t190 6987043 SM 8-09 PDF

Service Manual
T190 Compact Track Loader
S/N 531660001 & Above

S/N 531760001 & Above
Dealer Copy -- Not for Resale
EQUIPPED WITH
BOBCAT INTERLOCK
CONTROL SYSTEM (BICS™)
6987043 (8-09) Printed in U.S.A. © Bobcat Company 2009
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
P-90216 B-15954 B-15956

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

B-15967 B-15958 B-15955
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 approved attachments not approved by
Avoid exhaust fume leaks which lift arm support device. Replace it Bobcat Company.
can kill without warning. Exhaust if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-15966 B-15951 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.
MSW11-0409
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ALPHABETICAL INDEX
ACCESS PANEL (INSIDE) ..................................... 50-01

ACCESS PANEL (INSIDE) (SJC) ...........................50-01 FINAL DRIVE TRANSMISSION (CHAINCASE) .. 10-01
AIR CLEANER .................................................... 70-01 FLYWHEEL AND HOUSING ................................ 70-01
AIR CLEANER SERVICE ....................................... 10-01 FLYWHEEL RPM SENSOR ....................................60-01
AIR CONDITIONING SYSTEM FLOW ................... 80-01 FRONT AUXILIARY HYD. COUPLER BLOCK .......20-01
ALTERNATOR ........................................................ 60-01
FUEL SYSTEM.............................................10-01, 70-01
FUEL TANK .............................................................50-01
BACK-UP SYSTEM ................................................ 60-01
BATTERY................................................................ 60-01
BLOWER FAN ........................................................ 80-01 HEATER COIL .........................................................80-01
BOBCAT INTERLOCK CONTROL HEATER VALVE ......................................................80-01
SYSTEM (BICS) ................................................... 60-01 HIGH FLOW VALVE ................................................20-01
BOBCAT CONTROLLER (ACS) ............................. 60-01 HYDRAULIC CONNECTION SPECS. .............. SPEC-01
BOBCAT CONTROLLER (GATEWAY AND HYDRAULIC CONTROL VALVE .............................20-01
AUXILIARY) .......................................................... 60-01 HYD./HYDRO FLUID SPECIFICATIONS .......... SPEC-01
BOBCAT CONTROLLER (SJC) (DRIVE) ............... 60-01 HYDRAULIC FLUID RESERVOIR ..........................20-01
BOB-TACH (HAND LEVER) ........................ 10-01, 50-01 HYDRAULIC/HYDROSTATIC FILTERS ..................20-01
BOB-TACH (POWER).................................. 10-01, 50-01 HYDRAULIC/HYDROSTATIC SYSTEM..................10-01
BRAKE .................................................................... 40-01 HYDRAULIC PUMP (STANDARD)..........................20-01
BUCKET POSITION VALVE ................................ 20-01
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)..20-01
HYDRAULIC PUMP (SJC) (HIGH FLOW)...............20-01
CALIBRATION ........................................................ 60-01
HYDARULIC PUMP (SJC) ......................................20-01
CAMSHAFT AND TIMING GEARS.........................70-01
HYDRAULIC SYSTEM INFORMATION ..................20-01
CHAINCASE ........................................................... 40-01

HYDROSTATIC MOTOR ..................................... 30-01
CHARGE PRESSURE ............................................ 30-01
HYDROSTATIC MOTOR CARRIER ........................30-01
COMPRESSOR ...................................................... 80-01
HYDROSTATIC PUMP ........................................ 30-01
CONDENSER ......................................................... 80-01
HYDROSTATIC PUMP (SJC) ............................. 30-01
CONTROL HANDLE/LEVER .................................. 50-01
HYDROSTATIC SYSTEM INFORMATION ..........30-01
CONTROL HANDLE/LEVER (ACS) ....................... 50-01
CONTROL HANDLE/LEVER (SJC) ........................ 50-01
INSTRUMENT PANELS ..........................................60-01
CONTROL PANEL .................................................. 50-01
CONTROL PANEL (SJC)........................................ 50-01
LIFT ARMS ..............................................................50-01
CONTROL PANEL SETUP ..................................... 60-01
LIFT ARM BYPASS CONTROL VALVE .............. 20-01
CONTROL PEDALS AND LINKAGE ...................... 50-01
LIFT ARM SUPPORT DEVICE ........................... 10-01
CONTROL PEDALS (ACS) .................................... 50-01
LIFTING AND BLOCKING THE LOADER...............10-01
CONTROL SYSTEM (ACS) .................................... 50-01
LIGHTS ................................................................60-01
CONVERSIONS ............................................SPEC-01
T190 LOADER SPECIFICATIONS .................... SPEC-01
CRANKSHAFT AND PISTONS .............................. 70-01
LOADER STORAGE AND RETURN TO SERVICE 10-01
CYLINDER (LIFT) ................................................... 20-01
LUBRICATING THE LOADER.................................10-01
CYLINDER (BOB-TACH) ........................................ 20-01
LUBRICATION SYSTEM .........................................70-01
CYLINDER (TILT) ................................................ 20-01
CYLINDER HEAD ................................................... 70-01
MAIN RELIEF VALVE ..............................................20-01
MAINTENANCE CLOCK .........................................60-01
DIAGNOSTICS SERVICE CODES ..................... 60-01
MUFFLER................................................................70-01
DRIVE BELT ........................................................... 30-01
DRIVE COMPONENTS .......................................... 40-01
OIL COOLER...........................................................20-01
OPERATOR CAB .........................................10-01, 50-01
ELECTRICAL SYSTEM INFORMATION ................ 60-01
OPERATOR SEAT (SUSPENSION)........................50-01
ELECTRICAL/HYRAULIC CONTROLS.................. 60-01
ELECTRICAL/HYRAULIC CONTROLS (SJC)........ 60-01
PASSWORD SETUP (IF EQUIPPED WITH
ENGINE ................................................................. 70-01
KEYLESS START).................................................60-01
ENGINE COOLING SYSTEM ...................... 10-01, 70-01
PIVOT PINS ............................................................10-01
ENGINE INFORMATION ........................................ 70-01
POWER BOB-TACH (OPTION)....................10-01, 50-01
ENGINE LUBRICATION SYSTEM.......................... 10-01
POWER BOB-TACH BLOCK...................................20-01
ENGINE SPEED CONTROL (SJC) ........................ 70-01
PRESSURE RELIEF VALVE ...................................80-01
EVAPORATOR COIL .............................................. 80-01
PRESSURE SWITCH..............................................80-01
EVAPORATOR/HEATER UNIT ............................... 80-01
EXPANSION VALVE ............................................... 80-01
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ALPHABETICAL INDEX (CONT’D)
RADIATOR.............................................................. 70-01
REAR AUXILIARY DIVERTER VALVE ....................20-01
REAR DOOR ...................................................... 50-01
REAR GRILL ...........................................................50-01
RECEIVER/DRIER ..................................................80-01
REGULAR MAINTENANCE ................................... 80-01
REMOTE STARTTOOL KIT-MEL1563 ....................10-01
REMOTE START TOOL (SERVICE TOOL)
KIT-6689779 ..........................................................10-01
SEAT BAR ...............................................................50-01

