 - 0,40 (0.0099 - 0.015)
Ring Gap (2nd Ring) 0,30 - 0,45 (0.012 - 0.017)
Ring Gap (Oil Ring) 0,25 - 0,45 (0.0099 - 0.017)
Side Clearance of Ring Groove:
Top Ring 0,050 - 0,090 (0.0020 - 0.0035)

Second Ring 0,090 - 0,12 (0.0035 - 0.0047)
Oil Ring 0,020 - 0,060 (0.00079 - 0.0023)
Pistons
Piston Pin Bore 28,000 - 28,013 (1.1024 - 1.1028)
Connecting Rod
Piston Pin O.D. 28,006 - 28,011 (1.1026 - 1.1027)
Small End Bushing I.D. 28,031 - 28,046 (1.1036 - 1.1041)
Oil Clearance Between Piston Pin & Small End Bushing 0,020 - 0,040 (0.00079 - 0.0015)
Connecting Rod Alignment Allowable Limit 0,05 (0.002)
Oil Pump
Oil Pressure Rated RPM 193,1 - 393,0 kPa (1,9 - 3,9 bar) (28 - 57 psi)
Allowable Limit 144,8 kPa (1,4 bar) (21 psi)
Idle Speed Allowable Limit 48,3 kPa (0,48 bar) (7 psi)
Clearance Between Inner Rotor & Outer Rotor 0,030 - 0,090 (0.002 - 0.003)
Clearance Between Outer Rotor & Pump Body 0,100 - 0,184 (0.00394 - 0.00724)
End Clearance Between Inner Rotor & Cover 0,025 - 0,075 (0.00099 - 0.0029)

Specifications (Cont’d)
parentheses.
Crankshaft
Crankshaft Alignment Limit Permitted 0,02 (0.0008)
Oil Clearance Between Journal & Bearing 0,030 - 0,073 (0.0012 - 0.0028)
Limit Permitted 0,020 (0.0079)
Journal O.D. 79,977 - 79,990 (3.1487 - 3.1492)
Oil Clearance Between Crank Pin & Bearing 0,017 - 0,048 (0.00067 - 0.0018)
Crank Pin O.D. 49,980 - 49,991 (1.9678 - 1.9681)
Crank Pin I.D. (Blue) 53,010 - 53,020 (2.0870 - 2.0874)
Crank Pin I.D. (No Color) 53,000 - 53,010 (2.0867 - 2.0870)
Crankshaft Side Clearance 0,15 - 0,35 (0.0059 - 0.013)
Timing Gear
Timing Gear Backlash:

Crank Gear-Cam Gear 0,0410 - 0,139 (0.00162 - 0.00547)
Idle Gear-Cam Gear 0,0410 - 0,134 (0.00162 - 0.00527)
Idle Gear-Injection Pump Gear 0,0410 - 0,134 (0.00162 - 0.00527)
Oil Clearance Between Idle Gear Shaft & Idle Gear Bushing: 0,050 - 0,091 (0.0020 - 0.0035)
Idle Gear Bushing I.D. 35,025 - 35,050 (1.3790 - 1.3799)
Idle Gear Shaft O.D. 34,959 - 34,975 (1.3764 - 1.3769)
Idle Gear Side Clearance 0,15 - 0,25 (0.0059 - 0.0098)
Thermostat
Valve Opening Temperature 74,5 - 78,5°C (166.1 - 173°F)
Valve Fully Open 90°C (194°F)

parentheses.
Torque Values
Thread Size Material

(Dia. x Pitch)
Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 ft-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb) (69 - 87 ft-lb)
M14 x 1.5 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m

(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)
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, 54
Engine will not start. 2, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 19, 27, 28, 29
Difficult to start. 1, 2, 5, 7, 8, 9, 10, 11, 12, 13, 15, 16, 17, 18, 19, 20, 25, 27, 28, 29,54
No power for 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 warning. 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

Troubleshooting (Cont’d)

1. Alternator belt is loose or damaged. 28. Worn valve and seats.
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 crankcase.
6. Fuel tank empty. 33. Switch/sensor is defective.
7. Faulty stop control operation. 34. Oil pump worn.
8. Plugged fuel line. 35. Relief valve is sticking open.
9. Plugged fuel filter. 36. Relief valve is sticking 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 flywheel alignment.

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 deflectors.
24. Incorrect tappet adjustment. 51. Coolant level to low.
25. Sticking valves. 52. Plugged oil pump pipe strainer.
26. Incorrect fuel lines. 53. Broken valve spring.
27. Worn cylinder bores. 54. Damaged Battery

ENGINE INFORMATION (CONT’D) Remove the air cleaner. (See Housing Removal And
Engine Removal And Installation
Remove the muffler. (See Removal And Installation on
Page 70-30-1.)
DANGER Figure 70-10-2
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 2
• Keep out of this area when lift arms are raised P-90575


Loosen the engine speed control cable adjustment nuts
D-1009-0409 (Item 1) and remove the engine speed control cable from
the ball pivot (Item 2). [Figure 70-10-2].
Figure 70-10-3
WARNING
1
W-2059-0598
2
Put jackstands under the rear corners of the loader.
P-85852
Drain the hydraulic reservoir. (See Removing And Disconnect engine ground cable (Item 1) and chassis
Replacing Hydraulic Fluid on Page 10-120-2.) ground cable (Item 2) [Figure 70-10-3].
Disconnect the steering linkage.
Remove the battery from the loader. (See Removal And

Drain the engine coolant from the cooling system. (See

Removing And Replacing Coolant on Page 10-90-3.)

ENGINE INFORMATION (CONT’D) Figure 70-10-6
Engine Removal And Installation (Cont'd) 2

1
Figure 70-10-4
2 3
3
4
1
4
P-85857
5
Disconnect flywheel rpm sensor (Item 1) [Figure 70-10-
P-85849 6].
Cut cable ties (Item 2) [Figure 70-10-6].

Disconnect engine oil pressure sender connector (Item 1)
[Figure 70-10-4]. Disconnect the engine starter positive cable (Item 3)

[Figure 70-10-6].
Disconnect the alternator wiring (Item 2) [Figure 70-10-
4]. Disconnect the starter wiring harness connector (Item 4)
[Figure 70-10-6].
Disconnect the engine ground cable (Item 3) [Figure 70-
10-4]. Figure 70-10-7
Disconnect fuel shut-off solenoid connector (Item 4)

[Figure 70-10-4].
Cut cable tie (Item 5) [Figure 70-10-4].

1
Figure 70-10-5
P-85854
Disconnect fuel line (Item 1) [Figure 70-10-10] for lift

pump and plug.
P-85853
Disconnect glow plug wiring (Item 1) [Figure 70-10-5].

Engine Removal And Installation (Cont'd)
Figure 70-10-8
P-85894
Disconnect radiator hose (Item 1) [Figure 70-10-10].

P-85855
Figure 70-10-11
Disconnect and plug fuel return line (Item 1) [Figure 70-

10-8].

Figure 70-10-9
1
P-85892
Disconnect radiator hose (Item 1) [Figure 70-10-11] from

the thermostat housing.
P-85895
Disconnect coolant return line (Item 1) [Figure 70-10-

13].


1
Figure 70-10-12
1
P-85909
Mark and disconnect the drive motor hoses (Item 1)

P-85893 [Figure 70-10-14].
Disconnect the tandem pump case drain hose (Item 2)

Disconnect coolant temperature connector (Item 1) [Figure 70-10-14].
[Figure 70-10-12] from thermostat housing.

Cap or plug all hoses and fittings.
NOTE: The hydraulic fittings (Item 1) [Figure 70-10-
Figure 70-10-13 17] on the hydrostatic pump must be
tightened to 156 - 170 N•m (115 - 125 ft-lb)
torque.
1 Figure 70-10-15
2
1
1
2
P-85897
Remove and cap fan inlet hose (Item 1) [Figure 70-10-

13].
P-85907
Remove and cap fan outlet hose (Item 2) [Figure 70-10-

13]. Disconnect tandem pump suction hoses (Item 1) [Figure
70-10-15].
Disconnect the charge pump inlet hose (Item 2) [Figure

70-10-15].

Figure 70-10-16
1 P-85911
Remove the mounting bolt (Item 1) [Figure 70-10-18]

P-85908 from the left engine mount.
Installation: Tighten the mounting bolt (Item 1) [Figure

Disconnect hydraulic control valve inlet hose (Item 1) 70-10-18] to 135 N•m (100 ft-lb) torque.
[Figure 70-10-16].

Figure 70-10-19
Figure 70-10-17
P-85910
P-85876 Remove the mounting bolt (Item 1) [Figure 70-10-19]

from the right engine mount.
Remove rear engine mounting bolt (Item 1) [Figure 70- Installation: Tighten the mounting bolt to 135 N•m (100
10-17]. ft-lb) torque.
Installation: Tighten the mounting bolt to 135 N•m (100

ft-lb) torque.

Figure 70-10-20
P-85912
Install the engine removal attachment (MEL1653-5)

[Figure 70-10-21] on the engine.
Figure 70-10-22

1
P-76872
Use the engine removal tool (MEL 1653-1) [Figure 70-

P-85920
10-20] and the attachment (MEL 1653-5) [Figure 70-10-
21] to aid in the removal and installation of the engine.
Install the engine removal attachment (Item 1) on the left
hand muffler support bracket (Item 2) [Figure 70-10-22].
Installation: Use 9,525 x 38,1mm (0.375 x 1.5 in) bolts

and nuts grade 5 minimum.
Tighten the all bolts and nuts that hold the engine
removal attachment onto the engine.

Figure 70-10-23
P-85918
Install the engine removal attachment (Item 1) on the

right hand muffler support bracket (Item 2) [Figure 70-

10-22].
Figure 70-10-24
P-85919
Install the engine removal tool (Item 1) into the

attachment (Item 2) and insert the pin (Item 3) [Figure
70-10-24].
Install the chain hoist on the eyelet [Figure 70-10-24] of

the removal tool.
Remove the engine/hydrostatic pump assembly from the

loader.

Engine Mount Replacement Washer

Engine
Figure 70-10-25 Mounting
Bracket
7 Engine
1
Mount
2
Snubbing Spacer
3 Washer
4
Loader
Frame P-90300
8
5
Install the new engine mount as shown in the cut away
P-85989 side view [Figure 70-10-27].
Tighten the mounting bolts to 135 N•m (100 f.-lb) torque.

Use the following procedure to install new rear engine
mount: Figure 70-10-27

Remove the existing mount from the engine. Refer to 1
engine removal and installation for engine mount 4
locations.
Replace all three engine mounts one rear and two sides. 5 2
Use the parts shown to install the new engine mounts 6 3

[Figure 70-10-25]:
7
Hex Nut - (Item 1)
Washer - (Item 2)
Cup Washer - (Item 3) P-85990A
Engine Mount - (Item 4)

Use the parts shown to install the new side engine
Tube Spacer - (Item 5) mounts [Figure 70-10-25].
Engine Mount - (Item 6) Mounting Bolt - (Item 1)
Cup Washer - (Item 7) Cup Washer - (Item 2)
Mounting Bolt - (Item 8) Engine Mount - (Item 3)
Tube Spacer - (Item 4)
Engine Mount - (Item 5)
Cup Washer - (Item 6)
Retaining Nut - (Item 7)

ENGINE INFORMATION (CONT’D) Compression - Checking
Engine Mount Replacement (Cont’d) Figure 70-10-29
Figure 70-10-28
Washer
Engine
Mounting 1
Bracket
Engine
Mount
Snubbing
Washer
Spacer P-85940
Loader
Frame P-85987
procedure:
Install the new engine mount as shown in the cut away
side view [Figure 70-10-27]. MEL10630 - Engine Compression Kit

MEL1655 - Compression Adapter
Tighten the mounting bolts to 135 N•m (100 ft-lb) torque.
The engine must be at operating temperature.
Remove the glow plugs. (See CYLINDER HEAD on

Page 70-80-1.)
Install the correct compression adapter (Item 1) [Figure

70-10-29] into the cylinder head.

Compression - Checking (Cont’d)
Figure 70-10-30
P-85939
Push the button on the compression gauge to release

P-85941 pressure [Figure 70-10-31].
Connect the fuel stop solenoid.

Connect the compression gauge to the adapter [Figure
70-10-30].

Make sure the engine speed control is fully backward
(engine idle).
Disconnect the fuel stop solenoid.
Crank the engine with the starter cranking rpm.
If the measurement is below the allowable limit, check

the cylinder, piston ring, top clearance, valve and cylinder
head.
Compression Pressure should be 3,9 MPa (39,2 bar)

(569 psi)
Allowable Limit (minimum) is 2,9 MPa (29,0 bar) (421 psi)
No more than 10% variance among cylinders.

ENGINE SPEED CONTROL Disassembly And Assembly
Figure 70-20-1
1 2
P-85791
P-85789
Remove the nut (Item 1) and remove the two conical
washers (Item 2) [Figure 70-20-3].
Remove the handle (Item 3) [Figure 70-20-3].

Figure 70-20-2
Installation: Install the two conical washers with the
concave surfaces facing each other (Item 2) [Figure 70-
20-3].

until the speed control lever moves backward and
2 1 forward at a comfortable tension.
3
Figure 70-20-4
P-85790
The speed control cable (Item 1) is connected to the

speed control handle (Item 2) by a ball and socket end
[Figure 70-20-2].
Disconnect the speed control cable (Item 1) from the

speed control handle (Item 2) [Figure 70-20-2].
P-85792
Loosen the jam nut (Item 3) [Figure 70-20-2] from the
speed control cable.
Inspect and replaced any damaged parts [Figure 70-20-
Remove the cable from the speed control handle. 4].

ENGINE SPEED CONTROL (CONT’D) Figure 70-20-7
Cable Removal And Installation
1
Remove the speed control lever. (See Removal And

P-85805
Figure 70-20-5
P-85801
Remove the bolt (Item 1) [Figure 70-20-7] from the

clamp that secures the cable.
Figure 70-20-8

1 2
1
P-85806
Remove the bolt (Item 1) [Figure 70-20-5] from the

clamp that secures the cable.
Figure 70-20-6 3
P-90575
The speed control cable is connected to the linkage by a

1 ball and socket end [Figure 70-20-8].
Loosen the jam nut (Item 1) [Figure 70-20-8] from the

speed control cable.
Disconnect the speed control cable (Item 2) from the

linkage (Item 3) by rolling the cable away from the engine
[Figure 70-20-8].
P-85801
Remove the speed control cable.
Remove the three bolts (Item 1) [Figure 70-20-6] from

the clamps that secure the cable.

ENGINE SPEED CONTROL (SJC) S/N A3NV12469 Figure 70-21-3
AND BELOW & S/N A3NW11130 AND BELOW
Raise the operator cab. (See Raising on Page 10-30-2.) 1
Figure 70-21-1 1
2
1
P-90735
Remove the four bolts (Item 1) and washer (Item 2)

[Figure 70-21-3].
Lay the assembly down.

P-90733
Figure 70-21-4

Remove the two mounting nuts (Item 1) [Figure 70-21-1]
1
from the right side foot rest.
1
Remove the foot rest from the loader.
Figure 70-21-2
2
2
P-90754
1
2 Loosen the engine speed control cable u-bolt nuts (Item
1) and remove the engine speed control cables from the
ball pivots (Item 2) [Figure 70-21-4].
P-90734 Remove panel assembly from the loader.
Loosen the clamping bolt (Item 1) and remove the engine

speed control foot pedal (Item 2) [Figure 70-21-2].
Installation: Install the engine speed foot pedal (Item 2)

but do not tighten the clamping bolt. Set the hand throttle
to high idle then place the foot pedal to high idle and
tighten the clamping bolt (Item 1) [Figure 70-21-2].

(CONT'D)
Disassembly And Assembly 4 3
Figure 70-21-5
2 1
2
P-90769
3
Remove the nut (Item 1) and pivot bolt (Item 2) from the
1 engine speed control hand bracket assembly (Item 3)
[Figure 70-21-7].
P-90756
Remove the engine speed control hand throttle cam lever

(Item 4) [Figure 70-21-7].
Remove the spring (Item 1) from the engine speed

control foot pedal pivot assembly (Item 2) and the engine
Figure 70-21-8
speed control hand throttle bracket (Item 3) [Figure 70-
21-5]
Figure 70-21-6
P-90767
The pivot assembly shown disassembled [Figure 70-21-

P-90755 8].
NOTE: No lubrication is necessary or recommended

Remove the two bolts (Item 1) [Figure 70-21-6] from the
on the engine speed control.
engine speed control hand assembly.

(CONT'D)
Figure 70-21-9
1
P-90773
The engine speed control foot pedal pivot assembly roller

bearing [Figure 70-21-11] shown disassembled.
P-90736

engine speed control foot pedal pivot.
Figure 70-21-10
P-90771
The engine speed control foot pedal pivot assembly

shown disassembled, [Figure 70-21-10] replace worn
parts as needed.



AND ABOVE & S/N A3NW11131 AND ABOVE
Figure 70-22-1 1
2
1
P-90735
Remove the four bolts (Item 1) and washer (Item 2)

[Figure 70-22-3].
Lay the assembly down.

P-90733
Figure 70-22-4

Remove the two mounting nuts (Item 1) [Figure 70-22-1]
from the right side foot rest. 1
Remove the foot rest from the loader.
Figure 70-22-2 2
P100359
1
2 Loosen the engine speed control cable u-bolt nuts (Item
1) and remove the engine speed control cables from the
ball pivots (Item 2) [Figure 70-22-4].
P-90734 Remove panel assembly from the loader.
Loosen the clamping bolt (Item 1) and remove the engine

speed control foot pedal (Item 2) [Figure 70-22-2].
Installation: Install the engine speed foot pedal (Item 2)

but do not tighten the clamping bolt. Set the hand throttle
to high idle then place the foot pedal to high idle and
tighten the clamping bolt (Item 1) [Figure 70-22-2].

(CONT'D)
4
Figure 70-22-5 3
2 1
5
2
P100381
3
Remove the nuts (Item 1) and pivot bolts (Item 2) from

1 the engine speed control hand bracket assembly (Item 3)
[Figure 70-22-7].
P100382
Remove the engine speed control hand throttle cam lever

(Item 4) and engine throttle cable lever Item 5) [Figure
Remove the spring (Item 1) from the engine speed

70-22-7].
control foot pedal pivot assembly (Item 2) and the engine
speed control hand throttle bracket (Item 3) [Figure 70-
Figure 70-22-8
22-5]
Figure 70-22-6
P100380
P-90755 The pivot assemblies shown disassembled [Figure 70-

22-8].
Remove the two bolts (Item 1) [Figure 70-22-6] from the
engine speed control hand assembly.

(CONT'D)
Figure 70-22-9
1
P100375
The engine speed control foot pedal pivot assembly roller

bearing [Figure 70-22-11] shown disassembled.
P-90736

engine speed control foot pedal pivot.
Figure 70-22-10
P100376
The engine speed control foot pedal pivot assembly

shown disassembled, [Figure 70-22-10] replace worn
parts as needed.



MUFFLER
Figure 70-30-1
2
1
1 1
3 3

P-85843
Open the rear door and remove the rear grille and side
panels. (See Removal And Installation on Page 50-60-1.)
Remove the bolts (Item 1) from the engine cover (Item 2)

[Figure 70-30-1] and remove engine cover.
Remove the muffler mounting bolts (Item 3) [Figure 70-

30-1].
Remove exhaust manifold to muffler mounting bolts (Item

4) [Figure 70-30-1].
Remove the muffler from the loader.
Installation: Tighten the muffler mounting bolts to 43 - 47



AIR CLEANER Figure 70-40-3
Housing Removal And Installation
Open the rear door. 3 4
Figure 70-40-1
1
1
2
P-85694
Disconnect the wire connector (Item 1) [Figure 70-40-3]

from the air cleaner sender.
P-85689 Loosen the hose clamp (Item 2) and disconnect the hose
(Items 3) [Figure 70-40-3] from the air cleaner.

Remove the top two mounting bolts (Item 1) [Figure 70- NOTE: Disconnect the scavenger hose (Item 4)
40-1] from the air cleaner mount bracket. [Figure 70-40-3] if equipped.
Figure 70-40-2 Remove the air cleaner from the loader.
P-85688
Remove the bottom mounting bolt (Item 1) [Figure 70-

40-2] from the air cleaner mount bracket.

AIR CLEANER (CONT’D)
Housing Bracket Removal And Installation
Figure 70-40-4
P-85691
Remove the three bolts (Item 1) and remove the air

cleaner bracket (Item 2) [Figure 70-40-4].

ENGINE COOLING SYSTEM Figure 70-50-2
Radiator Removal And Installation
Remove the rear grille and side panels. (See Removal 1

Remove the oil cooler. (See Removal And Installation on

Page 20-90-1.)
WARNING
P-85606
AVOID BURNS
Do not remove radiator cap when the engine is hot. Remove hose (Item 1) [Figure 70-50-2] on the engine oil
You can be seriously burned. cooler and drain the coolant into a container.
W-2070-1203
Figure 70-50-3
Figure 70-50-1

1
2
3
2 4
P-85949
P-90574
Disconnect the pressurized expansion tank fill hose (Item

Loosen the radiator cap (Item 1) from the pressurized 1), disconnect the coolant air bleed hose (Item 2) and the
expansion tank. Disconnect and plug radiator air bleed radiator hose (Item 3) [Figure 70-50-3].
Remove the radiator hold down bolt (Item 4) [Figure 70-
50-3].

ENGINE COOLING SYSTEM (CONT'D) Figure 70-50-6
Radiator Removal And Installation (Cont'd)
Figure 70-50-4
2 2
1 P-85954
Remove radiator hold down bolt (Item 1) [Figure 70-50-

P-90555 6].
Remove the radiator (Item 2) [Figure 70-50-6].

Disconnect the radiator hose (Item 1) and remove the
radiator hold down bolt (Item 2) [Figure 70-50-4]. Lift the radiator up and remove it from the loader.

Figure 70-50-5 NOTE: Coolant recovery tank removed for photo
clarity
P-85952
Remove radiator hold down bolt (Item 1) [Figure 70-50-

5].

ENGINE COOLING SYSTEM (CONT’D)
Hydraulic Fan Description
The proportioning valve meters the flow through the fan

motor. The proportioning valve receives signals from the
controller which gathers information from both the engine
and hydraulic temperature sensors.
The hydraulic fan is used to cool the engine and

hydraulic / hydrostatic systems. The hydraulic fan
consists of a fan and hydraulic motor that is controlled by
a proportioning valve.
NOTE: The proportioning valve is factory set and can

not be adjusted accurately in the field due to
the adjustment being tamper proof.
The fan speed is determined by the engine coolant

temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (rpms)
can range from 0 - 4000 rpms.
The hydraulic fan speed at cold engine startup will range

from 0 to 500 rpms until the engine coolant and the
hydraulic fluid reach normal operating temperatures.
During normal operating temperatures the fan speed may

range from approximately 1900 - 3500 rpms.

ENGINE COOLING SYSTEM (CONT’D) Installation: Install coil mounting nut with the
counterbored space (Item 4) [Figure 70-50-8] facing
Hydraulic Fan Disassembly And Assembly towards the coil and tighten securely by hand.
Figure 70-50-7 Installation: Tighten coil valve stem (Item 3) [Figure 70-
50-8] to 28 - 34 N•m (21 - 25 ft-lb) torque.
Figure 70-50-9
4
1
3
1
P-76714A 2
NOTE: The mounting gasket (Item 1), proportioning

P-76637
valve, and proportioning valve O-rings, back

up washer and coil mounting nut (Item 2) are
available from Bobcat Parts. The fan motor Inspect and replace O-rings (Item 1) and back up washer
(Item 3) [Figure 70-50-7] must be replaced as (Item 2) [Figure 70-50-9] if necessary.
an assembly if damaged.
Figure 70-50-10
Remove the filter cover (Item 4) [Figure 70-50-7].
Installation: Tighten filter cover (Item 4) [Figure 70-50-

7] to 47,5 - 54 N•m (35 - 40 ft-lb) torque.
Figure 70-50-8
1
4
3
P-76717
2
Remove the pressure transducer (Item 1) [Figure 70-50-
1 10].
P-76716A Installation: Tighten the pressure transducer (Item 1)

[Figure 70-50-10] to 10 - 10,9 N•m (7.4 - 8.1 ft-lb) torque.
Remove coil mounting nut (Item 1), the coil (Item 2), and
the coil valve stem (Item 3) [Figure 70-50-8].
NOTE: Coil mounting nut must be replaced each time

it is removed. Coil mounting nuts are
available from Bobcat Parts.

ENGINE COOLING SYSTEM (CONT'D) Blower Housing Removal And Installation
Hydraulic Fan Disassembly And Assembly (Cont’d)
Figure 70-50-11
IMPORTANT
damage the system.
I-2003-0888
Remove the air conditioning condenser if equipped. (See

1 Removal And Installation on Page 80-60-1.)
Remove the oil cooler. (See Removal And Installation on

Page 20-90-1.)
P-76726
Remove the radiator. (See Radiator Removal And
Inspect and replace the O-ring (Item 1) [Figure 70-50-11]
if necessary.
Figure 70-50-13

Lower Fan Duct Removal And Installation
Figure 70-50-12
1 1
2
P-90063
1
Remove the four bolts (Item 1)[Figure 70-50-13].
P-85470
Remove the blower housing (Item 2)[Figure 70-50-13]
from the loader.
Unhook the rubber straps (Item 1) [Figure 70-50-11] and
remove lower fan duct.
NOTE: Engine and hydraulic fan assembly removed
for photo clarity.
NOTE: Line up the bushings and bolts thru the fan

shroud

ENGINE COOLING SYSTEM (CONT’D) Fan Removal And Installation
Hydraulic Fan Motor Assembly Removal And Figure 70-50-16

Installation
Figure 70-50-14
1
1 2
2
5
4
5 1
P-90313
3
P-85897 Remove the four bolts (Item 1) and the cover plate (Item
2) [Figure 70-50-16].
Remove the fan motor inlet hose (Item 1) and outlet hose Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb)

(Item 2) [Figure 70-50-14]. torque.
Remove the fan case drain hose (Item 3) [Figure 70-50- Figure 70-50-17
14].
Remove the charge pressure hose (Item 4) [Figure 70-

50-14].
Cap and plug all hose’s.

1
Disconnect the electrical connectors (Item 5) [Figure 70-
50-14].
Figure 70-50-15
P-90065
Remove the nut (Item 1) [Figure 70-50-17] and washer

1 1 from the motor shaft.
Installation: Tighten the nut to 61 - 75 N•m (45 - 55 ft-lb)

torque.
P-90268
Remove the four bolts (Item 1) [Figure 70-50-15].
Remove fan assembly (Item 2) [Figure 70-50-15].

ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-20
Hydraulic Fan Motor Removal And Installation
Figure 70-50-18
2 2
P-90062
Use the following procedure to remove the fan hub from

P-90069 the fan motor shaft:
Install a bushing (Item 1) [Figure 70-50-20] in the hub to

Remove and discard the two nuts and cotter pins (Item 1) protect the fan motor shaft and threads during removal.
[Figure 70-50-18].

Use two bolts to position a puller (Item 2) on the bushing
Remove the two washers (Item 2) [Figure 70-50-18]. (Item 1) as shown [Figure 70-50-20].
Installation: Tighten the nuts to 10,2 N•m (7.5 ft-lb) NOTE: If a puller is not available one can be made if
torque. needed to remove the hub from the shaft.
Figure 70-50-19 Tighten the bolts and strike the puller with a hammer to
loosen the hub from the motor shaft.
P-90076
Remove and discard the two bolts (Item 1) [Figure 70-

50-19] then remove motor.
Installation: Tighten the bolts to 10,2 N•m (7.5 ft-lb)

torque.
NOTE: Always install new bolts, nuts, cotter pins,

and rubber gasket when installing the fan
motor.

ENGINE COOLING SYSTEM (CONT'D) Water Pump Disassembly And Assembly
Water Pump Removal And Installation Figure 70-50-22
Drain the cooling system.

3
Remove the alternator belt.
Remove the water pump bolts.

2
Figure 70-50-21
1
4
1 P-90019
Remove the flange (Item 1) [Figure 70-50-22].
Press the shaft (Item 2) and impeller (Item 3) [Figure 70-

50-22] out the impeller side of the water pump.

2
P-90018 Remove the impeller (Item 3) [Figure 70-50-22] from the
shaft.
Remove the water pump (Item 1) [Figure 70-50-21]. Remove the seal (Item 4) [Figure 70-50-22].
Installation: Always use a new gasket (Item 2) [Figure Install a new seal (Item 4) [Figure 70-50-22] when
70-50-21] when installing the water pump. assembling the water pump.

ENGINE COOLING SYSTEM (CONT'D)
Thermostat Housing Removal And Installation
Figure 70-50-23
7 4

5
6
P-90166
Remove the bolts (Item 1), housing (Item 2), gasket (Item
3) and thermostat (Item 4) [Figure 70-50-23].
Remove bolts (Item 5), housing (Item 6), and gasket

(Item 7) from the cylinder head [Figure 70-50-23].

ENGINE COOLING SYSTEM (CONT’D)
Thermostat - Checking
Figure 70-50-24
P-37172
Push down the thermostat valve and insert a string

between the valve and the valve seat.

Place the thermostat and a thermometer in a container
with water and gradually heat the water [Figure 70-50-
24].
Hold the string to suspend the thermostat in the water.

When the water temperature rises, the thermostat valve
will open, allowing it to fall down from the string.
Continue heating the water and read the temperature

when the valve has risen by about 8 mm (0.315 in).
If the measurement is not acceptable, replace the

thermostat.
Thermostat’s valve Factory spec. 74,5 - 78,5°C

opening tempera- 166.1 - 173°F
ture
Temperature at Factory spec. 90°C
which thermostat 194°F
completely opens

LUBRICATION SYSTEM Installation: Apply oil to O-ring.
Oil Pan Removal And Installation Oil Pump Removal And Installation
Remove the engine and hydrostatic pump assembly from Figure 70-60-3
Page 70-10-7.)
The engine will have to be on an engine stand or

suspended in the air safely to remove the oil pan.
Figure 70-60-1
2
1
1
P-85061
Remove the bolts from the front cover / oil pump (Item 1)
[Figure 70-60-3].

Installation: Use a liquid gasket adhesive.Tighten the
P-85062 front cover / oil pump mounting bolts to 24 - 27 N•m (18 -
20 ft-lb) torque.
Remove oil pan bolts (Item 1) securing oil pan (Item 2)

[Figure 70-60-2]. Slightly tapping on the oil pan with a
soft mallet will break loose the oil pan from the engine
block.
Installation: Use a liquid gasket adhesive to the oil pan

side of the oil pan gasket. Tighten oil pan bolts to 39 - 75
Figure 70-60-2
2
1
P-85056
Remove the oil strainer (Item 1) and O-ring (Item 2)

[Figure 70-60-2] from the engine block.

LUBRICATION SYSTEM (CONT’D) Remove oil pump cover screws. Measure the clearance
between the lobes of the inner rotor and outer rotor
Relief Valve - Testing [Figure 70-60-5].
Figure 70-60-4 Installation: Tighten cover screws to 7,9 - 9,3 N•m (5.8 -
6.8 ft-lb)
Clearance 0,030 - 0,090 mm

Between Inner & (0.0012 - 0.0035 in)
Outer Rotor
Allowable limit 0,30 mm (0.012 in.)
If the clearance exceeds the allowable limit, replace the

oil pump.
Figure 70-60-6
1
2
4
3 P-85057
Remove the relief valve retaining screw (Item 1) from the

front cover / oil pump (Item 2) and remove the relief valve

spring (Item 3) and relief valve (Item 4) [Figure 70-60-4].
Measure free length of relief valve spring (Item 3) [Figure

70-60-4] and check the entire surface of spring for any
scratches. Replace if out of spec or any scratches.
Free Length 60,0 - 60,5 mm

P-85059
(2.37 - 2.38 in)
Allowable Limit 55,0 mm (2.17 in)
Measure the clearance between the outer rotor and
Installation: Tighten relief valve retaining screw (Item 1) pump body [Figure 70-60-6].
[Figure 70-60-4] 69 - 78 N•m (51 - 57 ft-lb) torque.
Clearance 0,100 - 0,184 mm
Oil Pump Inspection Between Outer (0.00394 - 0.00724 in)
Rotor & Body
Figure 70-60-5 Allowable limit 0,30 mm (0.012 in)

oil pump.
P-85058

LUBRICATION SYSTEM (CONT’D) Oil Filter Cooler Removal And Installation
Oil Pump Inspection (Cont’d) Figure 70-60-8
Figure 70-60-7
1
3
2
P-85072
P-85060
Remove the cooling hose’s (Item 1) [Figure 70-60-8].
Put a piece of press gauge on the rotor face [Figure 70- Remove oil filter cartridge (Item 2) and the oil cooler joint
60-7]. screw (Item 3) [Figure 70-60-8].

Install the cover and tighten the bolts. Remove oil cooler (Item 4) [Figure 70-60-8].
Remove the cover carefully. Measure the width of the Installation: Tighten oil cooler joint screw (Item 3)
press gauge [Figure 70-60-7]. [Figure 70-60-8] 64 - 73 N•m (47 - 54 ft-lb) torque.
If the clearance exceeds the allowable limit replace the

oil pump.
End Clearance 0,25 - 0,75 mm

(0.00099 - 0.0029 in)
Allowable limit 0,225 mm (0.00886 in)

LUBRICATION SYSTEM (CONT’D)
Engine Oil Pressure - Testing
Remove the oil pressure sender.
Figure 70-60-9
PI-10010

Install a pressure gauge [Figure 70-60-9].
Start the engine and run until it is at operating

temperature.
If the oil pressure is less than the allowable limit, check

the following items:
* Engine Oil Level Low

* Oil Pump Defective
* Oil Galley Plugged
* Oil Strainer Plugged
* Excessive Clearance at the Rod & Main Bearings
* Oil Pump Relief Valve Stuck
At Idle Speed Allowable 48,3 kPa (0.49 bar) (7 psi)

Limit
At Rated Speed 193,0 - 393,0 kPa
(1,9 - 3,9 bar) (28 - 57 psi)
Allowable Limit 144,8 kPa (1,4 bar) (21 psi)

FUEL SYSTEM Fuel Shutoff Solenoid Removal And Installation
Fuel Shutoff Solenoid - Checking Figure 70-70-3
Figure 70-70-1
P-85956
P-85956
Stop the engine and open the rear door [Figure 70-70-1]. Disconnect the connector (Item 1) [Figure 70-70-3].

Disconnect the connector (Item 1) [Figure 70-70-1] from Figure 70-70-4
the fuel shutoff solenoid.
Use an ohmmeter to check the fuel shutoff solenoid.
Figure 70-70-2
P-85957
Remove the mounting screws (Item 1) [Figure 70-70-4]

of the fuel shutoff solenoid.
P-85955
Reverse the above procedure to install the fuel shutoff
solenoid.
The reading between electrical connector terminal C and
terminal A must be between approximately 0.33 ohm
[Figure 70-70-2].
The reading between electrical connector terminal C and

terminal B must be between approximately 24.5 ohm.

FUEL SYSTEM (CONT'D) Move the speed control lever to the high engine idle
position.
Fuel Injection Pump - Checking
Turn the flywheel to increase the pressure. If the
The injection pump contains parts which have a very pressure can not reach the allowable limit, replace the
close tolerance and its operation has a direct effect on injection pump assembly.
the performance of the engine.
Fuel Tightness of Pump 18,6 MPa
Element Allowable Limit (186,3 bar) (2702 psi)
WARNING With the speed control lever at the low engine idle
position, turn the flywheel until the pressure is at 18,6
AVOID INJURY OR DEATH MPa (186,3 bar) (2702 psi).
penetrate skin or eyes, causing serious injury or Turn the flywheel back approximately one-half turn. Keep
death. Fluid leaks under pressure may not be visible. the flywheel at this position, and measure the time it
Use a piece of cardboard or wood to find leaks. Do takes the pressure to decrease from 17,7 MPa (176,5
not use your bare hand. Wear safety goggles. If fluid bar) (2560 psi).
from a physician familiar with this injury. Fuel Tightness of Delivery 5 Seconds
W-2072-0807
Valve Allowable Limit

procedure:
MEL 1237 - Adapter Fuel Line

MEL 1173-1 Pressure Gauge
To check the discharge pressure at the fuel injection

pump, use the following procedure:
Disconnect a high pressure fuel line from the injection

pump. Loosen the other end of the same fuel line so it
can be turned away from the fitting.
Figure 70-70-5
B-8235
Connect the adapter fuel line (Item 1) to the fitting and

connect the pressure gauge (Item 2) [Figure 70-70-5].

FUEL SYSTEM (CONT'D) Disconnect the fuel inlet hose (Item 1) and the fuel return
hose (Item 2) [Figure 70-70-7] from the injection pump
Fuel Injection Pump Assembly Removal And vent.
Installation
Cap the inlets on the injection pump vent where the
Remove the alternator. (See Removal And Installation on hoses were removed [Figure 70-70-7].
Page 60-30-5.)
.
Figure 70-70-6
Figure 70-70-8
2
1
P-85085

P-85082
Clean the area around the injection pump thoroughly.

Remove the high pressure fuel lines (Item 1) [Figure 70-
Disconnect the high pressure fuel lines (Item 1) [Figure 70-8] from the injection pump.
70-70-6] from the fuel injectors.
Remove the engine speed control linkage (Item 2)
[Figure 70-70-8].
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 70-70-7
P-85082

FUEL SYSTEM (CONT'D) Figure 70-70-11
Fuel Injection Pump Assembly Removal And

Figure 70-70-9
P-85215
Make flywheel stop tool as shown above in [Figure 70-

70-11].
P-85095
A 144 mm (5.67 in)
Remove the window cover for the fuel injection pump B 104 mm (4.09 in)

assembly (Item 1) [Figure 70-70-9] from the flywheel C 20,0 mm (0.787 in)
housing. D 10,0 mm dia. (0.394 in dia.)
Figure 70-70-10 E 12,0 mm dia. (0.472 in dia.)

F 16,0 mm dia. (0.630 in dia.)
G 16,0 mm dia. (0.630 in dia.)
1 H 32,0 mm (1.26 in)
I 16,0 mm (0.630 in)
Figure 70-70-12
M8 X 1.25
5,0mm
5,0mm (0.20 in) (0.20 in) dia
0,79 rad
P-85094
Place the number four piston at top dead center on the

compression stroke and lock the flywheel in place using
10mm (0.39 in) 4,0mm (0.16 in)
the flywheel stopper tool as described below.
Look for the alignment mark on the idler gear and 45mm (1.8 in)
P-85091
injection pump gear (Item 1)[Figure 70-70-10] then using
a white marking pen or the like put a alignment mark to
help reassemble these gears in mesh later. Construct two fuel camshaft lock screws as shown above
[Figure 70-70-12]
NOTE: When the already existing marks align with
each other, there is no need to put another
alignment mark.

Fuel Injection Pump Assembly Removal And 2

Figure 70-70-13
P-85093
Remove the lubricating oil pipe (Item 1) [Figure 70-70-

15].
P-85095
Remove the three injection pump mounting nuts (Item 2)
[Figure 70-70-15]
Remove the two plugs (Item 1) [Figure 70-70-13].

Installation: Tighten the lubricating oil pipe to 16 - 19
Installation: Tighten the plugs to 9,81 - 11,2 N•m (7.24 - N•m (12 - 14 ft-lb) torque.
8.31 ft-lb) torque.
Installation: Tighten the injection pump mounting nuts to
Figure 70-70-14 18 - 20 N•m (13 - 15 ft-lb) torque.
Figure 70-70-16
2
1
P-85090
P-85095
Install one lock tool in the upper plug opening (Item 1)
and tighten until it comes in contact with the fuel
camshaft. Make sure the fuel camshaft is not moving. Remove injection pump support (Item 1) [Figure 70-70-
Install second lock tool in lower opening (Item 1) [Figure 16].
70-70-14] and repeat the process.
Remove injection pump assembly (Item 2) [Figure 70-
NOTE: Do not over tighten the lock screws after they 70-16].
have contacted the fuel camshaft. Otherwise
the injection pump may become damaged.

FUEL SYSTEM (CONT'D)
Governor Housing Disassembly And Assembly
The governor serves to keep the engine speed constant Q 2,955 - 2,965 mm dia.
by automatically adjusting the amount of fuel supplied to (0.1164 - 0.1167 in dia.)
the engine according to changes in the engine load. R 3,020 - 3,030 mm dia.
(0.1189 - 0.1192 in dia.)
Disassemble and assemble the governor and fuel S Ra = 1.6a
camshaft as shown in figure. AA Governor housing side
BB Press in side
Check all the parts for wear or damage and replace as a 0,60 mm radius (0.024 in radius)
needed. b 1,0 mm radius (0.039 in radius)
C0.2 Chamfer 0,20 mm (0.0079 in)
Figure 70-70-17
C0.4 Chamfer 0,40 mm (0.016 in)
C0.5 Chamfer 0,50 mm (0.020 in)
C1 Chamfer 1,0 mm (0.039 in)
Make the tool as shown in figure [Figure 70-70-17] or

purchase part number below to connect the governor
connecting rod to the rack pin of the fuel injection pump.

MEL1667 - Jig for Governor Connecting Rod
(Item 1) [Figure 70-70-17] Material: S43C-D

(Item 2) [Figure 70-70-17] Permanent Magnet: 8 mm
dia. (0.31 in dia.) Thickness: 3 mm (0.12 in)
P-85182
Jig for Governor Connecting Rod
Application: Use this tool for connecting the governor

connecting rod to the rack pin of the fuel injection pump
assembly.
A 0,50 mm (0.020 in)

B 12,7 - 13,0 mm (0.500 - 0.511 in)
C 8,70 - 9,00 mm (0.343 - 0.354 in)
D 39 mm dia (1.54 in dia.)
E 10,0 ‘mm (0.394 in)
F 7,0 mm (0.28 in)
G 6,0 mm (0.24 in)
H 80,0 mm (3.15 in)
I 27,95 - 28,05 mm (1.101 - 1.104 in)
J 5,0 mm (0.20 in)
K 3,000 - 3,010 mm dia, 6,0 mm depth
(0.1182 - 0.1185 in dia, 0.24 in depth)
L 9,0 mm (0.35 in)
M 5,0 mm (0.020 in)
N 14,45 - 14,55 mm (0.5689 - 0.5728 in)
O 5,0 mm (0.020 in)
P 4,0 mm (0.16 in)

FUEL SYSTEM (CONT’D) NOTE: (See Fuel Injection Pump Removal And
Installation on Page 70-70-12.) for proper
Governor Housing Disassembly And Assembly alignment of the governor connection rod
(Cont’d) procedure. The procedure will require a
special tool as shown on page 70-70-6.
Figure 70-70-18
Figure 70-70-20
3 2 1
P-85095
P-85100
Remove the fuel injection pump assembly. (See Fuel
Injection Pump Assembly Removal And Installation on

Slide off the governor connecting rod (Item 1) [Figure 70-
Page 70-70-3.)
70-19] from the rack pin of injection pump assembly.
Remove the governor lubricating pipe (Item 1) [Figure
For convenient sake, temporarily hook the start spring on
70-70-18].
the rack pin hole of the governor connecting rod.
Remove the stop solenoid (Item 2) [Figure 70-70-18].
Remove the governor housing mounting bolts.
Remove the sight cover (Item 3) [Figure 70-70-18] from
Installation: Tighten the governor housing bolts to 9,81 -
the injection pump unit.
11,2 N•m (7.24 - 8.31 ft-lb) torque.
Figure 70-70-19
Figure 70-70-21
2
1
1
3
P-85099
P-85097
Unhook the start spring (Item 1) from the rack pin (Item
2) [Figure 70-70-19] of injection pump assembly. Remove the governor housing assembly (Item 1) [Figure
70-70-21] from the injection pump unit.
NOTE: The injection pump unit is lubricated with
Installation: Reverse procedure to install. Tighten the
engine oil. Oil will leak when the governor
nut to 2.9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
housing is removed from the injection pump.
NOTE: Be careful not to drop the nut inside.

FUEL SYSTEM (CONT’D) Figure 70-70-24
Governor Disassembly And Assembly
Figure 70-70-22
1
1
2
P-85189
Remove the governor fork lever assembly (Item 1) from

P-85101 the housing [Figure 70-70-24].
Figure 70-70-25
Remove the governor fork shaft lever (Item 1) using a
bolt 4 mm dia. (0.16 in dia.), pitch 0,7 mm (0.03 in) at

least a inch long (Item 2) [Figure 70-70-22].
NOTE: When assembling the inside parts, lightly put 3

oil on each inside part.
Figure 70-70-23 2
1 2
P-85190
Remove the spring pin (Item 1), then remove speed

control lever (Item 2) and the return spring (Item 3)
[Figure 70-70-25].
P-85188
Unhook the governor spring (Item 1) at the fork lever

(Item 2) [Figure 70-70-23].

FUEL SYSTEM (CONT’D)
Governor Disassembly And Assembly (Cont’d)
Figure 70-70-26
P-85192
Remove the start spring (Item 1) [Figure 70-70-26] from

the governor housing.

After reassembling the governor housing assembly,
check the movement of the governor fork lever (Item 2),
the speed control lever, stop lever, governor spring (Item
3) and governor fork lever shaft (item 4) [Figure 70-70-
26].
NOTE: When assembling the inside parts, lightly put

oil on each inside part.
NOTE: Be careful not to deform the start spring.