SEAT BAR SENSOR ...............................................60-01
SERVICE PC (LAPTOP COMPUTER) ....................60-01
SERVICE SCHEDULE ............................................10-01
SPARK ARRESTOR MUFFLER ............................. 10-01
SPEED SENSORS (SJC)....................................... 60-01
STARTER ................................................................60-01
STEERING DRIFT COMPENSATION .....................60-01
STOPPING THE ENGINE AND
LEAVING THE LOADER .......................................10-01
SYSTEM CHARGING AND RECLAMATION ......... 80-01

TEMPERATURE/PRESSURE ................................ 80-01
THERMOSTAT........................................................ 80-01
TIRE MAINTENANCE .............................................10-01
TORQUE SPECIFICATIONS FOR BOLTS .... SPEC-01
TOWING THE LOADER ..........................................10-01
TRACTION LOCK....................................................60-01
TRANSPORTING LOADER ON A TRAILER ..........10-01
TROUBLESHOOTING.............................................80-01
TURBOCHARGER ..................................................70-01
WINDOW (FRONT DOOR) .................................... 50-01

WINDOW (REAR)................................................... 50-01
WINDOW (SIDE) .................................................... 50-01
WINDOW (TOP) ..................................................... 50-01
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SAFETY &
CONTENTS MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SYSTEM
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SYSTEM
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X
LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI DRIVE

SYSTEM
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

MAIN FRAME
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

ELECTRICAL
SYSTEM &
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ANALYSIS
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01
ENGINE
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 SERVICE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HVAC
SPECIFICATIONS
SPECIFICATIONS
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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.
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.
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.
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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.
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903

operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
IMPORTANT
• The AEM Safety Manual delivered with the machine
This notice identifies procedures which must be gives general safety information.
followed to avoid damage to the machine.
I-2019-0284 • The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
• The 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
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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.).
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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.
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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.
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SERIAL NUMBER LOCATION Engine Serial Number
Always use the serial number of the loader when Figure 2

requesting service information or when ordering parts.
Early or later models (identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 1
P-48002
The engine serial number is in the location shown

[Figure 2].

P-45263
The loader serial number plate is located on the outside

of the loader frame [Figure 1].
Explanation of loader Serial Number:
XXXX XXXXX
Model 1.-Model/ Engine Model 2.-Production
Combination Sequence (Series)
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.
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DELIVERY REPORT
Figure 3
B-16315
The Delivery Report must be filled out 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. Make sure it is filled out completely [Figure

3].
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LOADER IDENTIFICATION
FRONT LIGHTS
SEAT BAR
GRAB OPERATOR SEAT

HANDLES WITH SEAT BELT
STEERING
LEVER
▼ REAR AUXILIARY
QUICK COUPLERS
TILT CYLINDER
† BUCKET STABILIZER ROD
FRONT AUXILIARY
QUICK COUPLERS
BUCKET STEPS

SAFETY TREAD
● OPERATOR CAB
REAR WINDOW (ROPS & FOPS)
LIFT ARM LINK
REAR GRILL
LIFT ARM
LIFT CYLINDER
TAIL LIGHT
LIFT ARM
SUPPORT DEVICE
REAR LIGHT
REAR DOOR
❒ TRACKS
B-15984
B-15985A
▼ OPTIONAL OR FIELD ACCESSORY (Not Standard Equipment)