FUEL SYSTEM (CONT’D)
A M35 x P1.5, 6,0 mm depth (0.24 in depth)
Fuel Camshaft Removal And Installation
B 35,0 mm dia.,12,0 mm depth
Remove the fuel injection pump assembly. (See Fuel (1.38 in dia., 0.472 in depth)
Injection Pump Assembly Removal And Installation on C 30,0 mm dia.,27,5 mm depth
Page 70-70-3.) (1.18 in dia., 1.08 in depth)
D 40,00 - 40,20 mm dia. (1.575 - 1.582 in dia.)
Remove the fuel injection pump unit. (See Fuel Injection
Pump Assembly Removal And Installation on Page 70- E 35,90 - 36,10 mm dia. (1.414 - 1.421 in dia.)
70-3.) F 2.09 rad (120 degrees)
G M8 x P1.25
H 9,0 mm dia (0.35 in dia.)
WARNING I
J
19,0 mm dia. (0.748 in dia.)
12,0 mm (0.472 in)
K 15,0 mm (0.591 in)
Eye and body protection is required when welding or
grinding. Wear approved goggles, helmet and L 27,5 mm (1.08 in)
clothing. Failure to wear eye and body protection can M 31,0 mm (1.22 in)
result in serious injury. N 2.26 in. (57,5 mm)
W-2009-1285
O 3.94 in. (100 mm)
Figure 70-70-27 P 3,75 - 4,00 mm (0.148 - 0.157 in)

Q 16,17 mm (0.6366 in)
a 5,0 mm radius (0.20 in radius)
b 0,40 mm radius (0.016 in radius)
C0.2 Chamfer 0,20 mm (0.0079 in)
C0.5 Chamfer 0,50 mm (0.020 in)
To remove and replace the fuel camshaft, make the tool

as shown in figure [Figure 70-70-27] or purchase part
number below.
MEL1666 - Injection Pump Gear Puller
P-85123

FUEL SYSTEM (CONT'D) F 16,0 mm dia. (0.630 in dia.)
Fuel Camshaft Removal And Installation (Cont’d) G 16,0 mm dia. (0.630 in dia.)
H 32,0 mm (1.26 in)
Figure 70-70-28
I 16,0 mm (0.630 in)
Figure 70-70-30
2
1 2
P-85186A
1
P-85183
Remove the governor sleeve (Item 1) and remove the
two fuel camshaft lock allen screws (Item 2) [Figure 70-

70-28]. Install injection pump housing to the engine and tighten.
Fix the flywheel with the flywheel stop tool (Item 1)
NOTE: Do not use the fuel camshaft locks screws [Figure 70-70-32].
when removing governor weight, otherwise
damage may occur to the allen screws or the Loosen the injection pump gear mounting nut (Item 2)
governor housing. [Figure 70-70-32].
Figure 70-70-29 Installation: Tighten injection pump gear mounting nut to

138 - 156 N•m (102 - 115 ft-lb).
NOTE: The injection pump gear mounting nut is a left

hand thread to loosen turn towards B and to
tighten turn towards A as seen from the
flywheel side
Figure 70-70-31
P-85215 2

70-29].
A 144 mm (5.67 in)

B 104 mm (4.09 in)
P-85121
C 20,0 mm (0.787 in)
D 10,0 mm dia. (0.394 in dia.)
Remove the fuel injection pump gear (Item 1) using the
E 12,0 mm dia. (0.472 in dia.)
tool (Item 2) [Figure 70-70-31].

FUEL SYSTEM (CONT'D) Fuel Injection Pump Removal And Installation
Fuel Camshaft Removal And Installation (Cont’d) Figure 70-70-34
Figure 70-70-32
2
2
1
1
1
3 P-85199
P-85122
Remove all injection pipes (Item 1) [Figure 70-70-34].
Loosen fuel camshaft stopper mounting bolts (Item 1) Remove overflow hose (Item 2) [Figure 70-70-34].
and remove camshaft stopper (Item 2) [Figure 70-70-

32]. Remove fuel stop solenoid (Item 3) [Figure 70-70-34].
Installation: Tighten fuel camshaft stopper mounting Remove sight cover from housing (Item 4) [Figure 70-
bolts to 9,81 - 11,2 N•m (7.24 - 8.37 ft-lb). 70-34].
NOTE: When reassembling fuel camshaft stopper NOTE: The injection pump can be removed and
make sure the oil path hole (Item 3) [Figure 70- installed with the crankshaft at any position.
70-32] is the proper alignment.
Figure 70-70-35
Figure 70-70-33
3 1
1
2
2
P-85099
P-85120
Unhook the start spring (Item 1) from the rack pin (Item 2)
Remove fuel camshaft (Item 1), then remove fuel [Figure 70-70-35] of injection pump assembly.
camshaft stopper bearing screws (Item 2) [Figure 70-70-
33]. Remove the nut (Item 3) [Figure 70-70-35].
If replacing the fuel camshaft bearings tighten the fuel Installation: Reverse procedure to install. Tighten the
camshaft stopper bearing plate screws (item 2) [Figure nut to 2.9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
70-70-33] to 3,9 - 4,2 N•m (2.9 - 3.1 ft-lb) torque.
NOTE: Be careful not to drop the nut inside.

Fuel Injection Pump Removal And Installation

(Cont’d)
Figure 70-70-36
1
2
P-85200
Remove the fuel injection pump (Item 1) [Figure 70-70-

38].
Installation: Reverse procedure to install. Tighten the

P-85100 bolts to 24 - 27 N•m (18 - 20 ft-lb) torque.Tighten nuts to
18 - 20 N•m (13 - 15 ft-lb)
Slide off the governor connecting rod (Item 1) [Figure 70- Remove top cover (Item 2) [Figure 70-70-38] for

70-36] from the rack pin of injection pump assembly. adjusting the governor connecting rod.
Figure 70-70-39
For convenient sake, temporarily hook the start spring on
the rack pin hole of the governor connecting rod.
4
Figure 70-70-37
1 2
3 5
P-85203
1
Hook the governor connecting rod (Item 1) to the rack pin
(Item 2) and hand tighten the nut (Item 3) [Figure 70-70-
P-85198 39].
Place service jig (Item 4) (Refer to page 70-70-6) in place

Remove all of the mounting bolts and nuts (Item 1) of top cover and make sure the magnet is contacting the
[Figure 70-70-37] from the fuel injection pump. governor connecting rod (Item 1) [Figure 70-70-39].
Holding down the service jig tighten the nut to specified
torque.
Hook starter spring (Item 5) to rack pin (Item 2) [Figure

70-70-39].

to 2,9 - 4,0 N•m (2.1 - 2.9 ft-lb) torque.
NOTE: A = 27,95 - 28,05 mm (1.100 - 1.104 in)

Fuel Injection Pump - Timing
IMPORTANT
Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
Remove fuel injection high pressure lines.
P-85104
Remove the fuel shutoff solenoid. (See Fuel Shutoff
Solenoid Removal And Installation on Page 70-70-1.)
Rotate the flywheel counterclockwise (viewed from the
Figure 70-70-40 flywheel side) until fuel fills up the hole of the delivery
valve holder for the number one cylinder as shown in
[Figure 70-70-41] below.
1
Figure 70-70-42

P-85102
Align timing mark between the injection pump assembly

and the flywheel housing (Item 1) [Figure 70-70-40].
P-85098
NOTE: Timing the injection pump is done by rotating

the injection pump assembly up for advance, After fuel fills up the hole of the number one cylinder
down for retard. delivery valve holder (Item 1) [Figure 70-70-42] turn
back the flywheel clockwise 1,6 rad (90°) then turn
counterclockwise to 0,17 rad (10°) before top dead
center.
Slowly turn the flywheel counterclockwise and stop

turning when the fuel begins to come up to get the
present injection timing (Item 1) [Figure 70-70-42].

FUEL SYSTEM (CONT'D) Fuel Injector Removal And Installation
Injection Pump - Timing (Cont’d)
Figure 70-70-43
WARNING
1 W-2072-0807
P-85103
IMPORTANT
Check to see the degree marks on the flywheel (Item 1)
[Figure 70-70-43]. The flywheel has a 1TC mark for the Do not bend the high pressure fuel injection tubes

crank angle before the top dead center of cylinder when removing or installing them.
number one. I-2029-0289
NOTE: If the injection pump timing is not within the

specification, then rotate the injection pump
assembly upwards for advancing, downwards
for retarding injection pump timing.
The injection timing is 0,00960 - 0,0357 rad. (0.550 -

2.05°) before T.D.C.

Fuel Injector Removal And Installation (Cont’d)

1
Figure 70-70-44
P-85117
Remove the overflow pipe (Item 1) [Figure 70-70-45].

P-85085
Installation: Tighten the overflow pipe assembly
retaining screws to 9,81 - 11,2 N•m (7.24 - 8.31 ft-lb)
The following are some problems caused by faulty torque.
injectors:

Figure 70-70-46
-Engine is hard to start or will not start
-Rough engine operation and idle
-Engine will not have full power
-Excessive exhaust smoke
1
Disconnect the high pressure fuel lines (Item 1) [Figure
70-70-44] from the fuel injectors and from the injection
pump.
Remove the high pressure fuel lines from the engine.
Remove the glow plugs. (See Glow Plugs Removal And

Remove the cylinder head valve cover (See Cylinder P-85118

Head Removal And Installation on Page 70-80-4.)
Remove the nozzle holder clamps (Item 1) [Figure 70-

70-46].
Installation: Tighten the nozzle holder clamp screws to

24 - 27 N•m (18 - 20 ft-lb) torque.

FUEL SYSTEM (CONT'D) Fuel Injector Nozzle Pressure - Checking
Fuel Injector Removal And Installation (Cont’d) The tool listed will be needed to do the following
procedure:
Figure 70-70-47
OEM1064 - Injector Nozzle Tester
Figure 70-70-49
P-85119
Remove the injector nozzle (Item 1) [Figure 70-70-47]

3EEABAC1P012A
from the cylinder head.

Pull on the injector nozzle to remove the injector nozzle Set the injection nozzle to the nozzle tester.
from the cylinder head.
Slowly move the tester handle to measure the pressure
Figure 70-70-48 at which fuel begins jetting out from the nozzle.
If the measurement is not within the factory

specifications, replace or repair the injection nozzle
assembly.
1 NOTE: Injection nozzle gasket must be replaced

2
when the injection nozzle is removed for
checking.
Injection Factory 18,6 -19,6 MPa

pressure spec. (186,4 - 96 bar)
(2703 - 2844 psi)
P-37583
[Figure 70-70-48] shows the injector nozzle removed

from the cylinder. Inspect the injector and replace if
necessary.
Check and replace the injector nozzle O-rings (Item 1)

and the nozzle washer (Item 2) before installing new or
used injectors. [Figure 70-70-48].

FUEL SYSTEM (CONT'D) Valve Seat Tightness
Nozzle Spray Condition The tool listed will be needed to do the following
procedure:
procedure: OEM1064 - Injector Nozzle Tester
OEM1064 - Injector Nozzle Tester Figure 70-70-51
Figure 70-70-50
Correct Incorrect
3EEABAC1P014A

3EEABAC1P013A
Set the injection nozzle to a nozzle tester.
Set the injection nozzle to a nozzle tester, and check the Raise the fuel pressure, and keep at 16,7 MPa (166,7
nozzle spraying condition. bar) (2418 psi) for 10 seconds.
If the spraying condition is defective, replace or repair the If any fuel leak is found, replace or repair the injection
injection nozzle assembly. nozzle assembly.
Valve seat tightness Factory spec No fuel leak at

16,7 MPa
(166,7 bar)
(2418 psi)

CYLINDER HEAD Glow Plugs Removal And Installation
Glow Plugs - Testing Figure 70-80-3
Figure 70-80-1 1 2
1 3
2
3
P-85178
P-85178
Disconnect the glow plug nuts (Item 1),remove glow plug
connecting strap (Item 2) and glow plugs (Item 3) [Figure
Disconnect the glow plug nuts (Item 1), remove glow plug 70-80-3].
connecting strap (Item 2) and glow plugs (Item 3) [Figure

70-80-1]. Installation: Tighten the glow plug to 7,7 - 9,3 N•m (5.7 -
6.8 ft-lb) torque.
Installation: Tighten the glow plug to 7,7 - 9,3 N•m (5.7 -
6.8 ft-lb) torque. Figure 70-80-4
Figure 70-80-2
2 1
P-85179
P-85179
NOTE: Adjust the direction of the ditch (Item 1)
[Figure 70-80-4] to the terminal side when the
Touch one probe to the end of the glow plug (Item 1) and seal is installed on the glow plug.
the other probe to the body of glow plug (Item 2) [Figure
70-80-2].
Use an ohmmeter to check the glow plugs.The

resistance should be approximately one ohm.
Repeat the procedure for each glow plug.
NOTE: Adjust the direction of the ditch (Item 3)

[Figure 70-80-2] to the terminal side when the
seal is installed on the glow plug.

CYLINDER HEAD (CONT'D) Valve Clearance Adjustment
Glow Plugs Removal And Installation (Cont’d) Figure 70-80-6
Figure 70-80-5
2
1
3
P-85181
P-48708
Adjust the valve clearance as follows:
Photo [Figure 70-80-5] shows the glow plug removed Loosen the lock nut (Item 1) [Figure 70-80-6].
from the engine. Inspect the glow plugs and replace

when necessary. Turn the adjustment screw (Item 2) [Figure 70-80-6] until
the correct clearance is obtained.
NOTE: The clearance is measured between the

rocker arm and bridge head (Item 3) [Figure
70-80-6].

CYLINDER HEAD (CONT'D) Valve Timing - Checking
Valve Clearance Adjustment (Cont’d) Figure 70-80-9
Figure 70-80-7 3 4
2
4 3 2 1
B 8 7 6 5 4 3 2 1 A
1 P-85974
B-05569
NOTE: (A) is the front cover side, (B) is the flywheel Remove the engine / hydrostatic pump package from the
housing side. loader. (See Engine Removal And Installation on Page

70-10-7.)
Figure 70-80-8
Remove the flywheel. (See Flywheel Removal And
Cylinder Number 1 2 3 4
Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal on Page 70-100-1.)
Valve Number 1 2 3 4 5 6 7 8
Make sure timing marks are in correct alignment [Figure
70-80-9].
Valve Injection Pump Gear (Item 1) [Figure 70-80-9].

I=Intake I E I E I E I E
E=Exhaust Idle Gear (Item 2) [Figure 70-80-9].
Crank Gear (Item 3) [Figure 70-80-9].
Cam Gear (Item 4) [Figure 70-80-9].

Adjust the valve clearance cold as follows:
0,13 - 0,17 mm (0.0052 - 0.0068 in) Intake & Exhaust
Use the following sequence to set the valves [Figure 70-

80-7] & [Figure 70-80-8]:
1. With the No. 1 cylinder set at compression top dead

center set valves 1,2,3 and 6.
2. With the No. 1 cylinder at overlap position set valves

4,5,7 and 8.

CYLINDER HEAD (CONT'D) Figure 70-80-12
Cylinder Head Removal And Installation
Figure 70-80-10 1
4 2 1
P-85118
Remove the nozzle holder clamps (Item 1) [Figure 70-

P-85174 80-12].
Remove the glow plug connecting strap (Item 1), glow Installation: Tighten the nozzle holder clamp bolts to 24
plugs (Item 2), and injection pipes (Item 3) [Figure 70- - 27 N•m (18 - 20 ft-lb) torque.
80-10].

Figure 70-80-13
Remove the valve cover (Item 4) [Figure 70-80-10] and
gasket.
Installation: Gradually tighten the valve cover bolts to
9,81 - 11,2 N•m (7 - 8 ft-lb) torque. Tighten center bolts
first, then work your way to the front and back of the 1
valve cover.
Installation: Tighten injection pipe retaining nuts to 23 -
Installation: Tighten glow plugs to 7,7 - 9,3 N•m (5.7 -
6.8 ft-lb) torque.
Figure 70-80-11
P-85119
1
Remove the nozzle holder assembles and nozzle

gaskets (Item 1) [Figure 70-80-12].
Installation: Tighten the nozzle holder clamp bolts to 24

- 27 N•m (18 - 20 ft-lb) torque.
P-85117
Remove the overflow pipe (Item 1) [Figure 70-80-11].

Installation: Tighten overflow pipe to 9,81 - 11,2 N•m (7 -
8 ft-lb) torque.

Cylinder Head Removal And Installation (Cont'd) 1

2
Figure 70-80-14
1 2
P-85170
Remove the thermostat housing bolts and then remove

P-85115 the housing (Item 1), gasket (Item 2) and thermostat
(Item 3) [Figure 70-80-16].
Remove rocker arm assembly (Item 1)[Figure 70-80-14] Figure 70-80-17

as a unit.

Remove push rods (Item 2) and bridge arms (Item 3)
[Figure 70-80-14].
Figure 70-80-15
P-85168
Remove the cylinder head bolts in order of #10 to #1

[Figure 70-80-17].
P-47245 NOTE: (A) is the front cover side, (B) is the flywheel
housing side.
Installation: The push rod (Item 1) must be seated in the Installation: Put oil on the bolt threads. Tighten the bolts
tappet (Item 2) [Figure 70-80-15] correctly or the push in the correct sequence in order of #1 - #10 to 187 - 196
rods will be damaged. N•m (138 - 144 ft-lb).
After installing the rocker arm assembly and push rods, NOTE: It is not necessary to retighten the cylinder
the valve lash must be adjusted. (See Valve Clearance head bolts after the engine has been run for 30
Adjustment on Page 70-80-2.) minutes.

Cylinder Head Removal And Installation (Cont'd)
Figure 70-80-18 1
P-47252
Find the average measurement of the highest piston

protrusion and the lowest piston protrusion (recorded
P-85171
earlier) for each piston (Item 1) [Figure 70-80-20].
Figure 70-80-21
Remove the cylinder head (Item 1) and gasket (Item 2)
[Figure 70-80-18].

Figure 70-80-19 a b c
2 B
P-85967
When identifying which head gasket you need [Figure

70-80-21] shows the correct number of notches and how
1 they should look (a) 2 notches, (b) 1 notch and (c) no
notch.
A
P-85968
Figure 70-80-22
Gasket Size
When replacing just the head gasket (Item 1), use a new Piston Protrusion
(Number)
gasket that has the same mark (Item 2) [Figure 70-80-
19] as the original gasket. 2 notches 0,0775 - 0,150 mm
0.00306 - 0.00590 in
When replacing the gasket after an engine rebuild, the 0,150 - 0,250 mm
1 notch
piston protrusion must be measured. 0.00591 - 0.00984 in
no notches 0,2500 - 0,3425 mm
(See Cylinder Head Top Clearance on Page 70-80-8.) 0.009843 - 0.01348 in
NOTE: (A) is the front cover side, (B) is the flywheel Select the correct gasket size (thickness) from the chart
housing side. [Figure 70-80-22].
After the gasket and cylinder head have been installed,

turn the crankshaft by hand to be sure there is no
interference between the piston, cylinder, and valves.

CYLINDER HEAD (CONT'D) Cylinder Head - Servicing
Cylinder Head Disassembly And Assembly Clean the surface of the cylinder head.
Figure 70-80-23 Figure 70-80-25
PI-9987 P-51629
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 70-80-25] on the
spring [Figure 70-80-23]. cylinder head.

Figure 70-80-24 NOTE: Do not put the straight edge across
combustion chambers.
Put a feeler gauge (Item 2) [Figure 70-80-25] between

the straight edge and the surface of the cylinder head.
Figure 70-80-26
5
4 Valve
3
6 Spring
2 Retainer
1 Seal
Collets
Cap
B-4122C
Remove the valve cap (Item 1) and valve spring collet

(Item 2) [Figure 70-80-23] and [Figure 70-80-24].
Remove the valve spring retainer (Item 3) and the spring

PI-9988
(Item 4) [Figure 70-80-23] and [Figure 70-80-24].
Remove the seal (Item 6) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides
70-80-23] and [Figure 70-80-24]. and two diagonal as shown in figure [Figure 70-80-26].
The maximum distortion of the head surface is ± 0,05

mm (± 0.002 in). If the measurement exceeds the
specification, replace the cylinder head.

CYLINDER HEAD (CONT'D) Remove the solder (Item 1) [Figure 70-80-28] and
measure it.
Cylinder Head Top Clearance
If the measurement exceeds the specifications, check the
Figure 70-80-27 oil clearance of the crank pin journal or the piston pin.
Top Clearance 0,6 - 0,8 mm (0.024 - 0.031 in)

2
Valve Guide - Checking
1 Remove the valve and spring from the cylinder head.

(See Cylinder Head Disassembly And Assembly on Page
70-80-7.)
Remove the carbon from the valve guide.
Figure 70-80-29
P-85172 1
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 70-80-27] being checked at T.D.C.

Put 4 pieces of 1,5 mm (0.06 in) diameter solder (Item 2)
[Figure 70-80-27] on the top of the piston. Use grease to
hold them in position. 2
NOTE: Put the solder in position so they do not touch

the valves.
B-14335
Turn the piston to bottom dead center.
Install the cylinder head and tighten to the correct torque Measure the valve stem O.D. (Item 1) [Figure 70-80-29].
in the correct sequence. (See Cylinder Head Removal
And Installation on Page 70-80-4.) Measure the valve guide I.D. (Item 2) [Figure 70-80-29].
Turn the crankshaft until the piston exceeds T.D.C. Calculate the clearance. If the clearance exceeds the
Remove the cylinder head. allowable limit, replace the valve and/or valve guide.
Figure 70-80-28
Valve Guide I.D. 7,030 - 7,045 mm
(0.2768 - 0.2773 in)
Valve Stem O.D. 6,960 - 6,975 mm
(0.2741 - 0.2746 in)
Clearance Between 0,055 - 0,085 mm
Valve Stem and Guide (0.0022- 0.0033 in)
Allowable Limit 0,10 mm
(0.0039 in)
P-85173

CYLINDER HEAD (CONT'D) Reconditioning The Valve And Valve Seat
Valve Guide Removal And Installation Figure 70-80-32
Figure 70-80-30
225 mm (8.86”)
20 mm 70mm (2.8”) 45 mm
(0.79”) (1.8”)
11,7-11,9 mm
(0.461-0.468”) 6,50-6,60 mm
(0.256-0.259”)
5,0 mm 8,50-8,90 mm 20,0 mm
(0.2”) (0.335-0.350 “) (0.79”)
6,70-7,00 mm PI-9993
12,5-12,8 mm
(0.264-0.275”) 25,0 mm (0.493-0.503”)
(0.98”)
MC-1364
Grind the valve face to the correct angle using a valve
refacer [Figure 70-80-32].
To remove and replace the valve guide, make the driver
tools as shown in figure [Figure 70-80-30]. Clean the valve seat and combustion chamber.

Figure 70-80-31 Figure 70-80-33
PI-9992 P-51632
Press the used valve guide out of the cylinder head using Install the valve into the guide. Measure the valve
the special driver tool [Figure 70-80-31]. recessing with a depth gauge [Figure 70-80-33].
Put oil on the outside diameter of the new valve guide.

Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 and 2)
[Figure 70-80-31], press the new guide until the tool
contacts the cylinder head.
Ream the valve guide to the correct specifications.

Reconditioning The Valve And Valve Seat (Cont’d) 1

30° Exhaust
Figure 70-80-34 30° Intake
1. Cylinder Head
Surface PI-9995
2. Recessing
3. Protrusion
Check the seat surface and valve face (Item 1) [Figure
PI-9990 70-80-36].
If the measurement exceeds the allowable limit, replace (a) identical dimensions above and below the valve seat
the valve or cylinder head [Figure 70-80-34].
If the seat surface (b) needs correction, slightly correct

the seat using a 45 degree cutter and then resurface the
Recessing 0,65 - 0,85 mm
seat surface with a 15 degree cutter to get the correct
(0.026 - 0.33 in)
width (Item 2) [Figure 70-80-36].
Allowable Limit (Recessing) 1,20 mm (0.0472 in.)
Valve Seat Width
Figure 70-80-35
Intake & Exhaust 3,3 - 3,6 mm
(0.13 - 0.14 in)
Valve Seat & Face Angle
Intake 45 degrees
Exhaust 45 degrees
45° Exhaust
15° Exhaust 45° Intake
15° Intake
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-80-35].

Valve Spring
Figure 70-80-37
A-2759
Put the spring on a tester and compress to specified

B-3680 length [Figure 70-80-38].
Read the compressed load on the gauge. If the

Measure the length of the valve spring. If the measurement exceeds allowable limit, replace the
measurement is less than the allowable limit, replace the spring.

spring [Figure 70-80-37].
Setting Length 31,5 mm (1.24 in)
Free Length 35,1 - 35,6 mm (1.39 - 1.40 in) Setting Load 60,8 N (14.3 lb)
Allowable Limit 34,6 mm (1.36 in) Allowable Limit 45,9 N (10.3 lb)
Put the spring on a flat surface, place a square on the

side of the spring [Figure 70-80-37].
Rotate the spring and measure the maximum tilt. If the

measurement exceeds the allowable limit, replace the
spring.
Tilt Allowable Limit 1,0 mm (0.039 in)

Valve Tappets
Remove the oil pan and oil pump strainer. (See Oil Pan
Remove the idler gear and camshaft. (See Idler Gear
And Camshaft Removal And Installation on Page 70-100-
5.)
1
Figure 70-80-39
1
P-85175
Measure the OD of the tappet (Item 1) [Figure 70-80-41].

tappets.
Tappet OD 9,965 - 9,980mm

(0.3924 - 0.3929 in)
P-85141 Clearance 0,020 - 0,050 mm
Between Tappet (0.00079 - 0.0019 in)
and Tappet
Turn engine with the crankshaft facing up and remove the
Bore
valve tappets (Item 1) [Figure 70-80-39].
Figure 70-80-40
P-85142
Measure the ID of the tappet bore (Item 1) [Figure 70-

80-40].
Tappet Bore ID 10,000 -10,015 mm

(0.39370 - 0.39429 in)
Clearance Between 0,020 - 0,050 mm
Tappet (0.00079 - 0.0019 in)
and Tappet Bore

CYLINDER HEAD (CONT'D) Bridge Arm And Bridge Arm Shaft - Checking
Rocker Arm And Shaft - Checking Figure 70-80-43
Figure 70-80-42
1
1
2
P-85177
B-3697
Measure the bridge arm ID (Item 1) [Figure 70-80-43].
Measure the rocker arm I.D. (Item 1) [Figure 70-80-42] If the clearance exceeds the allowable limit, replace the
with an inside micrometer. bridge arm (Item 1) [Figure 70-80-43].

Measure the rocker arm shaft O.D. (Item 2) [Figure 70- Bridge arm ID. 9,050 - 9,065 mm
80-42] with an outside micrometer. (0.3170 - 0.3181 in)
If the clearance exceeds the allowable limit, replace the Figure 70-80-44
bushing.
If the clearance still exceeds the allowable limit after the

bushing is replace, replace the rocker arm shaft.
Oil Clearance Between Rocker Arm

& Shaft 0,016 - 0,045 mm
(0.00063 - 0.0017 in)
(0.0059 in)
Rocker Arm Shaft O.D. 14,973 - 14,984 mm
(0.58949 - 0.58992 in)
Rocker Arm I.D. 15,0 - 15,018 mm
(0.59056 - 0.59125 in) 1
P-85176
Measure the bridge arm shaft OD (Item 1) [Figure 70-80-

44].

bridge arm shaft (item 1) [Figure 70-80-44].
Oil Clearance between 0,018 - 0,042 mm

Bridge arm and Bridge (0.0.00071 - 0.0016 in)
arm shaft.
Bridge arm shaft OD. 9,023 - 9,8032 mm
(0.3553 - 0.3555 in)

Bridge Arm Shaft - Removal And Installation
Figure 70-80-45
1
P-85972
Remove the used valve bridge arm shaft (Item 1), then
P-85969 clean valve bridge arm shaft mounting hole. Use the
valve bridge arm replacing tool to press in new shaft
[Figure 70-80-46].
Make valve bridge arm shaft replacement tool as shown
above [Figure 70-80-45]. Figure 70-80-47

A 9,50 mm (0.374 in)
1
B 19,0 mm (0.748 in)
2
C 23,2 mm (0.913 in)
D 42,00 - 42,40 mm (1.654 - 1.669 in)
E 12,5 mm dia. (0.492 in dia.) through hole
F 61,0 mm (2.40 in)
G 18,7 mm (0.736 in)
H 30,90 - 31,70 mm (1.217 - 1.248 in)
a 0,30 mm radius (0.012 in radius)
C0.5 Chamfer 0,50 mm (0.020 in)
C1 Chamfer 1,0 mm (0.039 in) P-85973

Install bridge arm shaft (Item 1) using the valve bridge
shaft replacing tool (Item 2) [Figure 70-80-47] to the
proper depth in [Figure 70-80-48].

CYLINDER HEAD (CONT'D) Push Rod Alignment - Checking
Bridge Arm Shaft - Removal And Installation (Cont’d) Figure 70-80-49
Figure 70-80-48
P-76926
P-85970
Place the push rod on V blocks [Figure 70-80-49].
Set the depth of the bridge arm shaft (Item 1) to 31,1 - Measure the push rod alignment [Figure 70-80-49].
31,7 mm (1.23 - 1.24 in) [Figure 70-80-48].

If the push rod exceeds the allowable limit, replace the
push rod.
Push Rod Allowable Limit 0,25 mm

Alignment (0.0098 in)


CRANKSHAFT AND PISTONS Figure 70-90-3
Piston And Connecting Rod Removal And

Installation
Remove the cylinder head. (See Cylinder Head Removal

1
Remove the top edge from the cylinder bore with a ridge
reamer.
Remove the oil pan and oil pump strainer. (See Oil Pan
Figure 70-90-1
P-85143
1 Remove the connecting rod bolts (Item 1) [Figure 70-90-

3].
NOTE: Mark the location of the rod bearings to

prevent them from becoming interchanged.

Installation: Tighten the connecting rod bolts to 69 - 73
Installation: Apply engine oil to the connecting rod bolts

and lightly screw in by hand.
P-85141
Installation: Install the rod bearing with the centrally
lined groove towards the connecting rod, and the non
Figure 70-90-2 grooved side towards the cap.
Top View of Crankcase
Installation: Make sure the marks on the connecting rod
and bearing are aligned and facing the injection pump
when installing the bearing cap.
P-85142
Remove the tappet (Item 1) [Figure 70-90-1] from the

tappet bore (Item 2) [Figure 70-90-2] using a magnetic
tool.
Installation: Apply engine oil to the tappet during

installation.
NOTE: Mark the location of the tappets to prevent

them from becoming interchanged.

CRANKSHAFT AND PISTONS (CONT’D) Piston And Connecting Rod - Servicing
Piston And Connecting Rod Removal And Figure 70-90-6

Installation (Cont’d)
1
Figure 70-90-4
P-85145
P-51633 Installation: When reassembling, align the marks (Item

1) on the connecting rod and piston (Item 2) [Figure 70-
90-6].
Use a hammer handle and push the piston / connecting

rod assembly out of the cylinder bore [Figure 70-90-4]. NOTE: Assemble the piston to the connecting rod
with the mark (Item 2) and the connecting rod
NOTE: Make sure the pistons are marked so they will mark (Item 1) [Figure 70-90-6] facing the
be returned to the same cylinder bore. injection pump side.
Figure 70-90-5
P-85144
Installation: Make sure the marks on the connecting rod

and bearing (Item 1) [Figure 70-90-5] are aligned and
facing the injection pump when installing the bearing cap.
Repeat the procedure to remove the other piston /

connecting rod assemblies from the engine block.

CRANKSHAFT AND PISTONS (CONT’D) Installation: When installing new rings, assemble the
ring so the mark (Item 1) near the gap faces the top of the
Piston And Connecting Rod - Servicing (Cont’d) piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item
Figure 70-90-7 3) [Figure 70-90-8].
Figure 70-90-9
1 2 3 4 5 6
7
4
P-85146
P-47272
Remove the top ring (Item 1), the second ring (Item 2)
and the oil ring (Item 3) [Figure 70-90-7].

Measure the I.D. of the piston pin bore in both horizontal
Remove the snap rings (Item 4) and piston pin (Item 7) and vertical directions [Figure 70-90-9].
[Figure 70-90-7].
If the measurement exceeds the allowable limit, replace
Separate the piston (Item 5) from the connecting rod the piston.
(Item 6) [Figure 70-90-7].
Piston Bore I.D. 28,0 - 28,013 mm
Installation: Heat the piston in clean engine oil to 80°C (1.1024 - 1.1028 in)
(176°F) and tap the piston pin into position. Place the
piston rings so that there are gaps every 120 degrees
(1.104 in)
with no gap facing the piston pin in the cylinder.
NOTE: Mark the piston (Item 5) and connecting rod

(Item 6) [Figure 70-90-7] with the same
number to ensure correct installation and
proper cylinder placement.
Figure 70-90-8
1
3
PI-10015

CRANKSHAFT AND PISTONS (CONT’D) Figure 70-90-11
Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-10
B-3622
Install a piston ring into the lower part of the cylinder

P-47273 bore. Measure the ring gap with a feeler gauge [Figure
70-90-11].
Measure the O.D. of the piston pin (Item 1) [Figure 70- If the gap exceeds the allowable limit, replace the ring.
90-10].

Top Ring Gap 0,25 - 0,40 mm
Measure the I.D. of the connecting rod small end bushing (0.0099 - 0.015 in)
(Item 2) [Figure 70-90-10].
Oil Ring Gap 0,25 - 0,45 mm
(0.0099 - 0.017 in)
Calculate the oil clearance. If the clearance exceeds the
allowable limit, replace the connecting rod. If it still
(0.0492 in)
exceeds the specifications, replace the piston pin.
Second Ring Gap 0,30 - 0,45 mm
Piston Pin O.D. 28,006 - 28,011 mm (0.012 - 0.017 in)
(1.1026 - 1.1027 in)
Bushing I.D. 28,031 - 28,046 mm
(1.1036 - 1.1041 in)
Oil Clearance Between 0,020 - 0,040 mm
Piston Pin & Bushing (0.00079 - 0.0015 in)
(0.0059 in)

CRANKSHAFT AND PISTONS (CONT’D) Cylinder Bore - Checking
Piston And Connecting Rod - Servicing (Cont’d) Figure 70-90-13
Figure 70-90-12
B-4066
PI-10017
Use a gauge to check the inside measurement of the
cylinder bore [Figure 70-90-13].
Remove the carbon from the ring grooves. Measure the
clearance between the ring and groove with a feeler Figure 70-90-14

gauge [Figure 70-90-12].

ring. If the clearance still exceeds the allowable limit,
replace the piston.
Top Ring 0,050 - 0,090 mm

(0.0020 - 0.0035 in)
Second Ring 0,090 - 0,12 mm
(0.0036 - 0.0047 in)
Oil Ring 0,020 - 0,060 mm
(0.0079 - 0.0023 in) P-37163
Measure the six points as shown in figure [Figure 70-90-

14] to find the maximum wear.
The factory specifications are:
94 - 94,022 mm (3.7008 - 3.7016 in).
The allowable limit is 94,15 mm (3.707 in).
If the cylinder bore is not within specifications, bore and

hone to oversize dimension.

CRANKSHAFT AND PISTONS (CONT’D) Crankshaft Gear Removal And Installation
Connecting Rod Alignment Remove the crankshaft. (See Crankshaft And Bearings
NOTE: The small end bushing is the basis of this
check, check the bushing for wear before Figure 70-90-16
doing this check.
Install the piston pin into the connecting rod. 3
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate. 1
2
Figure 70-90-15 4
2
P-85149
Remove the crankshaft sleeve (Item 1), the crankshaft

gears (Item 2), the seal (Item 3) and the key (Item 4)
[Figure 70-90-16].
Installation: Install a new seal (Item 3) when servicing

[Figure 70-90-16].
B-4067 Figure 70-90-17
If the gauge does not fit squarely against the face plate,
measure the space between the gauge and face plate
[Figure 70-90-15].
If the measurement exceeds the allowable limit, replace

the connecting rod.-
Rod Alignment 0,05 mm (0.002 in)
1
2
3
P-85148
Installation: Heat the crankshaft sleeve (Item 1) [Figure

70-90-16] and [Figure 70-90-17] to 150 - 200°C (302 -
392°F). Install the crankshaft sleeve onto the crankshaft
using the crankshaft sleeve guide (Item 2) and the
crankshaft replacing tool (Item 3) MEL - 1660 [Figure 70-
90-17].
Installation: Install the crankshaft sleeve (Item 1) with

the chamfered surface facing outward [Figure 70-90-17].

Crankshaft Gear Removal And Installation (Cont’D)
Figure 70-90-18
2
0,850 - 1,15 mm (0.0335 - 0.0452 in)
2
1 3
P-85153
Remove crankcase 2 (Item 2) from crankcase 1 (Item 1)

P-85150 [Figure 70-90-20].
Remove the crankshaft (Item 3) [Figure 70-90-20].

Installation: When installing the crankshaft sleeve
(Item 1) allow for a space (Item 2) [Figure 70-90-18] Figure 70-90-21

from the end of the crankshaft to the edge of the
crankshaft sleeve.
Crankshaft And Bearings Removal And Installation
Remove the piston and connecting rod assemblies. (See

Piston And Connecting Rod Removal And Installation on
Page 70-90-1.)
Figure 70-90-19
P-85995
This tool is used for aligning the crankcase 1 and

crankcase 2. Make two of these tools.
A 126,6 mm (4.984 in)

B 49,1 mm (1.93 in)
C 37,5 mm (1.48 in)
D 20 mm (0.79 in)
P-85151 E 14 mm dia. (0.55 in dia.)
F 14 mm dia. (0.55 in dia.)
G 14 mm dia. (0.55 in dia.)
Remove the crankcase mounting screws in order from Z
H 17,5 mm (0.689 in)
to A [Figure 70-90-19].
I 17,5 mm (0.689 in)
J 35 mm (1.4 in)
Installation: Tighten the crankcase mounting bolts from
A to J to 138 - 147 N•m (102 - 108 ft-lb) K 19 mm (0.75 in)
Installation: Tighten the crankcase mounting bolts from Material (Item 1) [Figure 70-90-21]: SS400
K to Z to 59 - 63 N•m (44 - 47 ft-lb).

Crankshaft And Bearings Removal And Installation

(Cont’d)
1
Figure 70-90-22
P-85156
Apply oil to the thrust bearings and install the crankshaft

(Item 1) [Figure 70-90-24].
1
P-85157 Figure 70-90-25
NOTE: Make sure both crankcases are clean and dry

before assembling. 3
Install the bearings (Item 1) into the crankcase 2 (Item 2)

[Figure 70-90-22].
2
Install the thrust bearings (Item 3) [Figure 70-90-22] with
the groove facing out.
1
Figure 70-90-23
1 4
P-85996
2 Align and install crankcase 2 (Item 2) to crankcase 1

(Item 1) [Figure 70-90-25].
Apply engine oil to the crankcase mounting bolts and

hand tighten from A to J and then K to Z [Figure 70-90-
19].
3 Install the jig (Item 3) [Figure 70-90-25] and tighten to 78
- 90 N•m (58 - 66 ft-lb)
NOTE: The jig helps to minimize the level difference

P-85155 between the crankcase 1 and crankcase 2 at
the flywheel side. The gap must be 0,05 mm
Install the bearings (Item 2) into the crankcase 1 (Item 1) (0.002 in) or smaller.
[Figure 70-90-23]. Tighten the crankcase mounting bolts from A to J to 138 -
147 N•m (102 - 108 ft-lb)
Install the thrust bearings (Item 3) [Figure 70-90-23] with
the groove facing out. Tighten the crankcase mounting bolts from K to Z to 59 -
63 N•m (44 - 47 ft-lb).
Carefully apply liquid gasket evenly (Item 4) to the
crankcase 1 (Item 1) [Figure 70-90-23]. Remove the jig (Item 3) [Figure 70-90-25].

CRANKSHAFT AND PISTONS (CONT’D) If the misalignment exceeds the allowable limit, replace
the crankshaft.
Crankshaft And Bearings - Servicing
Alignment 0,02 mm (0.0008 in)
Figure 70-90-26
Figure 70-90-28
2 2
1
P-85159
P-85160
Set a dial indicator with its tip on the end of the crankshaft
(Item 1) [Figure 70-90-26]. Place plastigage on the crankshaft (Item 3) [Figure 70-

90-28].
Measure the side clearance by moving the crankshaft
side to side (Item 2) [Figure 70-90-26]. Place crankcase 2 (Item 2) on crankcase 1 (Item 1)
[Figure 70-90-28] and torque the bolts.
If the misalignment exceeds the allowable limit, replace
the crankshaft. Torque the bolts A to Z [Figure 70-90-19]. (See
Crankshaft And Bearings Removal And Installation on
Side clearance of Factory Spec. 0,15 - 0,35 mm Page 70-90-7.)
crankshaft (0.0059 - 0.013 in)
Allowable limit 0,50 mm (0.020 in.) Remove crankcase 2 (Item 2) [Figure 70-90-28] and
measure the amount of the flattening with the scale to
Figure 70-90-27 determine the oil clearance.
Crankshaft Factory Spec. 79,977 - 79,990 mm

Journal O.D. (3.1487 - 31.1492 in)
Oil clearance Factory Spec. 0,030 - 0,073 mm
between (0.0012 - 0.0028 in)
crankshaft Allowable limit 0,20 mm
journal and (0.079 in)
crankshaft
bearing
A-2763
Put the crankshaft on V-blocks. Install a dial indicator on

the center journal [Figure 70-90-26].
Turn the crankshaft at a slow rate to obtain the

misalignment (one half of the alignment measurement).

Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-29
P-37145
Clean the crank pin and crank pin bearing.

P-85161
Put a strip of plastigage [Figure 70-90-30] on the center
of the crank pin.
Reference of undersize dimensions of crankshaft journal
[Figure 70-90-29]. NOTE: Never insert the plastigage into the crank pin

oil hole. Be sure not to move the crankshaft
Undersize 0,2 mm 0,4 mm while the connecting rod screws are
(0.0079 in) (0.016 in) tightened.
Dimension A 2,8 - 3,2 mm 2,8 - 3,2 mm
radius radius Install the connecting rod cap and tighten the connecting
(0.11 - 0.12 in (0.11 - 0.12 in rod screws to the specified torque, and remove the cap
radius) radius) again.
*Dimension 1,0 - 1,5 mm relief 1,0 - 1,5 mm Measure the amount of the flattening with the scale, and
B (0.040 - 0.059 in relief get the oil clearance.
relief) (0.040 - 0.059 in
relief) If the oil clearance exceeds the allowable limit, replace
Dimension C 79,777 - 79,790 79,577 - 79,590 the crank pin bearing.
mm dia. mm dia.
(3.1409 - 3.1413 (3.1330 -3.1334 If the same size bearing cannot be used because of the
in dia.) in dia.) crank pin wear, replace it with an undersized one
referring to the table.
The crankshaft journal must be fine-finished to higher
than ————(0.8-S) Crankpin Factory spec. 49,980 - 49,991 mm
*Holes are to be de-burred and edges rounded with O.D. (1.9678 - 1.9681 in)
relief
1.0 - 1.5 mm (0.040 - 0.059 in) Oil clear- Factory spec. 0,011 - 0,058 mm
ance (0.00067 - 0.0018 in)
between Allowable 0,20 mm (0.0079 in)
crank pin and limit
crank pin
bearing

Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-31
P-85162
2
Undersize dimensions of crankpin.
P-37147
Undersize 0,20 mm 0,40 mm
(0.0079 in) (0.016 in)
NOTE: To replace it with a specific STD service part,
make sure the crank pin bearing has the same Dimension 3,3 - 3,7 mm radius 3,3 - 3,7 mm
A (0.13 - 0.14 in radius

ID color as the connecting rod [Figure 70-90-
31]. radius) (0.13 - 0.14 in
radius)
ID Connecting rod Crank pin bearing *Dimen- 1,0 - 1,5 mm relief 1,0 - 1,5 mm
Color sion B (0.040 - 0.059 in relief
Large-end in. dia. Class Center wall thick
relief) (0.040 - 0.059 in
Blue 53,010 - 53,010 L 1,496 - 1,501 relief)
mm mm
Dimension 49,780 - 49,791 49,580 - 49,591
(2.0870 - 2.0874 (0.05890 -
C mm dia. mm dia.
in) 0.05909 in)
(1.9599 - 1.9602 in (1.9520 - 1.9524
with- 53,000 - 53,010 S 1,491 - 1,496 dia.) in dia.)
out mm mm
(0.8-S)
Color (2.0867 - 2.0870 (0.05870 -
The crank pin must be fine-finished to higher than ——
in) 0.05889 in)
——
*Holes to be de-burred and edges rounded with relief.
1,0 -1,5 mm (0.040 - 0.059 in)


CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal
Remove the flywheel. (See Flywheel Removal And

Remove the housing. (See Housing Removal And

Figure 70-100-1

P-90121
Remove the eight outside timing gearcase cover

mounting bolts (Item 1) [Figure 70-100-1].
Remove the eight inside timing gearcase cover mounting

bolts (Item 2) [Figure 70-100-1].
Remove the timing gearcase cover (Item 3) [Figure 70-

100-1].

CAMSHAFT AND TIMING GEARS (CONT’D)
Timing Gearcase Cover Installation
Figure 70-100-2
P-90004A
A 70,0 mm (2.76 in)

B 8,0 mm (0.31 in)

C 22,0 mm (0.866 in)
D 30,0 mm (1.18 in)
E 87,0 mm dia.
(3.43 in dia.)
F 82,036 - 82,071 mm dia.
(3.2298 - 3.2311 in dia.)
G 77,0 mm dia.
(3.03 in dia.)
H 57,0 mm dia. (2.24 in dia.)
I 35,0 mm dia. (1.38 in dia.)
J 30,0 mm dia. (1.18 in dia.)
K 84,0 mm (3.31 in)
L 3,5 mm (0.14 in)
M 3,0 mm (0.12 in)
N 6,60 - 6,80 mm (0.260 - 0.267 in)
O 8,0 mm (0.31 in)
P 67,0 mm dia. (2.64 in dia.)
Q 4,0 mm dia. (0.16 in) through hole
a Ra = 1.6 a
b 1,5 mm radius (0.059 in radius)
c Ra = 3.2 a
d 0,80 mm radius (0.031 in radius)
C0.5 Chamfer 0,50 mm (0.020 in)
C1.0 Chamfer 1,0 mm (0.039 in)
Make timing gearcase cover guide tool [Figure 70-100-

2].