❒ TRACKS - Optional tracks are available.
† Bucket - Several different buckets and other attachments are available for this machine.
● ROPS, FOPS - Roll Over Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure
per ISO 3449, Level I. Level II is available. Extra insulated cab is available as an option (Reduced noise level).
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SAFETY &
SAFETY & MAINTENANCE MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-131-1
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2 DRIVE
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1 SYSTEM
Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
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. . . . . . . . . . . . . . . . . . . . . 10-110-1

ELECTRICAL
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1 SYSTEM &
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2 ANALYSIS
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-3
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . 10-100-3 ENGINE
SERVICE
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-6
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Hydraulic / Hydrostatic Fluid Chart . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Removing And Replacing Hydraulic Charge Filter. . . . . . . . . . . . . 10-120-5
Removing And Replacing Case Drain Filters. . . . . . . . . . . . . . . . . 10-120-4
Removing And Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . 10-120-2
Removing And Replacing Hydraulic / Hydrostatic Filter . . . . . . . . 10-120-3
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Installing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Removing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
LOADER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . 10-170-1

Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Continued On Next Page
10-01 T190 Service Manual

19 of 888
SAFETY & MAINTENANCE (CONT’D)
LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Cab Door Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-3
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-2
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-160-1
REMOTE START TOOL KIT-MEL1563. . . . . . . . . . . . . . . . . . 10-60-1

Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-4
Remote Start Tool - MEL1563 . . . . . . . . . . . . . . . . . . . . . . 10-60-1
Service Tool Harness Communicator - MEL1566 . . . . . . . 10-60-3
Service Tool Harness Control - MEL1565 . . . . . . . . . . . . . 10-60-2
REMOTE START TOOL (SERVICE TOOL) KIT - 6689779 . . 10-61-1

Computer Service Tool Harness - 6689746 . . . . . . . . . . . . 10-61-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
Loader Service Tool Harness - 6689747 . . . . . . . . . . . . . . 10-61-3
Remote Start Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-5
Remote Start Tool (Service Tool) - 6689778 . . . . . . . . . . . 10-61-2
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
STOPPING THE ENGINE AND LEAVING THE LOADER . . 10-180-1

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-2
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
TRANSPORTING THE LOADER ON A TRAILER . . . . . . . . . 10-40-1

Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD

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

ITEMS MAY VARY.

20 of 888
LIFTING AND BLOCKING THE LOADER Figure 10-10-2
Procedure
WARNING
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
P-43747
Untrained operators and failure to follow instructions
can cause injury or death. Always park the loader on a level surface.
W-2003-0807
Put floor jack under the rear of the loader [Figure 10-10-
Figure 10-10-1 2].
Lift the rear of the loader and install jackstands [Figure

10-10-2].
Figure 10-10-3
B-7023A
WARNING P-24646
Put jackstands under the front axles and rear corners

Put the floor jack under the front of the loader [Figure 10-
of the frame before running the engine for service.
10-3].
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
Lift the front of the loader and put jackstands under the
W-2017-0286
axle tubes [Figure 10-10-3].
NOTE: Make sure the jackstands do not touch the

tracks. Make sure the tracks clear the floor or
any obstacles.
10-10-1 T190 Service Manual

21 of 888

22 of 888
LIFT ARM SUPPORT DEVICE Figure 10-20-1
Installing
WARNING 1
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 P-43747 P-24483

are missing. Using a damaged lift arm support or
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 storage position.
DANGER

The operator must be in the operator's seat, with the seat
belt fastened and 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 the attachment from the loader. (See BOB-

P-24484A
TACH (HAND LEVER) on Page 50-40-1.) OR (See BOB-
TACH (POWER) 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.

23 of 888
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, 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.
P-10136
Return the lift arm support device to storage position and
secure with clamping knobs.
Remove the jackstands.
P-24486A
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
under the cylinder (Inset) [Figure 10-20-3].

24 of 888
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. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for rollover protection.
ROPS / FOPS - Roll Over protective Structure per ISO

3471, and Falling Object Protective Structure per SAE
J1043 and 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
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

25 of 888
OPERATOR CAB (CONT’D)
Raising
WARNING
Always stop the engine before raising or lowering the
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 Installing on Page
10-20-1.) • STOP ENGINE before raising or lowering cab.
W-2758-0908
Figure 10-30-1
NOTE: On Advanced Control System (ACS) equipped
machines, the steering levers could contact
the cab frame while raising or lowering the
operator cab. The engine MUST be stopped
before raising or lowering the cab.
Figure 10-30-3

P-43747
Install jackstands under the rear of the loader frame

[Figure 10-30-1].
P-31267
Figure 10-30-2
Lift on the grab handles and bottom of the operator cab
[Figure 10-30-3] slowly until the cab is all the way up and
the latching mechanism engages.
P-31288 P-31289
Remove the nuts and plates [Figure 10-30-2] (both

sides) at the front corners of the cab.