CAMSHAFT AND TIMING GEARS (CONT’D) b Ra = 1.6 a
Timing Gearcase Cover Installation (Cont’d) c 0,80 mm radius (0.031 in radius)
d 1,5 mm radius (0.059 in radius)
Figure 70-100-3
e 0,20 mm radius (0.0079 in radius)
C0.3 Chamfer 0,30 mm (0.012 in)
Make timing gearcase oil seal replacing tool [Figure 70-
100-3].
Figure 70-100-4

P-85218
P-90006
Make timing gearcase guide screws as shown above
A 118 mm (4.65 in) [Figure 70-100-4].
B 12,0 mm (0.472 in) Figure 70-100-5

C 0,90 - 1,0 mm (0.36 - 0.039 in)
D 10,0,0 mm (0.394 in)
E 80,0 mm (3.15 in) 2
F 10,0,0 mm (0.394 in)
1
G 120 mm dia.
(4.72 in dia.)
H 100,90 - 101,10 mm dia.
(3.9725 - 3.9803 in dia.)
I 86,966 - 86,988 mm dia
.(3.4239 - 3.4247 in dia.)
J 79,0 mm dia. (3.11 in dia.) 3
K 15,0 mm dia. (0.591 in dia.) P-85999
L 30,0 mm dia. (1.18 in dia.)

M 13,0 mm (0.512 in) Apply engine oil to the timing gearcase oil seal (Item 1)
[Figure 70-100-5].
N 90,00 mm (3.54 in)
O 2,50 mm (0.0984 in) Install timing gearcase guide screws (Item 2) [Figure 70-
P 0,35 rad (20 degrees) 100-5].
Q 0,15 - 0,25 mm (0.0059 - 0.0098 in)
Install timing gearcase using the guide (Item 3) [Figure
a Ra = 3.2 a 70-100-5].

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-8
Timing Gearcase Cover Installation (Cont’d)
Figure 70-100-6
P-85997B
1
Tighten the seven outside timing gearcase cover
P-85998 mounting bolts (Item 1) [Figure 70-100-8].
Tighten the six inside timing gearcase cover mounting

Apply a liquid gasket (Three Bond 1217H) (Item 1) bolts (Item 2) [Figure 70-100-8].
[Figure 70-100-6] to the two crankcase seams.

Installation: Tighten the timing gearcase cover bolts to
Figure 70-100-7 103 - 117N•m (76 - 86 ft-lb) [Figure 70-100-8].
P-85217
Install timing gearcase oil seal using the timing gearcase

oil seal replacing tool (Item 1) [Figure 70-100-7].

CAMSHAFT AND TIMING GEARS (CONT’D) Idler Gear And Camshaft Removal And Installation
Timing Gears Backlash - Checking Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal on Page 70-100-1.)
When the gears are installed, check the backlash of the
gears. Remove the valve tappets. (See Valve Tappets on Page
70-80-12.)
Figure 70-100-9
Figure 70-100-10
1 2 3
1
2
4
P-85205
P-90008

Install a dial indicator to individually check backlash for
cam gear (Item 1), idle gear (Item 2), injection pump gear Rotate entire engine with the crankshaft (Item 1) [Figure
(Item 3) and crank gear (Item 4) [Figure 70-100-9]. 70-100-10] facing up to remove the tappets
Hold one gear while turning the other gear [Figure 70- Remove the three camshaft set bolts (Item 2) and
100-9]. remove the cam (Item 3) [Figure 70-100-10].
If the backlash exceeds the allowable limit, check the oil Remove the idle gear mounting bolts (Item 4) and
clearance of the shaft and gear. If the oil clearance is remove idle gear (Item 5) [Figure 70-100-10].
correct, replace the gear.
Installation: Make sure the timing marks are in correct
Crank Gear & Cam Gear 0,0410 - 0,139 mm alignment when installing the timing gears.
(0.00162 - 0.00547 in)
(0.0087 in)
Cam Gear & Idler Gear 0,0410 - 0,134 mm
(0.00162 - 0.00527 in)
(0.0087 in)
Injection Pump Gear & Idler 0,0410 - 0,134 mm
Gear (0.00162 - 0.00527 in)
(0.0087 in)

CAMSHAFT AND TIMING GEARS (CONT’D) Figure 70-100-13
Camshaft - Servicing
Figure 70-100-11
1 2
1
P-85212
2
Measure the camshaft journal (Item 1) and journal (Item

P-85209 2) [Figure 70-100-13].
Calculate the oil clearance. If the clearance exceeds the

Mount a dial indicator and check cam gear (Item 1) end allowable limit, replace the camshaft.
play (Item 2) [Figure 70-100-11].

Cylinder Block Bore 1 35,000 - 35,025 mm
Installation: Check the camshaft end play. If clearance I.D. (1.3780 - 1.3789 in)
exceeds the allowable limit, replace the camshaft retainer
Cylinder Block Bore 2 44,000 - 44,025 mm
plate [Figure 70-100-11].
I.D. (1.7323 - 1.7332 in)
Camshaft Journal 1 O.D. 34,934 - 34,950 mm
Camshaft End Play 0,10 mm (0.0039 in)
(1.3754 - 1.3759 in)
Allowable Limit
Camshaft Journal 2 O.D. 43,934 - 43,950 mm
(1.7297 - 1.7303 in)
Figure 70-100-12
Oil Clearance of Cam- 0,050 - 0,091 mm
shaft Journal (0.0020 - 0.0035 in)
(0.0059 in)
P-47263
Measure the cylinder block bore in the engine block

[Figure 70-100-12].

CAMSHAFT AND TIMING GEARS (CONT’D) Turn the camshaft at a slow rate. If the misalignment
exceeds the allowable limit, replace the camshaft.
Camshaft - Servicing (Cont’d)
Camshaft Alignment Allowable Limit 0,01 mm
Figure 70-100-14 (0.0004 in)
2 Idler Gear And Shaft - Servicing

1
Figure 70-100-16
P-85214
2
Measure the cam lobes at their highest point (Item 2)
[Figure 70-100-14].
P-85207

If the measurement is less than the allowable limit,
replace the camshaft (Item 1) [Figure 70-100-14]. Mount a dial indicator and check idle gear (Item 1) end
play (Item 2) [Figure 70-100-16].
Cam Lobe Height Intake 37,50 mm (1.476 in)
Cam Lobe Height Exhaust 37,90 mm (1.492 in) Installation: Check the idler gear end play. If the
clearance exceeds the allowable limit, replace the gear
Allowable Limit Intake 37,00 mm (1.457 in)
collar.
Allowable Limit Exhaust 37,40 mm (1.472 in)
Idler Gear End Play 0,15 - 0,25 mm
Figure 70-100-15 (0.0059 - 0.0098 in)
P-85213
Put the camshaft (Item 1) in V-blocks. Install a dial

indicator [Figure 70-100-15].

CAMSHAFT AND TIMING GEARS (CONT’D) Make this idle gear bushing replacing tool as shown
above [Figure 70-100-18].
Idler Gear And Shaft - Servicing (Cont’d)
A 196 mm (7.72 in)
Figure 70-100-17 B 25,00 mm (0.984 in)
C 150 mm (5.91 in)
D 34,5 mm dia. (1.36 in dia.)
E 38,075 - 38,100 mm dia. (1.4991 - 1.5000 in dia.)
F 20 mm dia. (0.79 in dia.)
1 2 a 0,0063 mm (0.000248 in)
b 0,0063 mm (0.000248 in)
Figure 70-100-19
1 2
P-85208
Measure idle gear bushing ID (Item 1) and idle gear shaft

OD (Item 2) [Figure 70-100-17].

Idler Gear Shaft O.D. 34,959 - 34,975 mm
1.3764 - 1.3769 in)
Idler Gear Bushing I.D. 35,025 - 35,050 mm
(1.3790 - 1.3799 in)
Oil Clearance Between 0,050 - 0,091 mm
Idler Shaft & Gear Bushing (0.0020 - 0.0035 in)
P-85210
(0.0039 in)
When removing idle gear bushing, press out bushing as
Installation: If the oil clearance exceeds the allowable shown above (item 1) [Figure 70-100-19].
limit, replace the idle gear bushing.
When replacing idle gear bushing, press in bushing as
Figure 70-100-18 shown above (item 2) [Figure 70-100-19].
P-85211

TURBOCHARGER Testing
Description Remove the turbocharger. (See Removal And Installation

on Page 70-110-2.)
Figure 70-110-1
Radial Clearance
Figure 70-110-2
1
1
P-85976
The turbocharger is placed between the exhaust and

P-76099
intake manifolds. It is driven by hot exhaust gases and

supplies air at more than atmospheric pressure to the
intake. It is lubricated by oil from the main galley. The Move the compressor / turbine wheel (up and down /
location of the turbo is between the engine and the right and left) (Item 1) [Figure 70-110-2].
blower housing.
If the wheel contacts the housing, replace the
The oil flows to the turbo by a tubeline (Item 1) and turbocharger assembly with a new one.
returns to the engine block through another tubeline
(Item 2) [Figure 70-110-1]. Check the oil tubelines for leaks.
The turbocharger internal components are not

serviceable.

TURBOCHARGER (CONT’D) Figure 70-110-4
WARNING
Turbochargers, operate at high speed and high 1
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
Remove the muffler. (See Removal And Installation on P-85978

Page 70-30-1.)
Remove the two exhaust manifold cover bolts (Item 1)
Remove the air cleaner. (See Housing Removal And
[Figure 70-110-4].
Figure 70-110-5
Figure 70-110-3

1
1
1
1
P-85979
P-85975
Remove the eight exhaust manifold bolts (Item 1)

Disconnect the two oil pipes (Item 1) [Figure 70-110-3].
[Figure 70-110-4].
Installation: Tighten the two tubelines (Item 1) [Figure
Installation: Tighten the eight bolts (Item 1) [Figure 70-
70-110-3] to 16 - 19 N•m (12 - 14 ft-lb) torque.
110-3] to 24 - 27 N•m (17.7 - 19.9 ft-lb) torque.

TURBOCHARGER (CONT’D)
Figure 70-110-6
P-85127
Remove the turbocharger assembly (Item 1) [Figure 70-

110-6].

Installation: During installation replace all gaskets with
new ones.


FLYWHEEL AND HOUSING Figure 70-120-2
Flywheel Removal And Installation
Remove the engine / hydrostatic pump package from the

loader. (See Engine Removal And Installation on Page
70-10-7.)
Remove the drive belt shield. (See DRIVE BELT on Page

30-60-1.)
Remove the drive belt tension pulley. (See Tensioner

Pulley Removal And Installation on Page 30-60-4.)
Remove the drive belt. (See DRIVE BELT on Page 30-

60-1.) P-85215
Figure 70-120-1
120-2].
A 144 mm (5.67 in)

B 104 mm (4.09 in)

C 20,0 mm (0.787 in)
D 10,0 mm dia. (0.394 in dia.)
E 12,0 mm dia. (0.472 in dia.)
F 16,0 mm dia. (0.630 in dia.)
G 16,0 mm dia. (0.630 in dia.)
1 2
H 32,0 mm (1.26 in)
P-85138
I 16,0 mm (0.630 in)
Figure 70-120-3
Remove the six mounting bolts (Item 1) from the pulley
(Item 2) [Figure 70-120-1].
Remove the pulley (Item 2) [Figure 70-120-1].
P-85218
Make flywheel guide bolts as shown above to aid in

removal and installation of flywheel [Figure 70-120-3].

FLYWHEEL AND HOUSING (CONT’D) Figure 70-120-5
Flywheel Removal And Installation (Cont’d)
Figure 70-120-4
P-85140A
Install two bolts (Item 1) [Figure 70-120-5] into the

P-85074 threaded holes on the flywheel and tighten to remove
flywheel.
Install flywheel stop tool (Item 1) [Figure 70-120-4]. Figure 70-120-6

Remove two flywheel bolts and replace them with the
flywheel guides bolts to aid in removal (Item 1) [Figure
70-120-3].
Remove the seven mounting bolts (Item 2)[Figure 70- 1

120-4] from the flywheel.
Installation: Apply engine oil to the bolts and tighten to

98,1 - 107 N•m (72.4 - 79.5 ft-lb) torque.
NOTE: Do not use a impact wrench. Serious damage

will occur. There is one positioning pin in the
crankshaft gear and it is installed in the
flywheel. P-85140
Install two guide bolts (Item 1) [Figure 70-120-6] to aid in

installation of the flywheel.

FLYWHEEL AND HOUSING (CONT’D) Housing Removal And Installation
Ring Gear Removal And Installation Remove the engine / hydrostatic pump package from the
loader. (See Engine Removal And Installation on Page
Figure 70-120-7 70-10-7.)
Remove the drive belt shield. (See DRIVE BELT on Page

30-60-1.)
Remove the drive belt tension pulley. (See Tensioner

Pulley Removal And Installation on Page 30-60-4.)
Remove the drive belt. (See DRIVE BELT on Page 30-

60-1.)
Remove the starter. (See Removal And Installation on

Page 60-40-1.)
1 Remove the flywheel. (See Flywheel Removal And

P-48850 Installation on Page 70-120-1.)
Figure 70-120-8
The ring gear (Item 1) [Figure 70-120-7] on the flywheel
is an interference fit. Heat the ring gear enough to

expand the gear. Hit the ring gear evenly around the gear
to remove it from the flywheel.
Clean the outer surface of the flywheel thoroughly so the

new ring gear will fit smoothly onto the flywheel. 1
Clean the new ring gear and heat it to a temperature of 2

232 - 260°C (450 - 500°F).
1
Fit the ring on the flywheel and be sure the gear is seated
correctly.
P-85137
Remove the four mounting bolts (Item 1) and the housing

(Item 2) [Figure 70-120-8].



EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Description
Exhaust Gas Recirculation (EGR) is a system in which the exhaust gas with lean oxygen is cooled and returned to the
cylinders again in order to lower the combustion temperature.
An External / Mechanical EGR consists of a water cooled EGR cooler, mechanical EGR valve, reed valve and thermo
valve. When the coolant temperature is high and the boost pressure is low, the EGR valve will not open. If the coolant
temperature is high and the boost pressure is also high, the EGR valve will open allowing cooled gas back into the intake
manifold.
The reed valve between the EGR valve and the intake manifold prevents fresh air from flowing into EGR system.
Figure 70-130-1
3
12
11

2
1
7 5
13
2
7
9
15
10
9
14
P-85105
The items listed below refer to [Figure 70-130-1].
1. Thermo Valve
2. Mechanical EGR Valve 9. Cooled EGR Gas
3. Cylinder Head 10. To The Intake Manifold
4. Reed Valve 11. Fresh Air
5. EGR Cooler 12. Cooled EGR Gas Merges With Fresh Air
6. Intake Manifold 13. Exhaust Gas
7. Boost Pressure 14. Coolant Inlet
8. Coolant Temperature 15. Coolant Outlet

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Cold Engine Coolant Temperature Test
(CONT'D)
Start the engine and run at low idle.
Testing
Start Service Analyzer and select [Monitor].
There are two tests for checking the EGR system. Both
tests will need to be performed and the coolant Select [Engine Temperature].
temperature must be monitored through the Service
Analyzer.
The Cold Engine Coolant Temperature Test will need to WARNING

be performed with the engine coolant below 55°C
(131°F). The Hot Engine Coolant Temperature Test will
AVOID BURNS
need to be performed with the engine coolant above
Some surfaces of the Exhaust Gas Recirculation
70°C (158°F).
system can be hot. Use caution when conducting
diagnostic tests.
Allow the engine to cool before servicing.

WARNING W-2716-0208
AVOID INJURY OR DEATH NOTE: Verify the engine temperature is below 55°C
When the engine is running during service, the (131°F). If the engine temperature is above
steering levers or joysticks must be in neutral and 55°C (131°F), let the engine cool down and
restart the Cold Engine Coolant temperature

the parking brake engaged.
W-2717-0208 Test.
NOTE: Monitor the engine coolant temperature using

the Service Analyzer.
MACHINE FALLING OR MOVING CAN CAUSE

SERIOUS INJURY OR DEATH
Put jackstands under the front and rear of the
machine before running engine for service.
W-2718-0208
1
1.)
Open the rear door.
Connect the Service PC (See SERVICE PC (LAPTOP

COMPUTER) on Page 60-150-1.) P-85108
Measure the surface temperature of the EGR system
WARNING (Item 1) [Figure 70-130-2] with an Infrared Thermometer.
If the engine coolant temperature is below 55°C (131°F)

AVOID INJURY OR DEATH and the surface temperature of the EGR system is 150°C
When an engine is running in an enclosed area, fresh (302°F) or below, the EGR system is OK, Continue with
air must be added to avoid concentration of exhaust the Hot Engine Coolant temperature Test.
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible If the surface temperature of the EGR system reads
gases which can kill without warning. 150°C (302°F) or above continue this Cold Engine
W-2050-0807 Coolant Temperature Test.

EXHAUST GAS RECIRCULATION (EGR) SYSTEM Figure 70-130-5
(CONT'D)
Testing (Cont’d)
Figure 70-130-3
P-85108

(Item 1) [Figure 70-130-5] with an Infrared Thermometer.
P-85984
With the engine coolant temperature above 70°C (158°F)
Disconnect the boost hose (Item 1) [Figure 70-130-3] and the surface temperature of the EGR system 150°C
from the EGR valve. (302°F) or above, the EGR system is OK.

Figure 70-130-4 If the surface temperature of the EGR system is 150°C
(302°F) or below continue this Hot Engine Coolant
Temperature Test.
Figure 70-130-6
P-85108

P-85980
If the surface temperature of the EGR system declines,
the thermo valve has failed. Disconnect the intake hose (Item 1) [Figure 70-130-6].
If the surface temperature of the EGR system stays

above 150°C (302°F), the EGR valve has failed.
Hot Engine Coolant Temperature Test
Verify the engine temperature is above 70°C (158°F), if

the engine temperature is below 70°C (158°F) run the
engine to bring the temperature above 70°C (158°F) then
continue with the Hot Engine Coolant Temperature Test.

(CONT'D)
Testing (Cont’d)
Figure 70-130-7
P-85108

P-85984
If the surface temperature of the EGR system increases,

the thermo valve has failed.
Disconnect the EGR hose (Item 1) [Figure 70-130-6].

If the surface temperature of the EGR system is 150°C
Figure 70-130-8 (302°F) or below, the EGR valve has failed.
1
2
P-85981
Connect a hose (Item 1) directly between the intake

manifold (Item 2) and the EGR valve (Item 3) [Figure 70-
130-8].

(CONT'D)
1 1
2
1
WARNING
4
AVOID BURNS
Some surfaces of the Exhaust Gas Recirculation
system can be hot. Use caution when conducting 3
diagnostic tests.
1
Allow the engine to cool before servicing. P-85110
W-2716-0208
Allow the engine to cool before working on the EGR Remove the four EGR cooler mounting bolts (Item 1) and
system. the EGR system assembly (Item 2) [Figure 70-130-11].
Figure 70-130-10 Installation: Replace the gaskets (Items 3 and 4)

[Figure 70-130-11] with new ones.

Figure 70-130-12
1
3
P-85982
2
Disconnect and cap the EGR valve coolant hoses (Item P-85113
1) [Figure 70-130-10].
Disconnect the boost pressure hose (Item 2) [Figure 70- NOTE: The gasket (Item 3) [Figure 70-130-11] and
130-10]. [Figure 70-130-12] is marked with the letter
“F” and must be installed downward.

(CONT'D)
Disassembly And Assembly 4
Figure 70-130-13 3
6
4
8 5
4
2
1 7
6 1
5 P-85111
3
2
4 Remove the two mounting bolts (Item 1) from the EGR
valve (Item 2) and EGR valve flange (Item 6) [Figure 70-
P-85112 130-14].
Remove the two mounting bolts (Item 3) from the reed

Remove the two mounting bolts (Item 1) from the EGR valve (Item 5) [Figure 70-130-14].

cooler flange (Item 2) [Figure 70-130-13].
Remove and replace the gaskets (Item 4) [Figure 70-
Remove and replace the gasket (Item 3) [Figure 70-130- 130-14].
13].
Installation: When reassembling replace with new
Remove the four bolts (Item 4) from the EGR cooler (Item gaskets.
5) and the EGR valve (Item 7) [Figure 70-130-13].
Remove and replace the gasket (Item 6) [Figure 70-130-

13].
Remove the thermo valve (Item 8) [Figure 70-130-13].
Installation: When reassembling replace with new

gaskets.
NOTE: If the thermo valve is dropped it must be

replaced with a new one.
Installation: Tighten the thermo valve to 30 - 39 N•m (22

- 28 ft-lb) torque.

HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-6
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Compressor Drive Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Compressor Drive Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Service Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . . . . 80-30-1
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . . . 80-30-1

The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . . . 80-30-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-8
Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-30-11
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-12
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-18
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-19
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Refrigerant Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Reclamation And Charging With Recovery / Charging Unit . . . . . . . . . . . . . . . . . . . 80-40-2
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Pressure Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-2
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-3
Schraeder Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4

EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-110-1

HEATER COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1

BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1


AIR CONDITIONING SYSTEM FLOW
Description
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2.) takes in low temperature, low pressure refrigerant gas through the
suction valve (low pressure side) and as the name indicates, pressurizes the refrigerant and forces it through the discharge
valve (high pressure side) and to the condenser (Item 2) (See Chart on Page 80-10-2.)
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver / drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver / drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.)
The expansion valve meters the amount of refrigerant entering the evaporator coil (Item 5) (See Chart on Page 80-10-2.)
As the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature,
low-pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown across the evaporator by the evaporator fan
(Item 6) (See Chart on Page 80-10-2.) Since the refrigerant is colder than the air, it absorbs the heat from the air which
results in cooled air, which is pushed into the cab by the blower. The moisture in the air condenses on the evaporator coil

and drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the low temperature low pressure gas is again drawn into the compressor.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6

1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Desiccant
3 Receiver Drier
Status Of R134a_______________________________________________
High Pressure Gas Low Pressure Liquid
High Pressure Liquid Low Pressure Gas
b-16691

AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3
Components
1
Figure 80-10-1
2
P-89545
Receiver/Drier: The receiver / drier (Item 1) [Figure 80-

P-89538 10-3] is the unit that receives the liquid refrigerant from
the condenser and removes moisture and foreign matter
from the system. It also serves as a storage tank for the
Compressor: The compressor (Item 1) [Figure 80-10-1] extra liquid refrigerant until it is needed by the evaporator.
is the pump that circulates the refrigerant throughout the

system. It raises the pressure of the refrigerant for heat Figure 80-10-4
transfer through the condenser and evaporator.
NOTE: The A/C system (Compressor) is

recommended to be turned on for at least 5
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-10-2 1
1 N-22206
Pressure Relief Valve: The pressure relief valve (Item 2)

[Figure 80-10-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [Figure 80-10-
4] is a safety feature that is designed to open and release
the A/C charge if the pressure reaches 3,7 MPa (36,9
P-85824 bar) (535 psi).
Condenser: The condenser (Item 1) [Figure 80-10-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

Components (Cont'd)
Figure 80-10-5 4 2
3
1
P-89497
1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
P-92602 10-7] cools and dehumidifies the air before it enters the
cab.
Heater / Evaporator Unit: The heater / evaporator unit Thermostat: The thermostat (Item 2) [Figure 80-10-7]
(Item 1) [Figure 80-10-5] is located behind the loader controls the temperature of the evaporator coil.

cab. The unit delivers the cold air for the A/C and warm
air for heat into the cab. The unit contains the blower, Heater Coil: The heater coil (Item 3) [Figure 80-10-7]
heat & A/C coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-10-6
Heater / Evaporator Blower: The blower (Item 4) [Figure
80-10-7] is used to push air through the heater and
evaporator coils and into the cab.
P-92659
Expansion Valve: The expansion valve (Item 1) [Figure

80-10-6] controls the amount of refrigerant entering the
evaporator coil.

Components (Cont'd)
Figure 80-10-8
1
1
2
3
4 P-89545
Pressure Switch: The pressure switch (Item 1) [Figure

P-92638 80-10-10] will disengage the compressor clutch at high
pressure readings over 2647,6 kPa (26,5 bar) (384 psi.)
on the high side, or at very low pressure of 193,0 kPa
Control Panel: The panel (Item 1) [Figure 80-10-8] has (1,9 bar) (28 psi) or less on the high side, which indicates
three separate components. loss of refrigerant.

Fan Switch: This is a four position rotary switch (Item 2)
[Figure 80-10-8]. When the fan switch is in the off
position the A/C will not engage, but the heat valve will
operate, as it is controlled by the ignition power.
A/C Switch: The rocker switch (Item 3) [Figure 80-10-8]

will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure 80-

10-8] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.
Figure 80-10-9
P-90353
Heater Valve: The heater valve (Item 1) [Figure 80-10-9]

is used to control the amount of engine coolant that flows
to the heater coil.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Safety Equipment
WARNING
Figure 80-10-11
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
R-134a inside a canister or in an A/C system is a liquid

under pressure. When it escapes or releases into the air,
ITS TEMPERATURE DROPS TO -5.8°C (21.6°F)
“INSTANTLY”. If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-10-12] to prevent frost bite if you
should get refrigerant on your hands.
P16398
Figure 80-10-12
WARNING

HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
P16399 refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
In servicing A/C and heater systems you will be exposed W-2373-0500
to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
10-11] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is
absolutely required.

REGULAR MAINTENANCE Recirculation Filter (Earlier Models)
Filters Figure 80-20-2
Fresh Air Filters
Figure 80-20-1 1
3
2
2
1 P-90490A
The recirculation filter is located behind the operators

seat inside the operators cab. Flip the clamps (Item 1)
P-90489A P-90492A holding the filter up and remove the filter (Item 2) [Figure
80-20-2].

The fresh air filters are located behind the side windows
outside the operators cab. (Right side shown) Remove Shake the filter or use a vacuum to clean. This can be
the clamping knob (Item 1) and filter cover (Item 2) done several times before replacement is required.
[Figure 80-20-1].
Install the filter into the opening and flip the clamps down
Shake the filter (Item 3) [Figure 80-20-1] or use low to hold the filter in place.
pressure air to remove dirt. This can be done several
times before replacement is required. Install the filter, Recirculation Filter (Later Models)
filter cover and clamping knob.
Figure 80-20-3
1
P100755
The recirculation filter is located behind the operator’s

seat inside the operator cab. The filter cover is held in
place with three clips. Pull the cover at each end (Item 1)
[Figure 80-20-3] to remove.
Rinse the filter elements with water or use a vacuum to

clean. Do not use solvents.
Line up the clips on the filter cover with the slots provided
and push the cover into place.

REGULAR MAINTENANCE (CONT’D) Figure 80-20-5
Compressor Drive Belt Adjustment
The air conditioning belt is a special maintenance free

type that is pretensioned over the pulleys. This belt
eliminates the need for a tensioning device and does not
require periodic adjustment. Contact your Bobcat dealer
for replacement parts.
Compressor Drive Belt Replacement

1
Figure 80-20-4
P-85993
Use a prybar at the two leverage points (Item 1) [Figure

1 80-20-5] to move the air conditioning pump until the
bottom air conditioning pump mounting bolt (Item 2)
[Figure 80-20-4] can be installed.
Tighten the three mounting bolts (Items 1 and 2) [Figure

80-20-4].
2 Close the rear door.
Condenser
P-85942A
The condenser should be cleaned with the oil cooler and
the radiator.
NOTE: The engine is shown removed for visual
clarity. Air Conditioning Lubrication
Loosen the top air conditioning pump mounting bolts Run the air conditioning for about five minutes every
(Item 1) [Figure 80-20-4]. week to lubricate the internal components.
Remove the bottom air conditioning pump mounting bolt

(Item 2) [Figure 80-20-4].
Move the air conditioning pump toward the engine as far

as it will go and remove the belt from the pulleys.
Inspect the pulleys for wear.
Install new belt.

REGULAR MAINTENANCE (CONT’D)
Air Conditioning Service Chart
Service Company/Phone Number:

Date:
Machine Model: Machine Dealer:
Machine Serial Number: Customer:
Machine Hours:
Pre Service Conditions 15 Minutes 30 Minutes Notes
Ambient Temperature:
Louver Temperature:
Cab Temperature At Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

Explain Services Required:
Post Service Conditions 15 Minutes 30 Minutes Notes

Ambient Temperature:
Louver Temperature:
Cab Temperature at Head Position:
Temperature Into Condenser:
High Side Pressure
Low Side Pressure
Ambient Humidity
Observations:

REGULAR MAINTENANCE (CONT’D) Later Models
Evaporator / Heater Coil Raise the operator cab. (See Raising on Page 10-30-2.)
Earlier Models Figure 80-20-8
Figure 80-20-6
P100756
Unhook cover latches (Item 1) [Figure 80-20-8] and

P-90419A remove the cover.

Figure 80-20-9
Remove cover screws (Item 1) [Figure 80-20-6] and
remove the cover.
Figure 80-20-7 1
P100757
2
Use low pressure air or water to remove debris from the

P-90420A heater coil (Item 1) and evaporator (Item 2) [Figure 80-
20-9].
Use low pressure air or water to remove debris from the Install the cover and lower the operator cab. (See
heater coil (Item 1) and evaporator (Item 2) [Figure 80- Lowering on Page 10-30-3.)
20-7].
Install the cover and lower the operator cab. (See

Lowering on Page 10-30-3.)

TROUBLESHOOTING
Blower Motor Does Not Operate
Possible Cause Inspection Solution

1. Blown fuse. Inspect the fuse/wiring. Replace fuse/repair wiring.
2. Broken wiring or bad Check the fan motor ground and connectors. Repair the wiring or connector.
connection.
3. Fan motor malfunction. Check the lead wires form the motor with a circuit Replace Motor.
tester.
4. Resistor malfunction. Check resistor using a circuit tester. Replace Resistor.
5. Fan motor switch malfunc- Check power into and out of the fan switch. Replace Fan Switch.
tion.
Blower Motor Operates Normally, But Air Flow Is Insufficient

1. Evaporator inlet obstruction. Check evaporator for plugging. Remove obstruction and clean
evaporator fins with air or
water.
2. Air leak. Check to make sure air ducts are properly con- Repair or adjust.
nected and seals are not damaged.

3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.
(frozen evaporator).
4. Plugged cab filters Check cab recirculation and fresh air filters. Clean or replace filters.
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal

1. System low on refrigerant. The high side pressure will be low and bubbles Repair any leaks and recharge
may be present in sight glass on receive drier. the refrigerant to the correct
level.
2. Excessive refrigerant. The high pressure side pressure will be high. Use refrigerant recovery
equipment to capture excess
refrigerant. Charge to the cor-
rect refrigerant level.
The Compressor Does Not Operate At All, Or Operates Improperly

1. Loose belt. The belt is vibrating or oscillating. Replace belt.
2. Internal compressor mal- The compressor is locked up and the belt slips. Replace compressor.
function.
Magnetic clutch related
3. Low battery voltage. Clutch slips. Recharge the battery.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch surface. Clutch slips. Replace or clean the clutch
surface.
6. Open coil. Clutch does not engage and there is no reading Replace clutch.
when a circuit tester is connected between the coil
and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and Repair.
ground. connections.
8. Wiring harness compo- Test the conductance of the pressure switch, ther- Check operation / thermostat
nents. mostat, Relay, etc. LED status.

TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 30 - 38°C (86 - 96°F)
and compressor speed of approximately 3200 RPM are:
High pressure side pressure: 1447,9 - 1827,1 kPa (14,5 - 18,3 bar) (210 - 265 psi)
Low pressure side pressure: 103,4 - 227,5 (1,0 - 2,3 bar) (15 - 33 psi)
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Defective compres- The high and low pressure side gauge pressures equal- Replace compressor.
sor. ize when the magnetic clutch is engaged.
Low pressure side Too
low.
1. Low refrigerant The high side pressure will be low and bubbles may be Repair any leaks and recharge
charge. present in sight glass on receiver drier. the refrigerant to the correct

level.
2. Clogged or closed The expansion valve’s inlet side is frosted. Moisture or Clean or replace the expansion
expansion valve. other contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat malfunc- The evaporator is frozen. Adjust thermostat’s tempera-
tion. ture setting or probe place-
ment or replace thermostat.
5. Restriction in Excessive frost on receiver drier. Replace receiver drier.
receiver drier.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the
formance. operating. fan.
2. Excessive refriger- The high pressure side pressure will be high. Use refrigerant recovery equip-
ant. ment to capture excess refrig-
erant. Charge to the correct
refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and compres-
sor. Measure oil from compres-
sor and add correct oil charge
back into compressor. Flush
system with nitrogen. Replace
drier.
4. Air in system. Pressure is high on both high and low sides. Evacuate and recharge with
refrigerant.
5. Restriction in drier, High pressure side will be high, and low pressure side Evacuate and flush system
condenser or high pres- will be low. replacing defective parts.
sure line.

Gauge Pressure Related Troubleshooting (Cont'd)

High pressure side Too
low.
1. Low refrigerant charge. The high side pressure will be low. Repair any leaks and
recharge the refrigerant to
the correct level.
System pressures Equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not pump- Equal high and low pressures. Replace compressor.
ing.

Troubleshooting Tree
P-90410

Troubleshooting Tree (Cont’d)
P-90411

P-90412

P-90413

Temperature / Pressure Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP F PSIG TEMP F PSIG
16 15.69 93 110.20
18 17.04 94 112.10
20 18.43 95 114.10
22 19.87 100 124.30
24 21.35 102 128.50
26 22.88 104 132.90
28 24.47 106 137.30
30 26.10 108 141.90
32 27.79 110 146.50
34 29.52 112 151.30
36 31.32 114 156.10
38 33.17 116 161.10
40 35.07 118 166.10
42 37.03 120 171.30

44 39.05 122 176.60
45 40.09 124 182.00
50 45.48 126 187.50
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00
85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 165 320.10
92 108.20 170 340.80

Temperature / Pressure Chart (Cont’d)
Evaporator
Pressures represent gas temperatures inside the coil. not the coil surface. For an estimate of the temperature of the air
coming off the coil add -13 - -12°C (8 - 10°F) to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 4.4°C (40°F) to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient Temperature=90°F

90°F
+40°F
130°F condenser temperature=200 psig
Conditions and pressures will vary from system to system. Check with MCC for system specifications.

TROUBLESHOOTING (CONT'D) Check the A/C condenser for dirt or mud and clean if
necessary. (See Removal And Installation on Page 80-
Poor A/C Performance 60-1.)
Start the loader, lock the park brake, and engage the A/C Check the A/C evaporator coil for dirt or mud and clean if
system with the blower fan on High. Run the loader at full necessary. (See Removal And Installation on Page 80-
throttle for approximately 15 minutes, with the loader cab 110-1.)
door closed.
Check the engine coolant to see if it is bypassing the
Figure 80-30-1 heater valve. (See Engine Coolant Bypassing The Heater
Valve on Page 80-30-18.)

P-90356
Figure 80-30-2
N-22411
Check the temperature at the louvers (Item 1) [Figure

80-30-1] with a thermometer [Figure 80-30-2].
The louver temperature should be between 2,2 - 11,6°C

(45 - 53°F.) depending on the amount of humidity in the
air and ambient temperature.
If louver temperature is too high. (See Troubleshooting

Tree on Page 80-30-4.)
Check the blower for proper operation, or noise, and

replace if necessary. (See Removal And Installation on
Page 80-130-1.)

HVAC Repair And Leaks
Figure 80-30-3
P-85954
Whenever the A/C system is opened to the atmosphere

or there has been a leak in the system, the receiver/drier

(Item 1) [Figure 80-30-3] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.

TROUBLESHOOTING (CONT'D) Figure 80-30-6
Electrical System
Check to see if the compressor clutch is engaging.

1
With an operator in the loader seat and the cab door
open, turn the loader key switch to RUN OR press the
RUN Button, without starting the loader.
Figure 80-30-4
P-90357
Locate the loader harness and the compressor clutch

wire (Item 1) [Figure 80-30-6].
2
1 Disconnect the loader harness (Item 1) [Figure 80-30-6]
from the compressor clutch wire.

Figure 80-30-7
P-92638
Push the A/C switch (Item 1) to the ON position. Turn the

blower switch (Item 2) [Figure 80-30-4] to the first ON
position.
1
The compressor clutch should make a click sound, which
indicates the clutch is engaging.
Figure 80-30-5
P-90358
1 With a multi meter, check the resistance to the

compressor clutch (Item 1) [Figure 80-30-7].
If there is no resistance value, replace the compressor

clutch.
P-85412
If the compressor clutch does not engage, check the

HVAC fuse (Item 1) [Figure 80-30-5] located in the fuse
panel.
Open the rear door (tailgate).

Electrical System (Cont'd)
Figure 80-30-8
P-90360
1
Using a multi meter check the loader wiring harness

P-90358 (Item 1) [Figure 80-30-10] for voltage.
The voltage should be around 12 volts.

With a multi meter, check the voltage to the compressor
clutch at the loader harness (Item 1) [Figure 80-30-8]. If there is no voltage at the wiring harness, check the

harness for broken wires.
The voltage reading should be around 12 volts.
Figure 80-30-11
If there is no power at the clutch, check the wiring
If there is power at the clutch, reconnect the wiring

harness to the compressor clutch.
Figure 80-30-9
1
P-90360
If there is voltage at the harness, check the resistance at

2
the pressure switch (Item 1) [Figure 80-30-11].
If there is no resistance value, check for low refrigerant

1 P-90361 level. (See Reclamation And Charging With Recovery /
Charging Unit on Page 80-40-2.)
Disconnect the loader harness (Item 1) from the pressure If a resistance value is seen, the pressure switch is good.
switch (Item 2) [Figure 80-30-9].
Reconnect the loader harness to the pressure switch.

TROUBLESHOOTING (CONT'D) If there is a resistance value, check the blower.
Electrical System (Cont'd) Figure 80-30-14
Figure 80-30-12
P-90363
P-90363
Disconnect the blower wiring connector (Item 1) [Figure
80-30-14] from the loader wiring harness.
Figure 80-30-15

Disconnect the thermostat wiring connector (Item 1
[Figure 80-30-12] from the loader wiring harness.
Figure 80-30-13
1
2 P-90362
1
Check the loader harness (Item 1) [Figure 80-30-15] for
P-90362 voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the

Check the loader harness (Item 1) [Figure 80-30-13] for harness for broken wires.
voltage. The voltage should be 12 volts.
If there is voltage at the wiring harness, check the
If there is no voltage at the wiring harness, check the resistance to the blower at the blower wiring connector
harness for broken wires. (Item 2) [Figure 80-30-15].
If there is voltage at the wiring harness, check the If there is no resistance value replace the blower. (See
thermostat (Item 2) [Figure 80-30-13] for resistance. Removal And Installation on Page 80-130-1.)
The resistance value of the thermostat should be 10 Ohm If there is a resistance value check the climate controls at
at 20°C (68°F). the control panel inside the loader cab.
If there is no resistance value, replace the thermostat.

(See Removal And Installation on Page 80-90-2.)

Figure 80-30-16 C
H
B
1 M
N-22288
If there is voltage at the wiring harness, check the blower

P-90364 switch [Figure 80-30-18] for resistance.
With the switch in the 1 position, there should be

Remove the control panel (Item 1) [Figure 80-30-16] resistance between C terminal and the B terminal. And
from the left side lower panel. also between the C terminal and the L terminal frame

[Figure 80-30-18].
Figure 80-30-17
resistance between C terminal and the B terminal. And
also between the C terminal and the M terminal frame
[Figure 80-30-18].

resistance between C terminal and the B terminal. And
1 also between the C terminal and the H terminal frame
[Figure 80-30-18].
If any of the above resistance tests fail, replace the

blower switch.
If the above resistance tests are good, check the A/C

P-90365 switch.
Disconnect the loader wiring harness (Item 1) [Figure

80-30-17] from the blower switch.
Check the loader harness for voltage. The voltage should

be 12 volts.


TROUBLESHOOTING (CONT’D) If no resistance value is found, replace the A/C switch.
Electrical System (Cont’d) If a resistance value is found, check the potentiometer.
Figure 80-30-19 The potentiometer will effect the A/C system and also
effect the operation of the heater.
If heater valve does not open, or close, or the A/C does

not work, check the potentiometer.
1
Figure 80-30-21
1
P-90367
At the loader cab, disconnect the loader harness (Item 1)

[Figure 80-30-19] from the A/C switch.

Check the harness for voltage. The voltage should be 12
P-90366
volts.
If there is no voltage at the wiring harness, check the At the loader cab, disconnect the loader harness (Item 1)
harness for broken wires. [Figure 80-30-21] from the potentiometer.
Figure 80-30-20 Check the loader harness (Item 1) [Figure 80-30-21] for
voltage. The voltage should be 12 volts.

1
2
N-22289
If there is voltage at the wiring harness, check the A/C

switch [Figure 80-30-20] for resistance.
With the switch in the OFF position there should be no

resistance between any of the three terminals on the A/C
switch.
With the switch in the ON position there should be

resistance between terminal (Item 1) and terminal (Item
2) [Figure 80-30-20].

TROUBLESHOOTING (CONT’D) Figure 80-30-24
Figure 80-30-22
A C
A C
B
N-22290
B
The resistance between the wire terminal A and wire

N-22290 terminal B frame [Figure 80-30-24] should be around 0 K
Ohm.
If there is voltage at the wiring harness, check the Check the resistance between the wire terminal C and
potentiometer [Figure 80-30-22] for resistance. wire terminal B frame [Figure 80-30-24] should be

around 10 K Ohm.
The resistance should be 10K Ohm between wire pin A
and wire pin C frame [Figure 80-30-22].
If no resistance is found replace the potentiometer.
Figure 80-30-23
P-90368
To check the resistance of the white wire, turn the

potentiometer control (Item 1) [Figure 80-30-23]
counterclockwise to the full A/C position.

TROUBLESHOOTING (CONT’D) Engine Coolant Bypassing The Heater Valve
Electrical System (Cont'd) Raise the lift arms and install an approved lift arm support
Figure 80-30-25
Figure 80-30-27
2 3
1 1
P-90369
P-90364A
To check the resistance of the white wire, turn the

potentiometer control (Item 1) [Figure 80-30-25] Push the A/C switch (Item 1) to the OFF position, turn the
blower switch (Item 2) to position 1, then turn the

clockwise to the full Heater position.
temperature control (Item 3) [Figure 80-30-27]
Figure 80-30-26 counterclockwise to the full A/C position, with the loader
ignition switch OFF.

REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.)
A C
Start the loader and run at high idle, for ten minutes.
Figure 80-30-28
N-22290
Check the resistance between the wire terminal A and

wire terminal B frame [Figure 80-30-26] should be 1
around 10 K Ohm.
Check the resistance between the wire terminal C and

wire terminal B frame [Figure 80-30-26] should be
around 0 K Ohm.
P-90371
If the resistance is not found replace the potentiometer.

Check the heater hose (Item 1) [Figure 80-30-28] for
temperature.
If the hose is hot, the heater valve is leaking by, and

needs to be replace.

Heater Valve Not Opening Or Closing
Figure 80-30-29
P-90370
NOTE: The HVAC assembly is removed for photo

2 3 clarity.
1
Place the remote start tool on the left fender of the loader,
P-90364A so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-30], as the key of the remote

start is turned to the ON position without starting the
Push the A/C switch (Item 1) to the OFF position, turn the loader. The heater valve should rotate. Place a mark on
blower switch (Item 2) to position 1 and turn the the loader shaft.
temperature control (Item 3) [Figure 80-30-29] to the
High A/C position, with the loader ignition switch OFF. Turn the remote start key to the OFF position and remove
the remote start tool from fender.
Lower operator cab.
REMOTE START TOOL KIT-MEL1563 on Page 10-60- Turn the temperature control (Item 3) [Figure 80-30-29]
1.) to the High Heater position, with the loader ignition switch
OFF.
Raise the operator cab.
Place the remote start tool on the left fender of the loader,
so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-30], as the key of the remote
start is turned to the ON position without starting the
loader. The heater valve should rotate.
If it does not rotate, check the potentiometer for proper

function. (See Electrical System on Page 80-30-12.)
Replace the heater valve. (See Removal And Installation

on Page 80-140-1.)


SYSTEM CHARGING AND RECLAMATION Connect the Refrigerant Identifier to its power source.
Refrigerant Identification Follow the steps displayed on the refrigerant identifier

screen.
Allow two minutes for the refrigerant identifier to display

WARNING the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
refrigerant can cause severe injuries to eyes. In Disconnect the refrigerant identifier from the loader A/C.
gas. If the refrigerant is dangerous or flammable, it must be
W-2371-0500 evacuated from the A/C system into a separate container
and properly and safely disposed of.
Figure 80-40-1
If R134a is found, evacuate the system.
1

N-23024
NOTE: It is recommended to identify the type of

refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-40-1]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems
that are reclaimed and charged from your
MEL1581 Recovery/Recycling/Recharging
Machine.
NOTE: This test is run with the loader engine OFF,

and the A/C switch in the OFF position.

Connect the Refrigerant Identifier to the low pressure

hose.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-3
Reclamation And Charging With Recovery / Charging

Unit

Figure 80-40-2
N-22291
IMPORTANT: Only trained technicians should

perform the reclaiming and recharging.
WARNING

P-90372
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
Locate the low pressure port (Item 1), and high pressure if it contacts the eyes and may cause serious
port (Item 2) [Figure 80-40-2]. frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
WARNING • NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
In the event of a leak, wear safety goggles. Escaping of 134A to the system must be done by a competent
refrigerant can cause severe injuries to eyes. In refrigeration dealer who has the proper equipment,
contact with a flame, R134a refrigerant gives a toxic knowledge, and experience to service refrigeration
gas. equipment.
W-2371-0500 W-2373-0500
Use an approved recovery / charging unit [Figure 80-40-

3] to evacuate the system.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-6

Unit (Cont'd)
Figure 80-40-4
N-22292
Turn the reclaimer unit [Figure 80-40-6] to the ON

position and follow the on screen instructions.
P-90374
NOTE: The A/C system holds 0,68 kg (1.5 lb) of
refrigerant.
Figure 80-40-5

Figure 80-40-7
P-90373
N-22381
Connect the reclaimer to the loader A/C charge ports

(Item 1) [Figure 80-40-4]. NOTE: The reclaimer unit, has a complete step by
step set of instructions [Figure 80-40-7] to
Connect the Blue hose (Item 2) [Figure 80-40-5] to the follow for reclamation and recharging of the
low pressure port and open the valve. A/C system. A trained technician should
follow these instructions as they may vary
Connect the Red hose (Item 3) [Figure 80-40-5] to the slightly depending on the model and brand of
high pressure port and open the valve. reclaimer used.