26 of 888
OPERATOR CAB (CONT’D)
Lowering
WARNING
Always stop the engine before raising or lowering the
cab. PINCH POINT CAN CAUSE INJURY
NOTE: Always use the grab handles to lower the cab. Remove your hand from the latching mechanism
when the cab is past the latch stop.
Figure 10-30-4 W-2469-0803
Figure 10-30-5
N-20120

P-31268A
Pull down on the bottom of the operator cab until it stops P-31288 P-31289
at the latching mechanism [Figure 10-30-4].
Install the plates and nuts [Figure 10-30-5] (both sides).
NOTE: The weight of the cab increases when
equipped with options and accessories such Tighten the nuts to 40 - 45 ft.-lb. (54 - 61 N•m) torque.
cab door, heater, air conditioning, etc. In
these cases, the cab may need to be raised
slightly from the latch to be able to release the
latch.
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 Advanced Control System (ACS) equipped

machines, the steering levers could contact
the cab frame while raising or lowering the
operator cab. The engine MUST be stopped
before raising or lowering the cab.
Support the cab and release the latching mechanism

(Inset) [Figure 10-30-4]. Remove your hand from
latching mechanism when the cab is past the latch stop.
Use both hands to lower the cab all the way down.

27 of 888
OPERATOR CAB (CONT’D) Special Applications Kit
Cab Door Sensor Figure 10-30-8
This machine may be equipped with a Cab Door Sensor.
Figure 10-30-6
S3999A
B-25286A
1 Available for special applications to restrict material from

2 entering cab openings. Kit includes 1/2 in. Lexan® front
door, top and rear windows [Figure 10-30-8].
P-68116
P-68115
See your Bobcat dealer for availability.
The cab door has a sensor (Item 1) [Figure 10-30-6]

Special Applications Kit Inspection And Maintenance
installed which deactivates the lift and tilt valves when the
door is open.
• Inspect for cracks or damage. Replace if required.
A decal is located on the latch mechanism (Item 2) • Pre-rinse with water to remove gritty materials.
[Figure 10-30-6]. • Wash with a mild household detergent and warm
water.
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6] • Use a sponge or soft cloth. Rinse well with water and
will be OFF when the door is closed, the key switch is dry with a clean soft cloth or rubber squeegee.
turned to RUN or the RUN / ENTER button is pressed, • Do not use abrasive or highly alkaline cleaners.
the seat bar is lowered and the PRESS TO OPERATE • Do not operate windshield wipers on a dry surface.
LOADER button is pressed.
• Do not clean with metal blades or scrapers.
Figure 10-30-7
The LIFT & TILT VALVE light (Item 3) [Figure 10-30-6]

will be ON when the door is open, the key switch is
turned to RUN or the RUN / ENTER 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].

28 of 888
TRANSPORTING THE LOADER ON A TRAILER Fastening
Loading And Unloading Figure 10-40-2
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. N-19048A P-73277
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

Alternate Front Tie Down
P-24480 P-24513A
1
P-24512A
Use the following procedure to fasten the Bobcat Loader
to the transport vehicle to prevent the loader from moving
A loader with an empty bucket or no attachment must be during sudden stops or when going up or down slopes
loaded backward onto the transport vehicle [Figure 10- [Figure 10-40-2].
40-1].
• Lower the bucket or attachment to the floor.
The rear of the trailer must be blocked or supported (Item • Stop the engine.
1) [Figure 10-40-1] when loading or unloading the loader • Engage the parking brake.
to prevent the front end of the trailer from raising up.
• Install chains at the front and rear loader tie down
positions [Figure 10-40-2].
• Fasten each end of the chain to the transport vehicle.

29 of 888

30 of 888
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 tracks will not turn.) There might be slight wear
to the tracks when the loader is skidded.
The towing chain (or cable) must be rated at one and

one-half times the weight of the loader. (See
Performance on Page SPEC-10-2.)

31 of 888

32 of 888
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 once will activate maximum flow.
P16114 Pressing the switch again will activate variable flow. The
switch will illuminate to indicate which flow rate is active.
Pressing the switch a third time will turn the flow OFF.
The remote start tool (Item 1) [Figure 10-60-1] is The switch is used when checking pressures and flow
required when the service technician is checking the rate.
hydraulic/hydrostatic system or adjusting the steering
linkage. The auxiliary pressure release (Item 3) [Figure 10-60-2]
is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for a few seconds.
NOTE: With the engine running; pushing and holding

the pressure release switch will cause the
engine to stop. To relieve the pressure; press
the switch until the engine stops.

33 of 888
REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Control - MEL1565
Remote Start Tool - MEL1563 (Cont’d) Figure 10-60-5
Figure 10-60-3
2
1 1
P16114
P16116
The service tool harness control (Item 1) [Figure 10-60-
5] is used to connect the remote start tool (Item 2)
Figure 10-60-4 [Figure 10-60-5] to the electrical system on the loader.

1 Figure 10-60-6
P16120
N-19561
The 10-pin rectangular connector (Item 1) [Figure 10-60-
3] is used to update software in the Deluxe
Instrumentation Panel (Item 1) [Figure 10-60-4]. Remove the plug (Item 1) [Figure 10-60-6] from the
loader harness connector.
NOTE: The Service PC must be connected to the
remote start tool to update the deluxe panel Connect the service tool harness control to the loader
software. harness connector.
The panel must be removed from inside the operator cab

and plugged into this connector [Figure 10-60-3].

34 of 888
REMOTE START TOOL-MEL1563 (CONT'D) Service Tool Harness Communicator - MEL1566
Service Tool Harness Control - MEL1565 (Cont’d) Figure 10-60-8
Figure 10-60-7 2
2
1
1
P16119
N-19631
The service tool harness communicator (Item 1) [Figure
10-60-8] is required to connect remote start tool to the
Loaders equipped with an attachment harness (Item 1) Service PC (Item 2) [Figure 10-60-8].
[Figure 10-60-7] must disconnect the attachment

harness from the loader harness (Item 2) [Figure 10-60-
7].
Connect the service tool harness to the ACD connector

and the loader harness connector.
NOTE: To monitor, diagnose or load new software

the Service PC must be connected to the
Remote Start Tool Switch.

35 of 888
REMOTE START TOOL KIT-MEL1563 (CONT’D) Figure 10-60-11
Remote Start Procedure
The tool listed will be needed to do the following

procedure:
MEL1563: Remote Start Tool Kit

1
Figure 10-60-9
N-19150
Remove the plug (Item 1) [Figure 10-60-10] or

disconnect the attachment control harness (Item 1)
[Figure 10-60-11] if connected.
Figure 10-60-12

P16115
The remote start tool (Item 1) [Figure 10-60-9] 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.
P13861
Raise the operator cab (if required by the procedure).
Open the rear door of the loader. Connect the remote start tool to the engine harness
connector [Figure 10-60-12].
Figure 10-60-10 NOTE: The key switch on the right-hand side
operator panel must be in the off position or
the Remote Start Kit will not operate.
WARNING
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
N-19151
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899

36 of 888
REMOTE START TOOL KIT-MEL1563 (CONT'D) Figure 10-60-14
Remote Start Procedure (Cont'd)
Figure 10-60-13
2
3 1
P16118
The traction lock switch (Item 1) [Figure 10-60-14] is

P16116 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
The remote start tool (Item 1) [Figure 10-60-13] has able to turn.
three rocker switches.

The maximum flow/variable flow switch (Item 2) [Figure
10-60-14] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
The auxiliary pressure release (Item 3) [Figure 10-60-14]

is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.

engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.
WARNING
• 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

37 of 888
REMOTE START TOOL KIT-MEL1563 (CONT'D)

engine to stop in three seconds. To relieve the
pressure at the rear or right hand auxiliary, (If
so equipped.) continue to hold the switch for
three seconds after the engine has stopped.
Figure 10-60-15

P-34661
Push the couplers on the front auxiliary block toward the

block and hold for five seconds to release the front
auxiliary pressure [Figure 10-60-15].

38 of 888
REMOTE START TOOL (SERVICE TOOL) KIT -
6689779
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 6689779,

can be used to service older loaders with the BOSS®
system using the supplied BOSS® Service Tool Harness
P/N 6689745.
The Remote Start Tool (Service Tool) Kit, P/N 6689779,

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.

39 of 888
REMOTE START TOOL (SERVICE TOOL) KIT - Figure 10-61-17
6689779 (CONT'D)
2
Remote Start Tool (Service Tool) - 6689778
Tools that will be needed to complete the following steps

5 3
are:
Order from Bobcat Parts P/N: 6689779 - Remote Start 6 4

Tool (Service Tool) Kit
Kit Includes:
6689778 - Remote Start Tool (Service Tool) 1
6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
6689745 - BOSS® Service Tool Harness
P-76439
Figure 10-61-16
The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-17] has five buttons.
The STOP button (Item 2) [Figure 10-61-17] is used to

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

The RUN button (Item 3) [Figure 10-61-17] is used to
turn the Remote Start Tool (Service Tool) on and
1 activates the loader ignition power. The button will
illuminate to indicate the service tool is active.
The START button (Item 4) [Figure 10-61-17] is used to

start the loader engine.
P-76678
The traction lock button (Item 5) [Figure 10-61-17] is
used to turn traction lock ON or OFF. Push the button and
The remote start tool (Item 1) [Figure 10-61-16] is the 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 or adjusting the steering
linkage. The auxiliary button (Item 6) [Figure 10-61-17] 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.

40 of 888
6689779 (CONT'D)
Loader Service Tool Harness - 6689747 2
Figure 10-61-18
P-76452
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
10-61-20].
The loader service tool harness (Item 1) [Figure 10-61- When the remote start procedure is completed, replace

18] is used to connect the remote start tool (service tool) the loader connector cap (Item 1) [Figure 10-61-19] or
(Item 2) [Figure 10-61-18] to the electrical system on the reconnect the attachment control harness to the loader
loader. harness [Figure 10-61-20].
Figure 10-61-19
P-76451
Loaders without an attachment control harness, remove

the loader harness cap (Item 1) [Figure 10-61-19] and
connect the Loader Service Tool Harness from the
Remote Start Tool (Service Tool).

41 of 888
REMOTE START TOOL (SERVICE TOOL) KIT - Computer Service Tool Harness - 6689746
6689779 (CONT'D)
Figure 10-61-22
Loader Service Tool Harness - 6689747 (Cont’d)
Figure 10-61-21
2 1
3 2
1 P-76450
P-76453 The computer service tool harness (Item 1) [Figure 10-

61-22] is required to connect remote start tool (service
tool) to the Service PC (Item 2) [Figure 10-61-22].
NOTE: The Remote Start Tool (Service Tool)
connection harness has two connectors (Item

1) and (Item 3). The main connector (Item 1)
[Figure 10-61-21] is always used for
connection to the loader harness.
The second connector (Item 3) [Figure 10-61-

21] 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 10-61-21].
NOTE: The right instrument panel (Deluxe

Instrumentation Panel or Standard Key Panel)
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

42 of 888
6689779 (CONT'D)
Remote Start Procedure
WARNING
With the 7-pin connector plugged into the loader and
Remote Start Tool RUN button is not illuminated, the
loader can still be started from the operator panel
inside the cab.
P-76451
Pressing the RUN button on the Remote Start Tool
disconnects the operator panel from the start circuit.
If the service technician will be working in the engine Loaders without an attachment control harness, remove
area it is important to remove the operator panel key the loader harness cap (Item 1) [Figure 10-61-24] and
or lock the keypad with a unique password. connect the Loader Service Tool Harness from the
W-2647-0707 Remote Start Tool (Service Tool).
Figure 10-61-25

procedure:
2
6689779: Remote Start Tool (Service Tool) Kit
Figure 10-61-23
1 1
P-76452
Loaders with an attachment control harness (7 pin or 14

pin), the attachment harness (Item 1) must be
disconnected from the loader harness (Item 2) [Figure
P-76450 10-61-25].
When the remote start procedure is completed, replace

The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
the loader connector cap (Item 1) [Figure 10-61-25] or
61-23] is required when the operator cab is in the raised
reconnect the attachment control harness to the loader
position for service and the service technician needs to
harness [Figure 10-61-25].
turn on the loader 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.

43 of 888
6689779 (CONT'D)
2
Figure 10-61-26
5 3
2
6 4
1
P-76439
3
1 The Remote Start Tool (Service Tool) (Item 1) [Figure 10-
61-27] has five buttons.
P-76453
The STOP button (Item 2) [Figure 10-61-27] 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 10-61-27] is used to
[Figure 10-61-26] 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
The second connector (Item 3) [Figure 10-61- illuminate to indicate the service tool is active.
26] is used for attachment ACD upgrades or
attachment operational diagnostics only. This The START button (Item 4) [Figure 10-61-27] is used to
connector has a cap attached to it to prevent start the loader engine.
damage or corrosion when not in use.
The traction lock button (Item 5) [Figure 10-61-27] is
Connect the Remote Start Tool (Service Tool) connector used to turn traction lock ON or OFF. Push the button and
(Item 1) to the loader harness connector (Item 2) and the the button will illuminate indicating the traction lock is
other Remote Start Tool (Service Tool) connector to the disabled in which the wheels or tracks are able to turn.
ACD harness connector (Item 3) [Figure 10-61-26].
The auxiliary button (Item 6) [Figure 10-61-27] is used to
NOTE: The right instrument panel (Deluxe activate the auxiliary hydraulics. The button will illuminate
Instrumentation Panel or Standard Key Panel) to indicate the auxiliary hydraulics are active. Pressing
must be in the off position or the Remote Start the button a second time will turn the flow OFF. The
Tool (Service Tool) will not 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

44 of 888
6689779 (CONT'D)
Figure 10-61-28
1 2
P-34661
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 10-61-29].
The gear icon with the left facing arrows (Item 1) [Figure
10-61-28] 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 10-61-28] 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 on the to the right and left
several times.

45 of 888

46 of 888
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

■ ■ ■
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 grill. Check coolant level COLD and
add premixed coolant as needed.
Fuel Filter Remove the trapped water.
Lift Arms, Cylinders, Bob-Tach Lubricate with multi-purpose lithium based grease.
Pivot Pins and Wedges
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.
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, Hoses and Check fluid level and add as needed. Check for damage and leaks. Repair or
Tubelines replace as needed.
Tracks Check for damaged or worn tracks and correct tension. ❏
Track Sprocket Nuts Check torque. Tighten as needed. See procedure in this manual.
Parking Brake, Foot Pedals, Check for correct operation. Repair or adjust as needed.
Hand Controls and Steering
Levers or Joysticks
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease fittings.
Fuel Filter Replace filter element.
Engine / Hydro. Drive Belt Check for wear or damage. Check idler arm stop. ▲
Drive Belts (Alternator, air Check condition and tension. Adjust or 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. ▲ ✶
Hydraulic / Hydrostatic Filter, Replace the hydraulic / hydrostatic filter, charge filter, and the reservoir ●
Charge Filter, Reservoir Breather breather.
Hydrostatic Motor Carrier Replace oil with high performance synthetic oil P/N 6682546.
Hydraulic Reservoir Replace the fluid.
Case Drain Filters Replace the filters. ▲
Engine Valves Adjust the engine valves. ❍
Coolant Replace the coolant Every 2 years
■ Or every 12 months.
▲ Perform at first 50 hours, then as scheduled.
❏ Check every 8 - 10 hours for the first 24 hours, then at 50 hour intervals.
● Replace the hydraulic / hydrostatic filter element after the first 50 hours, then when service code [M0217] is displayed
or as scheduled.
✶ Change oil and filter every 100 hours when operating under severe conditions.
❍ Perform at first 500 hours, then as scheduled.

47 of 888

48 of 888
AIR CLEANER SERVICE Outer Filter
Replacing Filter Elements Figure 10-80-3
Figure 10-80-1
1 1
P-76460G
P-24654
Figure 10-80-2
Remove the wing nut and remove the dust cover (Item 1)
[Figure 10-80-3].
Figure 10-80-4

1
B-15553M
1
It is important to change the air filter element only when

necessary. The Service indicator (Item 1) will FLASH and
P-24655
service code [M0117] (Air Filter Plugged) will show in the
Data Display (Item 2) when the Information button (Item
3) [Figure 10-80-1] is held for two seconds. Remove the wing nut and pull the outer filter element
(Item 1) [Figure 10-80-4] out and discard.
The Air Cleaner icon on the Deluxe Instrumentation
Panel, if equipped, will be ON (Item 1) [Figure 10-80-2]. NOTE: Make sure all sealing surfaces are free of dirt
and debris.
Replace the inner filter every third time the outer filter is
replaced or as indicated. Install new filter. Push all the way in until it contacts the
base of the housing. Install wing nut.
Install the dust cover and the wing nut [Figure 10-80-3].

49 of 888
AIR CLEANER SERVICE (CONT’D)
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

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

engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [M0117] (Air Filter Plugged),
replace the inner filter element.
Figure 10-80-5

1
P-24656
Remove the inner filter element (Item 1) [Figure 10-80-

5].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Install the new inner element [Figure 10-80-5].
Install the outer element.
Install the dust cover and the wing nut.

50 of 888
ENGINE COOLING SYSTEM Figure 10-90-2
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage.
1
WARNING
Wear safety glasses to prevent eye injury when any 2
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
P-76189
• Tools are being used.
W-2019-0907
NOTE: Be careful when raising and lowering the air
Cleaning conditioning condenser so that the air
conditioning condenser does not fall on the
oil cooler and damage the fins.
Open the rear door. (See REAR DOOR on Page 50-70-
1.) Raise the air conditioning condenser (Item 1) and use
low air pressure or water pressure to clean the top of the

Remove the rear grill. (See REAR GRILL on Page 50-60- oil cooler (Item 2) [Figure 10-90-2].
1.)
Figure 10-90-3
Figure 10-90-1
1 2
1
P-76190
P-39459
NOTE: Be careful when raising and lowering the oil

cooler so that the oil cooler does not fall on
Use low air pressure or water pressure to clean the top of
the radiator and damage the fins.
the air conditioning condenser (Item 1) [Figure 10-90-1],
if equipped. Raise the oil cooler (Item 1) and use low air pressure or
water pressure to clean the top of the radiator (Item 2)
Raise the overflow tank (Item 2) slightly and remove the [Figure 10-90-3].
two fasteners (Inset) [Figure 10-90-1].
Lower the oil cooler.
Lower the air conditioning condenser, if equipped.
Install the fasteners and lower the overflow tank. Check

the cooling system for leaks.
Install the rear grill and close the rear door.

51 of 888
ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant
Checking Level Open the rear door and remove the rear grill.
Open the rear door and raise the rear grill. Figure 10-90-5
Check coolant level using the level markers (Item 3)
[Figure 10-90-4] on the tank. Coolant must be at the
bottom marker when the engine is cold; top marker when
1
hot.
2
Close the rear door before operating the loader.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze. P-34869 P-45490
Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine Remove the coolant fill cap (Item 1) [Figure 10-90-5].
damage.

Disconnect the hose from the engine block to the oil filter
Too little antifreeze reduces the additives which cooler (Item 2) [Figure 10-90-5]. Drain the coolant into a
protect the internal engine components; reduces the container. Recycle or dispose of coolant in an
boiling point and freeze protection of the system. environmentally safe manner.
Always add a premixed solution. Adding full strength Mix new coolant in a separate container. (See Capacities
concentrated coolant can cause serious premature on Page SPEC-10-4.)
engine damage.
I-2124-0497 NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
Figure 10-90-4 propylene glycol with ethylene glycol.
Add premixed coolant, 47% water and 53% propylene

glycol to the recovery tank. See checking level at left.
One gallon and one pint (4,3 L) of propylene glycol mixed

1 with one gallon (3,8 L) of water is the correct mixture of
coolant to provide a -34° F (-37° C) freeze protection.
Fill the tank until it is at the lower marker on the tank.
Use a refractometer to check the condition of propylene

glycol in your cooling system and replace the coolant fill
cap.
NOTE: When installing the coolant fill cap, the cap

P-76781
must be tightened until it clicks.
NOTE: All access covers (Item 1) [Figure 10-90-4] Run the engine until it is at operating temperature. Stop
(both sides) must be in place to ensure the engine. Check the coolant level when cool. Add
correct air flow through the oil cooler which coolant as needed.
will ensure cooling for engine and hydraulic
system. Install the rear grill and close the rear door.

52 of 888
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 F° (C°) NO. 2 NO.1 corrosion and plugging of fuel system components.
+15° (9°) 100% 0% • Use of biodiesel blend fuel may result in premature
Down to -20° (-29°) 50% 50% failure of fuel system components, such as plugged
Below -20° (-29°) 0% 100% fuel filters and deteriorated fuel lines.
• Shorter maintenance intervals may be required, such

The following fuels may be used in this machine:
as cleaning the fuel system and replacing fuel filters
and fuel lines.
• Low Sulfur (500 ppm sulfur) Diesel Fuel.
• Using biodiesel blended fuels containing more than
• Ultra Low Sulfur (15 ppm sulfur) Diesel Fuel.
five percent biodiesel can affect engine life and cause
deterioration of hoses, tubelines, injectors, injector
• Biodiesel Blend Fuel - Must contain no more than five
pump and seals.

percent biodiesel mixed with low sulfur or ultra low
sulfur petroleum based diesel. This is commonly
Apply the following guidelines if biodiesel blend fuel is
marketed as B5 blended diesel fuel. B5 blended
used:
diesel fuel must meet ASTM D975 (US Standard) or
EN590 (EU Standard) specifications.
• Ensure the fuel tank is as full as possible at all times
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.

53 of 888
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. B-15526B
Figure 10-100-1
Use a clean, approved safety container to add fuel of the
correct specifications. 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].
WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
P-48468 sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
Remove the fill cap (Item 1) [Figure 10-100-1]. W-2103-0508

54 of 888
FUEL SYSTEM (CONT’D) After replacing the filter element or when the fuel tank
has run out of fuel, the air must be removed from the fuel
Fuel Filter system before starting the engine.
For the service interval for removing water from, or

replacing the fuel filter (See SERVICE SCHEDULE on
Page 10-70-1.) WARNING
Removing Water AVOID INJURY OR DEATH
Diesel fuel or hydraulic fluid under pressure can
Figure 10-100-3 penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0807
2
Figure 10-100-4

1
P-48388
Loosen the drain (Item 1) [Figure 10-100-3] at the

bottom of the filter element to remove water from the
filter. 2 1
Replacing Element
P-48389
Remove the filter element (Item 2) [Figure 10-100-3].
Open the vent (Item 1) [Figure 10-100-4] on the fuel filter
Clean the area around the filter housing. Put clean oil on
housing.
the seal of the new filter element. Install the fuel filter, and
hand tighten.
Squeeze the hand pump (priming bulb) (Item 2) [Figure
10-100-4] until fuel flows from the vent with no air
Remove the air from the fuel system. (See Removing Air
bubbles.
From The Fuel System on Page 10-100-3.)
Close the vent (Item 1) [Figure 10-100-4].
WARNING
sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508
Removing Air From The Fuel System

55 of 888

56 of 888
ENGINE LUBRICATION SYSTEM Removing And Replacing Oil And Filter
Checking And Adding Engine Oil For the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-70-1.)
Check the engine oil level every day before starting the
engine for the work shift. Run the engine until it is at operating temperature. Stop
the engine.
Figure 10-110-1
Open the rear door and remove the drain hose from its
storage position (Item 4) [Figure 10-110-1].
3
Figure 10-110-3
1
2
4
1
P-24679
P-48472

Remove the drain plug (Item 1) [Figure 10-110-3] and
Park the machine on level ground. Open the rear door drain the oil into a container and recycle or dispose of
and remove the dipstick (Item 1) [Figure 10-110-1]. used oil in an environmentally safe manner.
Keep the oil level between the marks on the dipstick. Do Install the oil drain cap.
not overfill.
Remove the oil filter (Item 2) [Figure 10-110-1] and clean
Engine Oil Chart the filter housing surface.
Figure 10-110-2 Put oil on the new filter gasket, install the filter and hand
tighten.
Remove the fill cap (Item 3) [Figure 10-110-1].
Put oil in the engine. For the correct quantity. (See

Capacities on Page SPEC-10-4.). Do not overfill.
Start the engine and let it run for several minutes. Stop
the engine and check for leaks at the filter.
Remove the dipstick (Item 1) [Figure 10-110-1] 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
B-16320
Use a good quality motor oil that meets API Service Always clean up spilled fuel or oil. Keep heat, flames,
Classification of CD or better [Figure 10-110-2]. sparks or lighted tobacco away from fuel and oil.
explosion or fire.
W-2103-0508

57 of 888

58 of 888
HYDRAULIC / HYDROSTATIC SYSTEM Hydraulic / Hydrostatic Fluid Chart
Checking And Adding Fluid Figure 10-120-3
Put the loader on a level surface, lower the lift arms and
tilt the Bob-Tach fully back.
Stop the engine.
Figure 10-120-1
P-24478C
P-24478B 1
P-64023A
Use only recommended fluid in the hydraulic system

[Figure 10-120-3]. (See Hydraulic System on
Page SPEC-10-3.)
P-24478C

Check the fluid level in the sight gauge (Item 1) [Figure
10-120-1].
Figure 10-120-2
P-48011
Open the rear door and raise the rear grill. Remove the
fill cap (Item 1) [Figure 10-120-2].
Add fluid as needed to bring the level to the center of the

sight gauge [Figure 10-120-1].
Lower the rear grill and close the rear door.

59 of 888
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Lower the operator cab. (See Lowering on Page 10-30-
3.)
Removing And Replacing Hydraulic Fluid
Add the correct fluid to the reservoir until the fluid level is
For the correct service interval (See SERVICE at the center of the sight gauge. (See Checking And
SCHEDULE on Page 10