COMPRESSOR

WARNING
support device. (See Installing on Page 10-20-1.) In the event of a leak, wear safety goggles. Escaping
Raise the operator cab. (See Raising on Page 10-30-2.) contact with a flame, R134a refrigerant gives a toxic
gas.
Evacuate the A/C system. (See Reclamation And W-2371-0500
Charging With Recovery / Charging Unit on Page 80-40-
2.)
Figure 80-50-3
Open the rear door.
Figure 80-50-1

1
P-89543
Remove the compressor hoses (Item 1) [Figure 80-50-3]

P-90357 from the compressor.
Installation: Tighten the compressor hoses to 29,8 N•m

Disconnect the loader harness (Item 1) [Figure 80-50-1] (22 ft-lb) torque.
from the compressor clutch wire.
Cap and plug the compressor hoses and the fittings with
Figure 80-50-2 with the proper A/C caps and plugs.
Figure 80-50-4
1
2 1
P-89538
P-89534
Remove the compressor mount bolt (Item 1) and the belt

(Item 2) [Figure 80-50-2]. Remove the compressor mount bolts and nuts (Item 1)
[Figure 80-50-4].
Installation: Tighten the compressor mount bolt to 46 Remove the compressor from the loader.
N•m (34 ft-lb) torque.

COMPRESSOR (CONT'D) If the amount of refrigerant in the system has decreased,
charge the system. (See SYSTEM CHARGING AND
Oil RECLAMATION on Page 80-40-1.)
Figure 80-50-5 Open the cab door and windows.
Run the blower at maximum speed.
Run the compressor for at least 20 minutes at 800 - 1200

1 RPM.
Remove the compressor from the loader. (See Removal

P-90486
The compressor (Item 1) [Figure 80-50-5] is factory filled

with 150 - 170 cc's of PAG 100 oil (Poly Alkelene Glycol).

Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
• When ever the evaporator, condenser or receiver-

drier is replaced.
• Whenever the refrigerant has leaked from the system.
When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce of oil should be
added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG 100 oil should be used, and never

mix R-12 and R-134a Oils.
The compressor oil should be checked as follows when

oil is being added to an in service loader.
There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. Therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run in advance to
ensure return of oil to the compressor.

COMPRESSOR (CONT'D) Figure 80-50-8
Oil Check
Figure 80-50-6
1
P-90486
NOTE: After draining the oil through the drain hole

P-90487 and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
Figure 80-50-7 8] several times by hand.

Measure the drained oil in a measuring cylinder.
Check the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
Figure 80-50-9
P-16534A
Remove the oil drain plug (Item 1) [Figure 80-50-6] and

drain the oil through the connectors and the oil drain hole 1
[Figure 80-50-7].
Installation: Tighten the oil drain plug to 13 - 15 N•m (9.4

- 10.8 ft-lb) torque.
P-90487
Add new compressor oil through the suction side

Installation: Add 150 - 170 cc's of PAG 100 oil.
NOTE: The suction port on the compressor is marked

with an SUC and is the larger port on the
compressor.


CONDENSER Figure 80-60-2

Remove the rear grille. (See Removal And Installation on 1

Page 50-60-1.)
Remove the refrigerant from the A/C system. (See

Unit on Page 80-40-2.)
P-89546
Figure 80-60-1

routes from the condenser to the receiver / dryer.
Cap and plug the hose and the condenser fittings with
1 the proper A/C caps and plugs.

Figure 80-60-3
P-85824 1
Remove the two brackets (Item 1) [Figure 80-60-1].
WARNING P-89548

refrigerant can cause severe injuries to eyes. In Disconnect the hose (Item 1) [Figure 80-60-3] that
contact with a flame, R134a refrigerant gives a toxic routes from the condenser to the compressor.
gas.
W-2371-0500 Cap and plug the hose and the condenser fittings with
the proper A/C caps and plugs.
Remove the condenser.


RECEIVER / DRIER Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
Receiver / Drier Removal And Installation
Cap and plug the hoses and the receiver / drier fittings
with the proper A/C caps and plugs.
WARNING NOTE: When replacing a receiver / drier in an A/C

system 30 in3 (1 fl oz) of PAG 100 oil must be
added to the system when recharging.
Figure 80-70-2
W-2059-0598
Remove the rear grille. (See Removal And Installation on

Page 50-60-1.)

Reclamation And Charging With Recovery / Charging 1

WARNING P-90493
In the event of a leak, wear safety goggles. Escaping Note the flow direction on the receiver / drier (Item 1)
refrigerant can cause severe injuries to eyes. In [Figure 80-70-2] for proper installation.
gas.
W-2371-0500
Figure 80-70-1
P-90488
NOTE: Mark the A/C hoses (Item 1) [Figure 80-70-1]

for proper installation.
Remove the two A/C hoses (Item 1) [Figure 80-70-1]

from the receiver / drier.

RECEIVER / DRIER (CONT’D) Pressure Relief Valve Removal And Installation
Receiver / Drier Removal And Installation (Cont’d) Figure 80-70-5
Figure 80-70-3
1
N-22205
P-92665
The pressure relief valve (Item 1) [Figure 80-70-5] is
located on the receiver / drier.
Loosen the two clamps (Item 1) and remove the receiver
/ drier (Item 2) [Figure 80-70-3]. Figure 80-70-6

Figure 80-70-4
N-22206
P-89521
The pressure relief valve [Figure 80-70-6] is designed to
open and release the A/C charge if the pressure reaches
Remove the two mount bolts (Item 1) [Figure 80-70-4] 3,7 MPa (36,9 bar) (535 psi).
from the receiver / drier mount bracket.
This will cause the A/C system to shut down, saving the
compressor.
The pressure relief valve is a secondary protection

device in the A/C system, with the pressure switch
shutting down the system at 2,6 MPa (26,5 bar) (384 psi).
NOTE: If a pressure relief valve is found open, check

the A/C system for problems. Replace the
complete receiver / drier unit.

RECEIVER / DRIER (CONT’D) Figure 80-70-8
Pressure Switch Removal And Installation
Figure 80-70-7
1
1 P-90488
Remove the pressure switch (Item 1) [Figure 80-70-8]

P-90361 from the A/C high pressure hose.
Remove the pressure switch from the loader.

Disconnect the loader wire harness (Item 1) [Figure 80-
70-7] from the pressure switch wire harness.

NOTE: The pressure switch can be changed without
evacuating the A/C system.
WARNING
gas.
W-2371-0500

RECEIVER / DRIER (CONT’D)
Schraeder Valve Removal And Installation
Figure 80-70-9
N-22166
The schraeder valve (Item 1) [Figure 80-70-9] is located

in the A/C high pressure hose and is located under the

pressure switch.

Remove the pressure switch.
With a schraeder valve removal tool, remove the valve

from the hose.

EVAPORATOR / HEATER UNIT Figure 80-80-3

Evacuate the A/C system. (See Reclamation And

Charging With Recovery / Charging Unit on Page 80-40- 1
2.)
2
Figure 80-80-1 2
P-90421
NOTE: Support the evaporator / heater unit before

1 1 removing the mounting hardware.

Figure 80-80-4
P-90363
3
Disconnect the expansion / heater unit wiring (Item 1)

[Figure 80-80-1].
2
Figure 80-80-2
3 1
P-90422
1 Disconnect the two A/C hoses (Item 1) [Figure 80-80-4].
Cap and plug the hoses and the expansion valve fittings
Installation: Tighten the A/C hoses to 29,8 N•m (22 ft-lb)

P-90423 torque.

NOTE: Cap the heater hoses and the heater valve
with plugs to prevent coolant loss from the Remove the two nuts (Item 3) [Figure 80-80-4].
system.
Remove evaporator / heater unit from the loader.
Remove the two hoses (Item 1) [Figure 80-80-2].


THERMOSTAT 4. Short circuit protection (Output shorted to ground)
Description 5. Temperature sensor open and short detection
The Electronic De-icing Thermostat (EDT) is a micro

DETECTION
controller based module that measures evaporator coil MALFUNCTION STATUS LED
INTERVAL
temperature and cycles the compressor clutch to
maintain a constant evaporator pressure. Onboard circuit Temperature Continuous 1x per second
protection and diagnostics are also built into the module. sensor
Temperature At A/C start up 2x per second
NOTE: The EDT has a six second delay before start sensor open and
up to protect the compressor clutch. short detection
The EDT will turn the clutch on when the evaporator coil Compressor Continuous 3x per second
temperature is above 2°C (35.6°F). If the EDT does not clutch short to
detect any malfunction, it will continue to operate and the battery
status LED will be lit continuously. When the evaporator
temperature is below -2°C (28.4°F), the EDT will turn off
the clutch and status LED.
Figure 80-90-1

1
P-90576
When the EDT detects an open or short from the

temperature sensor, the status LED (Item 1) [Figure 80-
90-1] will blink once per second and the output signal to
the clutch will be turned off. The status LED will flash two
times per second when EDT detects an open circuit
(current draw less than 200 mA), short circuit or over
current (current draw greater than 7A) from the clutch
output. The status LED will flash three times per second
when the compressor clutch is shorted to ground.
NOTE: The EDT will attempt to restart every 20

seconds until the fault is repaired.
The EDT has the following protection built in:

1. Over temperature
2. Over current from clutch output
3. Voltage (Above and below operational limits or

reverse voltage)

THERMOSTAT (CONT’D) Figure 80-90-4

NOTE: The thermostat can be changed without

evacuating the A/C system, or removing the 1
evaporator / heater unit from the loader.
NOTE: The evaporator / heater unit is shown

removed for photo clarity.
P-92613
Figure 80-90-2
Remove the thermostat probe (Item 1) [Figure 80-90-4]

from the A/C evaporator coil.
Figure 80-90-5

1 2
P-92606
Remove the nine screws (Item 1) and cover (Item 2)

[Figure 80-90-2].
P-92609
Figure 80-90-3
Remove the thermostat (Item 1) from the evaporator /

heater unit [Figure 80-90-5].
P-92603
Remove the three screws (Item 1) and left cover (Item 2)

[Figure 80-90-3].

EXPANSION VALVE Figure 80-100-2

1

1
Evacuate the A/C system. (See Reclamation And
2.)
2
1
WARNING P-90416
In the event of a leak, wear safety goggles. Escaping NOTE: The evaporator / heater unit is removed for
refrigerant can cause severe injuries to eyes. In photo clarity.
gas. Remove the four screws (Item 1) and the cover (Item 2)
W-2371-0500 [Figure 80-100-2].

Figure 80-100-3
Figure 80-100-1
1
2
1
1
P-90417
P-92659
Remove the five screws (Item 1) and the cover (Item 2)

Remove the two A/C hoses (Item 1) [Figure 80-100-1]
[Figure 80-100-3].
from the expansion valve.
Installation: Tighten the two A/C hose fittings to 29,8

Cap and plug the hoses and the expansion valve fittings

EXPANSION VALVE (CONT'D)
Figure 80-100-4
P-90418
Remove the two evaporator fittings (Item 1) [Figure 80-

100-4] from the expansion valve.

Installation: Tighten the two evaporator fittings to 29,8
Remove the two mount bolts (Item 2) [Figure 80-100-4].
Remove the expansion valve from the loader.
Cap and plug the evaporator tubelines (Item 1) [Figure

80-100-4] and the expansion valve fittings with the
proper A/C caps and plugs.
Figure 80-100-5
N-22085
The expansion valve [Figure 80-100-5] is replaced as a

complete unit.

EVAPORATOR COIL Figure 80-110-2

1
1
2
Evacuate the A/C system. (See Reclamation And 1
2.)
NOTE: The evaporator / heater unit is removed for

photo clarity. 1
P-90417
WARNING Remove the five screws (Item 1) and the cover (Item 2)
[Figure 80-110-2].
In the event of a leak, wear safety goggles. Escaping Figure 80-110-3


gas.
W-2371-0500
Figure 80-110-1
1
1
1
1
P-90418
Disconnect the two evaporator fittings (Item 1) [Figure

80-110-3] from the expansion valve.
2
1 Installation: Tighten the two evaporator fittings to 29,8
P-90416 N•m (22 ft-lb) torque.
Cap and plug the evaporator tubelines (Item 1) [Figure

80-110-3] and the expansion valve fittings with the proper
photo clarity.
A/C caps and plugs.
Remove the four screws (Item 1) and the cover (Item 2)
[Figure 80-110-1].

EVAPORATOR COIL (CONT'D)
Figure 80-110-4
2
2
3
P-90420A
Remove the thermostat probe (Item 1) [Figure 80-110-4]

from the evaporator coil.

Remove the two retaining clips (Item 2) [Figure 80-110-
4] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil (Item 3) [Figure 80-110-4].
Figure 80-110-5
P-90424
Inspect the evaporator coil [Figure 80-110-5] for leaks,

and replace as needed.
Clean with low pressure water or air.

HEATER COIL Figure 80-120-3
Remove the evaporator coil (If equipped with A/C). (See 2

Remove the heater valve. (See Removal And Installation

on Page 80-140-1.) 1

photo clarity.
3
Figure 80-120-1
P-90440
Remove the three screws (Item 1) and cover (Item 2)

[Figure 80-120-3].
1 2
Remove the tie strap and move the wire harness (Item 3)
[Figure 80-120-3] off to the side.

Figure 80-120-4
1
P-90419A
2 1
Remove the nine screws (Item 1) and the cover (Item 2)
[Figure 80-120-1].
Figure 80-120-2 1
2
1
P-90445
1
Remove the five screws (Item 1) and cover (Item 2)
3
[Figure 80-120-4].
P-90439
Remove the three screws (Item 1) and cover (Item 2)

[Figure 80-120-2].
Remove the two screws (Item 3) [Figure 80-120-2].

HEATER COIL (CONT'D)
Figure 80-120-5
P-90441
Remove the bolt, spacer, and nut (Item 1) [Figure 80-

120-5].

Remove the heater coil from the unit.
Figure 80-120-6
P-90443
The heater coil [Figure 80-120-6] can be cleaned with

low pressure air or water.

BLOWER FAN Disassembly And Assembly
Remove the evaporator / heater unit. (See Removal And

Remove the heater coil. (See Removal And Installation 2

on Page 80-120-1.)
Figure 80-130-1
1 1
2
P-90458
1 1 Remove the eight screws (Item 1) [Figure 80-130-2]

from the blower wheel cover.
2

the resistor.
P-90457
Figure 80-130-3
Remove the two screws (Item 1) [Figure 80-130-1].
Remove the blower fan (Item 2) [Figure 80-130-1] from 1

the evaporator / heater unit.
2
P-90465
Remove the outside rings (Item 1) and the blower wheel

cover (Item 2) [Figure 80-130-3].
Inspect the outside rings and blower wheel covers for

wear and replace as needed [Figure 80-130-3].

BLOWER FAN (CONT'D) Figure 80-130-6
Figure 80-130-4
P-90463
1 Check the blower housing and blower motor mount for

P-90459 wear and replace as needed [Figure 80-130-6].
Figure 80-130-7
NOTE: Mark the wires for proper installation.

Remove the two wires (Item 1) [Figure 80-130-4] from
the blower motor.
Figure 80-130-5
1 1
P-90461
Remove the blower wheel outside clamp (Item 1) [Figure

80-130-7] from the blower wheel.
P-90460
Remove the screw (Item 1) [Figure 80-130-5] from the

bottom side of the blower motor.
Remove the blower motor from the blower housing.

BLOWER FAN (CONT'D)
Figure 80-130-8
1
3
4
P-90462
Remove the blower wheel (Item 1), inside clamp (Item 2),
inside ring (Item 3), and spacers (Item 4) [Figure 80-130-

8] from the blower motor shaft and inspect for wear.
NOTE: The number and size of spacers (Item 4)

[Figure 80-130-8] may vary.
Repeat the procedure for the other blower wheel.


HEATER VALVE Figure 80-140-2

3 4
Raise the lift arms and install an approved lift arm 1
NOTE: The heater valve is not serviceable and must

be replaced as a complete assembly.
Remove any tie-straps that hold the heater hoses.

2
NOTE: The evaporator / heater unit is shown
removed for photo clarity. P-90415
Figure 80-140-1
with plugs to prevent coolant loss from the
system.
Remove the heater hose clamp (Item 1) [Figure 80-140-

2].

1
Remove the heater hose from the heater valve.
Remove the nut (Item 2) [Figure 80-140-2] from the

3 heater valve mount.
2 Remove heater hose clamp (Item 3) and the heater valve
(Item 4) [Figure 80-140-2] from the evaporator / heater
P-90414 unit.

with plugs to prevent coolant loss from the
system.
Remove the heater hose clamp (Item 1) [Figure 80-140-

1].
Remove the heater hose.
Disconnect the loader wiring harness (Item 2) [Figure

80-140-1] from the heater valve.
Remove the nut (Item 3) [Figure 80-140-1] from the

heater valve mount.


SPECIFICATIONS
(S650) LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1

Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2

HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
865 of 896 SPEC-01 S650 Service Manual

866 of 896 SPEC-02 S650 Service Manual

(S650) LOADER SPECIFICATIONS
Machine Dimensions
• Dimensions are given for loader equipped with standard tires and 74 inch Construction & Industrial bucket and may
vary with other bucket types. All dimensions are shown in millimeters. Respective imperial dimensions are given in
inches enclosed by parentheses.
• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
2106 mm
(82.9 in)
1832 mm
(72.1 in)
1880 mm
1507 mm (74 in)
(59.3 in)

97°
4026 mm
(158.5 in) 42°
800 mm
(31.5 in)
3149 mm
(124 in)
2447 mm
2065 mm (96.3 in)
(81.3 in)
25.2°
31.1°
1150 mm
(45.3 in)
207 mm
(8.1 in)
2753 mm
(108.4 in)
3474 mm
(136.8 in)
NA-1660
Changes of structure or weight distribution of the loader can cause changes in control and steering response and
can cause failure of the loader parts.
867 of 896 SPEC-10-1 S650 Service Manual

(S650) LOADER SPECIFICATIONS (CONT’D)
Performance
Rated Operating Capacity 1220 kg (2690 lb)

with 200 Pound Frame Mounted 1288 kg (2840 lb)
Counterweight Kit
with 300 Pound Frame Mounted 1311 kg (2890 lb)
Counterweight Kit
Tipping Load 2440 kg (5380 lb)
Operating Weight 3777 kg (8327 lb)
Breakout Force - Lift 2177 kg (4800 lb)
Breakout Force - Tilt 2313 kg (5100 lb)
Push Force 2087 kg (4600 lb)
Travel Speed
- Single Speed Loader 0 - 11,4 km/h (0 - 7.1 mph)
- Two-Speed Loader (Opt.) Low/High 0 - 11,4 km/h (0 - 7.1 mph) / 0 - 19,8 km/h (0 - 12.3 mph)
Engine
Make / Model Kubota / V3307-DI-TE3 Interim Tier IV

Fuel / Cooling Diesel / Liquid
Horsepower

- ISO 9249 EEC / SAE J1349 Net 52,4 kW (70.3 hp) @ 2400 rpm
- ISO 14396 Gross 54,6 kW (73.2 hp) @ 2400 rpm
- SAE 1995 Gross 55,4 kW (74.3 hp) @ 2400 rpm
Torque
- ISO 9249 EEC / SAE J1349 Net 253,1 N•m (186.7 lb-ft) @ 1600 rpm
- SAE 1995 Gross 264,4 N•m (195.0 lb-ft) @ 1600 rpm
Low Idle RPM 1250 - 1450
High Idle RPM 2525 - 2650
Number of Cylinders 4
Displacement 3,3 L (203 in3)
Bore / Stroke 94 / 120 mm (3.70 / 4.72 in)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Closed Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel - Compression
Air Induction Turbo-Charged
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Glow Plugs - Automatically activated as needed in RUN position.
Drive System
Main Drive Fully hydrostatic, 4-wheel drive

Transmission Infinitely variable tandem hydrostatic piston pumps, driving two fully reversing
hydrostatic motors
Final Drive Pre-stressed #120 HSOC endless roller chain (no master link) and sprockets in
sealed chaincase with oil lubrication (Chains do not require periodic
adjustments) Two chains per side with no idler sprocket
Axle Size 68,6 mm (2.70 in), Heat treated
Wheel Bolts Eight - 9/16 in Wheel bolts fixed to axle hubs

Controls
Vehicle Steering Direction and speed controlled by two hand operated steering levers or optional
joystick(s)
Loader Hydraulics
- Lift and Tilt Controlled by separate foot pedals or optional Advanced Control System (ACS)
or optional Selectable Joystick Controls (SJC)
- Front Auxiliary Controlled by electrical switch on Right Hand steering lever or joystick
- Rear Auxiliary (Option) Controlled by electrical switch on Left Hand steering lever or joystick
Auxiliary Pressure Release Pressure relieved through quick couplers; Push couplers in, hold for 5 seconds
Engine Hand lever speed control, additional foot operated speed control pedal with SJC
option, key-type start switch or optional keyless start panel or optional Deluxe
Instrumentation Panel and function error shutdown.
Starting Aid Glow plugs automatically activated as needed by Instrument Panel
Service Brake Two independent hydrostatic systems controlled by two hand operated steering
levers or optional joystick(s)
Secondary Brake One of the hydrostatic transmissions
Parking Brake (Standard) Mechanical disc, manually operated switch on left instrument panel
Parking Brake (Two-Speed Option) Spring applied pressure release multi-disk brake activated by manually operated
switch on left instrument panel

Hydraulic System
Pump Type Engine driven, gear type

Pump Capacity - Standard 87,1 L/min (23.0 U.S. gpm)
Pump Capacity - High-Flow Option 115,5 L/min (30.5 U.S. gpm)
System Relief at Quick Couplers 23,8 - 24,5 MPa (237,8 - 244,7 bar) (3450 - 3550 psi)
Filter (Hydraulic / Hydrostatic) Replaceable beta 10 micron = 200, drop in element
Filter (Charge) Replaceable beta 10 micron = 200, drop in element
Hydraulic Cylinders Double-acting; tilt cylinders have cushioning feature on dump and rollback
Bore Diameter:Lift Cylinder (2) 63,5 mm (2.50 in)
Tilt Cylinder (2) 76,2 mm (3.00 in)
Rod Diameter:Lift Cylinder (2) 44,5 mm (1.75 in)
Stroke:Lift Cylinder (2) 860,3 mm (33.87 in)
Control Valve - Standard 3-Spool, open center, manually operated with spring detent for lift float and
electrically controlled auxiliary spool
Control Valve - ACS and SJC 3-Spool, open center with electric actuator controlled lift with float and tilt.
Electrically controlled auxiliary spool
Fluid Lines SAE Standard tubelines, hoses and fittings
Fluid Type BOBCAT FLUID, Hydraulic / Hydrostatic
6903117 - (Two - 2.5 U.S. gal)
6903118 - (5 U.S. gal)
6903119 - (55 U.S. gal)
Hydraulic Function Time:
Raise Lift Arms 3.4 Seconds
Lower Lift Arms 3.0 Seconds
Bucket Dump 2.3 Seconds
Bucket Rollback 1.7 Seconds

Electrical System
Alternator Belt driven, 90 amps, open frame

Battery 12 volts, 950 cold cranking amps @ -18°C (0°F),
180 Minute reserve capacity @ 25 amps
Starter 12 volts, gear type, 3,0 kW (4.02 hp)
Instrumentation Gauges:
Engine Coolant Temperature, Fuel Level.
Warning lights:
Fuel Level, Seat Belt, Engine Coolant Temperature, Engine Malfunction,
Hydraulic System Malfunction, General Warning.
Indicators:
BICS Functions, Two-Speed, 3-Point Shoulder Belt, Turn Signals, Engine
Preheat.
Data Display:
Operating Hours, Engine rpm, Speed Management Setting, Maintenance Clock
Countdown, Battery Voltage, Service Codes, Engine Preheat Countdown,
Steering Drift Compensation Setting, Drive Response Setting.
Other:
Audible Alarm, Lights, Option / Accessory Switches.
Optional Deluxe Instrumentation Panel:

*Additional displays for: Engine rpm, Coolant Temperature and Oil Pressure;
System Voltage, Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Included: Keyless Start, Digital Clock, Job Clock,
Attachment Control Information, Password Lockout, Multi-language Display,
Help Screens, Diagnostic Capability and Engine / Hydraulic Systems Shutdown
Function.
Capacities
Fuel 103,1 L (27.2 U.S. gal)

Engine Oil with Filter Change 11,4 L (12.0 qt.)
Engine Cooling System 11,4 L (3.0 U.S. gal)
with Heater 11,7 L (3.1 U.S. gal)
without Heater
Hydraulic / Hydrostatic Reservoir 10,2 L (2.7 U.S. gal)
Hydraulic / Hydrostatic System 45,0 L (11.9 U.S. gal)
Chaincase Reservoir 39,2 L (10.35 U.S. gal)
Tires
Heavy Duty (Standard) 12.00 x 16.5, 12 Ply Rating

Heavy Duty Offset (Option) 12.00 x 16.5, 12 Ply Rating
Heavy Duty Poly Fill (Option) 12.00 x 16.5, 12 Ply Rating
Severe Duty (Option) 12.00 x 16.5, 12 Ply Rating
Severe Duty Poly Fill (Option) 12.00 x 16.5, 12 Ply Rating
Solidflex (Option) 33 x 6 x 11
Super Float Offset (Option) 33 x 15.50 - 16.5, 12 Ply Rating
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT
mix brands of tires used on the same loader.

TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
Thread
sae grade 5 sae grade 8
size
N•m 0.250 9,0 - 10,2 12,4 - 13,6
(in-lb) (80 - 90) (110 - 120)
0.3125 20,3 - 22,6 24,2 - 27,1
(180 - 200) (215 - 240)
N•m 0.375 34 - 38 47 - 54
(ft-lb) (25 - 28) (35 - 40)
0.4375 54 - 61 81 - 88
(40 - 45) (60 - 65)
0.500 88 - 95 122 - 136
(65 - 70) (90 - 100)
0.5625 122 - 136 170 - 190
(90 - 100) (125 - 140)

0.625 170 - 190 240 - 260
(125 - 140) (175 - 190)
0.750 300 - 330 410 - 450
(220 - 245) (300 - 330)
0.875 450 - 490 645 - 710
(330 - 360) (475 - 525)
1.000 645 - 710 985 - 1085
(475 - 525) (725 - 800)
1.125 880 - 975 1425 - 1600
(650 - 720) (1050 - 1175)
1.250 1200 - 1360 2000 - 2200
(900 - 1000) (1475 - 1625)
1.375 1630 - 1830 2720 - 2980
(1200 - 1350) (2000 - 2200)
1.500 2040 - 2240 3530 - 3870
(1500 - 1650) (2600 - 2850)
1.625 2720 - 2980 4680 - 5150
(2000 - 2800) (3450 - 3800)
1.750 3390 - 3730 5830 - 6500
(2500 - 2750) (4300 - 4800)
1.875 4270 - 4750 7450 - 8300
(3150 - 3500) (5500 - 6100)
2.000 5150 - 5700 8800 - 9800
(3800 - 4200) (6500 - 7200)

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 4 - 5 N•m
(3 - 4 ft-lb)
M 6 x 1.0 8 - 9 N•m 8 - 12 N•m
(6 - 7 ft-lb) (6 - 9 ft-lb)
M 8 x 1.25 8 - 12 N•m 15 - 22 N•m 24 - 34 N•m
(6 - 9 ft-lb) (11 - 16 ft-lb) (18 - 25 ft-lb)
M 10 x 1.25 18 - 24 N•m 30 - 41 N•m 49 - 68 N•m
(13 - 18 f.-lb) (22 - 30 ft-lb) (36 - 50 ft-lb)
M 12 x 1.25 30 - 41 N•m 54 - 73 N•m 94 - 118 N•m
(22 - 30 ft-lb) (40 - 54 ft-lb. (69 - 87 ft-lb)
M 14 x 1.25 49 - 68 N•m 79 - 108 N•m 157 - 186 N•m
(36 - 50 ft-lb) (58 - 80 ft-lb) (116 - 137 ft-lb)

HYDRAULIC CONNECTION SPECIFICATIONS
Straight Thread O-ring Fitting
Figure SPEC-30-1
Nut Nut
Washer
Washer
O-ring
O-ring
A-1852
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until

the washer is tight against the surface [Figure SPEC-30-
1].
Figure SPEC-30-2
O-ring Boss
Tightening Torque
x TORQUE
x N•m
Thread Size (ft-lb)
7/16” - 20 18 (13)
9/16” - 18 30 (22)
3/4” -1 6 54 (40)
7/8” - 14 81 (60)
1-1/16” - 12 114 (84)
1-3/16” - 12 133 (98)
1-5/16” - 12 160 (118)
1-7/16” - 12 209 (154)
1-5/8” - 12 221 (163)

HYDRAULIC CONNECTION SPECIFICATIONS Tubelines And Hoses
(CONT’D)
Replace any tubelines that are bent or flattened. They will
Flare Fitting restrict flow and cause heat.
Figure SPEC-30-3 Replace hoses which show signs of wear, damage or

weather cracked rubber.
Always use two wrenches when loosening and tightening

hose or tubeline fittings.
P-85926
Use the following procedure to tighten the flare fitting:

Tighten the nut until it makes contact with the seat.
Use the chart [Figure SPEC-30-4] to find the correct

tightness needed. If the fitting leaks after tightening,
disconnect it and inspect the seat area for damage.
Figure SPEC-30-4
Flare Fitting Tightening Torque

Tubeline x TORQUE
Outside x N•m
Diameter Thread Size (ft.-lb.)
1/4” 7/16” - 20 18 (13)
5/16” 1/2” - 20 23 (17)
3/8” 9/16” - 18 30 (22)
1/2” 3/4” - 16 54 (40)
5/8” 7/8” - 14 81 (60)
3/4” 1-1/16” - 12 114 (84)
7/8” 1-3/16” - 12 133 (98)
1” 1-5/16” - 12 160 (118)
1-1/4” 1-5/8” - 12 209 (154)
1-1/2” 1-7/8” - 12 221 (163)
2” 2-1/2” - 12 342 (252)

SPECIFICATIONS
Specifications WARNING
RECOMMENDED ISO VISCOSITY GRADE (VG) During cold weather (32°F [0°C] and below), do not
AND VISCOSITY INDEX (VI) operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -20°F (-30°C), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285
TEMPERATURE RANGE ANTICIPATED
DURING MACHINE USE
[3] BOBCAT All-Season Fluid
[4] BOBCAT Synthetic Fluid

[5] BOBCAT Biodegradable Hydraulic / Hydrostatic
Fluid (Unlike biodegradable fluids that are vegetable
based, Bobcat biodegradable fluid is formulated to
prevent oxidation and thermal breakdown at operating
temperatures.)
DO NOT use automatic transmission fluids in the loader

or permanent damage to the transmission will result.
WARNING
W-2072-0807
When temperatures below -18°C (0°F) are common, the

loader must be kept in a warm building. Extra warm-up
time must be used each time the loader is started during
cold temperature conditions. Cold fluid will not flow easily
and it makes action of the hydraulic function slower. Loss
of fluid flow to the hydrostatic transmission pump
(indicated by TRANS light ON) can cause transmission
damage in less than 60 seconds.


CONVERSIONS
Decimal And Millimeter Equivalent Chart

U.S. To Metric Conversion Chart


ALPHABETICAL INDEX
(S650) LOADER SPECIFICATIONS CONTROL SYSTEM (ACS) . . . . . . . .60-130-1

. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1 CONVERSIONS . . . . . . . . . . . . . . .SPEC-50-1
ACCESS PANEL (INSIDE) (SJC) . . . 50-121-1 CRANKSHAFT AND PISTONS . . . . . .70-90-1
ACCESS PANEL (INSIDE) . . . . . . . . . 50-120-1 CYLINDER (BOB-TACH) . . . . . . . . . . .20-22-1
AIR CLEANER SERVICE . . . . . . . . . . . 10-80-1 CYLINDER (LIFT) . . . . . . . . . . . . . . . . .20-20-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . 70-40-1 CYLINDER (TILT) . . . . . . . . . . . . . . . . .20-21-1
AIR CONDITIONING SYSTEM FLOW . 80-10-1 CYLINDER HEAD . . . . . . . . . . . . . . . .70-80-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . 60-30-1 DELIVERY REPORT . . . . . . . . . . . . . . . . 1-15
ARMREST . . . . . . . . . . . . . . . . . . . . . 50-150-1 DIAGNOSTIC SERVICE CODES . . . . .60-90-1
BACK-UP ALARM SYSTEM . . . . . . . 60-210-1 DRAIN MANIFOLD . . . . . . . . . . . . . . . .30-80-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 DRIVE BELT . . . . . . . . . . . . . . . . . . . . .30-60-1
BLOWER FAN . . . . . . . . . . . . . . . . . . 80-130-1 DRIVE COMPONENTS . . . . . . . . . . . .40-20-1
BOBCAT CONTROLLER (ACS) . . . . . 60-71-1 ELECTRICAL / HYDRAULIC CONTROLS
BOBCAT CONTROLLER (SJC) (DRIVE) (ACS) . . . . . . . . . . . . . . . . . . . . . . . . .60-141-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-72-1 ELECTRICAL / HYDRAULIC CONTROLS
BOBCAT CONTROLLERS (GATEWAY AND (SJC) . . . . . . . . . . . . . . . . . . . . . . . . .60-142-1
AUXILIARY) . . . . . . . . . . . . . . . . . . . . . 60-70-1 ELECTRICAL / HYDRAULIC CONTROLS

BOBCAT INTERLOCK CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-140-1
(BICS) . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1 ELECTRICAL SYSTEM INFORMATION
BOB-TACH (HAND LEVER) . . . . . . . . 10-140-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-1
BOB-TACH (HAND LEVER) . . . . . . . . . 50-40-1 EMERGENCY EXIT . . . . . . . . . . . . . .10-210-1
BOB-TACH (POWER) BLOCK . . . . . . 20-120-1 ENGINE COOLING SYSTEM . . . . . . .10-90-1
BOB-TACH (POWER) . . . . . . . . . . . . 10-141-1 ENGINE COOLING SYSTEM . . . . . . .70-50-1
BOB-TACH (POWER) . . . . . . . . . . . . . 50-41-1 ENGINE INFORMATION . . . . . . . . . . .70-10-1
BRAKE (SINGLE SPEED) . . . . . . . . . . 40-10-1 ENGINE LUBRICATION SYSTEM . . .10-110-1
BRAKE (TWO-SPEED) . . . . . . . . . . . . 40-11-1 ENGINE SPEED CONTROL (SJC) S/N
BUCKET POSITION VALVE . . . . . . . 20-100-1 A3NV12469 AND BELOW & S/N A3NW11130
AND BELOW . . . . . . . . . . . . . . . . . . . .70-21-1
CAB DOOR . . . . . . . . . . . . . . . . . . . . 50-140-1
ENGINE SPEED CONTROL (SJC) S/N
CALIBRATION . . . . . . . . . . . . . . . . . . 60-160-1 A3NV12470 AND ABOVE & S/N A3NW11131
CAMSHAFT AND TIMING GEARS . . 70-100-1 AND ABOVE . . . . . . . . . . . . . . . . . . . . .70-22-1
CHAINCASE . . . . . . . . . . . . . . . . . . . . 40-30-1 ENGINE SPEED CONTROL . . . . . . . .70-20-1
CHARGE PRESSURE . . . . . . . . . . . . . 30-40-1 EVAPORATOR / HEATER UNIT . . . . . .80-80-1
COMPRESSOR . . . . . . . . . . . . . . . . . . 80-50-1 EVAPORATOR COIL . . . . . . . . . . . . .80-110-1
CONDENSER . . . . . . . . . . . . . . . . . . . 80-60-1 EXHAUST GAS RECIRCULATION (EGR)
CONTROL HANDLE / LEVER (ACS) . 50-111-1 SYSTEM . . . . . . . . . . . . . . . . . . . . . . .70-130-1
CONTROL HANDLE / LEVER (SJC) . 50-112-1 EXPANSION VALVE . . . . . . . . . . . . . .80-100-1
CONTROL HANDLE / LEVER . . . . . . 50-110-1 FINAL DRIVE TRANSMISSION
(CHAINCASE) . . . . . . . . . . . . . . . . . .10-130-1
CONTROL PANEL (SJC) . . . . . . . . . . 50-101-1
FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-12
CONTROL PANEL SETUP . . . . . . . . 60-180-1
FLYWHEEL AND HOUSING . . . . . . .70-120-1
CONTROL PANEL . . . . . . . . . . . . . . . 50-100-1
FLYWHEEL RPM SENSOR . . . . . . . .60-170-1
CONTROL PEDALS AND LINKAGES (ACS)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
CONTROL PEDALS AND LINKAGES . 50-90-1 FRONT AUXILIARY HYDRAULIC COUPLER
BLOCK . . . . . . . . . . . . . . . . . . . . . . . .20-130-1
879 of 896 INDEX-01 S650 Service Manual

FRONT HORN . . . . . . . . . . . . . . . . . .60-220-1 MAIN RELIEF VALVE . . . . . . . . . . . . . 20-30-1
FUEL SYSTEM . . . . . . . . . . . . . . . . .10-100-1 MAINTENANCE CLOCK . . . . . . . . . 60-200-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . .70-70-1 MAINTENANCE SAFETY . . . . . . . . . . . . . . 1-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . .50-80-1 MUFFLER . . . . . . . . . . . . . . . . . . . . . . 70-30-1
HEADLINER . . . . . . . . . . . . . . . . . . . .50-180-1 OIL COOLER . . . . . . . . . . . . . . . . . . . 20-90-1
HEATER COIL . . . . . . . . . . . . . . . . . .80-120-1 OPERATOR CAB . . . . . . . . . . . . . . . . 10-30-1
HEATER VALVE . . . . . . . . . . . . . . . . .80-140-1 OPERATOR CAB . . . . . . . . . . . . . . . . 50-20-1
HYDRAULIC / HYDROSTATIC FILTERS OPERATOR SEAT (SUSPENSION) . . 50-31-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-70-1 OPERATOR SEAT . . . . . . . . . . . . . . . 50-30-1
HYDRAULIC / HYDROSTATIC FLUID PASSWORD SETUP (DELUXE
SPECIFICATIONS . . . . . . . . . . . . . SPEC-40-1 INSTRUMENTATION PANEL) . . . . . 60-190-1
HYDRAULIC CONNECTION PASSWORD SETUP (KEYLESS START
SPECIFICATIONS . . . . . . . . . . . . . SPEC-30-1 PANEL) . . . . . . . . . . . . . . . . . . . . . . . 60-191-1
HYDRAULIC CONTROL VALVE (ACS) OR PIVOT PINS . . . . . . . . . . . . . . . . . . . 10-180-1
(SJC) . . . . . . . . . . . . . . . . . . . . . . . . . .20-41-1
REAR AUXILIARY DIVERTER VALVE
HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
REAR DOOR (TAILGATE) . . . . . . . . . 50-70-1
HYDRAULIC FLUID RESERVOIR . . . .20-80-1
REAR GRILLE . . . . . . . . . . . . . . . . . . 50-60-1
HYDRAULIC PUMP (HIGH FLOW) . . .20-61-1
RECEIVER / DRIER . . . . . . . . . . . . . . 80-70-1

HYDRAULIC PUMP . . . . . . . . . . . . . . .20-60-1
REGULAR MAINTENANCE . . . . . . . . 80-20-1
HYDRAULIC SYSTEM INFORMATION
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1 REMOTE START TOOL (SERVICE TOOL) KIT
- 7003031 . . . . . . . . . . . . . . . . . . . . . . 10-61-1
HYDRAULIC/HYDROSTATIC SYSTEM
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1 REMOTE START TOOL KIT-MEL1563 10-60-1
HYDROSTATIC DRIVE MOTOR (TWO- RIGHT SIDE LOWER PANEL . . . . . 50-170-1
SPEED) . . . . . . . . . . . . . . . . . . . . . . . .30-21-1 SAFETY INSTRUCTIONS . . . . . . . . . . . . 1-10
HYDROSTATIC DRIVE MOTOR . . . . .30-20-1 SEAT BAR SENSOR . . . . . . . . . . . . .60-110-1
HYDROSTATIC MOTOR CARRIER (SJC) SEAT BAR . . . . . . . . . . . . . . . . . . . . . 50-10-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-31-1 SEAT BELT . . . . . . . . . . . . . . . . . . . . 10-220-1
HYDROSTATIC MOTOR CARRIER . . .30-30-1 SERIAL NUMBER LOCATIONS . . . . . . . . 1-14
HYDROSTATIC PUMP (SJC) . . . . . . . .30-51-1 SERVICE MANUAL REVISION . . . . . . SMR-1
HYDROSTATIC PUMP . . . . . . . . . . . . .30-50-1 SERVICE PC (LAPTOP COMPUTER)
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1 SERVICE SCHEDULE . . . . . . . . . . . . 10-70-1
INSTRUMENT PANELS . . . . . . . . . . . .60-50-1 SPARK ARRESTOR MUFFLER . . . . 10-170-1
LEFT SIDE LOWER PANEL . . . . . . .50-160-1 SPEED SENSORS (SJC) . . . . . . . . . . 60-80-1
LIFT ARM BYPASS CONTROL VALVE 20-50-1 STARTER . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LIFT ARM SUPPORT DEVICE . . . . . .10-20-1 STEERING DRIFT COMPENSATION 60-161-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . .50-50-1 STOPPING THE ENGINE AND LEAVING THE
LIFTING AND BLOCKING THE LOADER LOADER . . . . . . . . . . . . . . . . . . . . . . 10-200-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1 SYSTEM CHARGING AND RECLAMATION
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .60-60-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
LOADER IDENTIFICATION . . . . . . . . . . . 1-16 THERMOSTAT . . . . . . . . . . . . . . . . . . 80-90-1
LOADER STORAGE AND RETURN TO TIRE MAINTENANCE . . . . . . . . . . . 10-160-1
SERVICE . . . . . . . . . . . . . . . . . . . . . .10-190-1 TORQUE SPECIFICATIONS FOR BOLTS
LUBRICATING THE LOADER . . . . . .10-150-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
LUBRICATION SYSTEM . . . . . . . . . . .70-60-1 TOWING THE LOADER . . . . . . . . . . . 10-50-1

TRACTION LOCK . . . . . . . . . . . . . . . 60-120-1
TRANSPORTING LOADER ON A TRAILER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TROUBLESHOOTING . . . . . . . . . . . . . 80-30-1
TURBOCHARGER . . . . . . . . . . . . . . . 70-110-1
TWO-SPEED / BRAKE VALVE . . . . . . 30-70-1
WINDOW (REAR) . . . . . . . . . . . . . . . 50-130-1
WINDOW (SIDE) . . . . . . . . . . . . . . . . 50-132-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . 50-131-1


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: S650 - 1

Date: 15 July 2009
Product: Bobcat Loader
Model: S650
Manual No: 6987168 (7-09)

The following Sections are a revision to the above Service Manual.
COVER
70-10
883 of 896 SMR-1 S650 Service Manual


ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 15 August 2009
Model: S650
Manual No: 6987168 (8-09)

S630 Service Manual (P/N 6987168) Dated 8-09 contains updated service information which replaces the previous
S630 Service Manual (P/N 6987168) Dated 7-09.


ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 15 September 2009
Model: S650
Manual No: 6987168 (9-09)

COVER
20-10
20-20
30-10


ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 15 October 2009
Model: S650
Manual No: 6987168 (10-09)

COVER 60-01
FORWARD 60-50
60-90
10-30 60-130
10-150 60-140
10-200 60-141
10-210 60-142
60-150
20-80 60-160
60-190
50-01 60-191
50-20 60-200
50-80 60-220
50-150
50-160 70-40
50-170
50-180 SPEC-10
ALPHABETICAL INDEX


ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 15 December 2009
Model: S650
Manual No: 6987168 (12-09)

COVER
10-100
20-120
30-20
30-21
50-70
50-91
50-120
60-50
60-60
60-130
70-20
70-21 ADDED
70-70
SPEC-10
SPEC-40
ALPHABETICAL INDEX


ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 15 June 2010
Model: S650
Manual No: 6987168 (6-10)

FRONT COVER
10-20 60-10
10-40 60-20
10-80 60-90
10-90
10-110 70-90
10-120
10-130 SPEC-40
10-170
20-21
20-61
30-30
30-31
50-01
50-20
50-30
50-60
50-112


ROUTE TO
ATTENTION
SERVICE MANAGER X

Date: 15 October 2010
Model: S650
Manual No: 6987168 (10-10)

S630 Service Manual (P/N 6987168) Dated 10-10 contains updated service information which replaces the
previous
S630 Service Manual (P/N 6987168) Dated 6-10.


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2 of 896

Dealer Copy -- Not for Resale

CORRECT CORRECT CORRECT

P-90216 NA1204 NA1193

WRONG WRONG WRONG

Dealer Copy -- Not for Resale

NA1200 NA1191 B-6589

3 of 896 1-1 S650 Service Manual

4 of 896 1-2 S650 Service Manual

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

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

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-01

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

Dealer Copy -- Not for Resale

5 of 896 1-3 S650 Service Manual

6 of 896 1-4 S650 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Dealer Copy -- Not for Resale

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

7 of 896 1-5 S650 Service Manual

8 of 896 1-6 S650 Service Manual

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

Dealer Copy -- Not for Resale

4. The seat bar must be 12. Safety treads must be in good

6. Machine signs (decals) must 14. Check hydraulic fluid level,

7. Steering levers, hand controls 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

9 of 896 1-7 S650 Service Manual

Dealer Copy -- Not for Resale

22. Check for any field

10 of 896 1-8 S650 Service Manual

11 of 896 1-9 S650 Service Manual

Dealer Copy -- Not for Resale

• The Skid-Steer Loader Operator Training Course is

DANGER available through your local dealer or at

WARNING • The Skid-Steer Loader Safety Video is available from

12 of 896 1-10 S650 Service Manual

The dealer and owner / operator review the

Cutting or drilling concrete containing sand or rock

Call Before You Dig

Dealer Copy -- Not for Resale

13 of 896 1-11 S650 Service Manual

Check hydraulic tubes, hoses and fittings for damage

Maintenance Always clean fluid spills. Do not use gasoline or diesel

Flammable debris (leaves, straw, etc.) must be removed

Dealer Copy -- Not for Resale

Do not use the machine where exhaust, arcs, sparks or

Check the spark arrestor exhaust system regularly to

Battery gas can explode and cause serious injury. Use

14 of 896 1-12 S650 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect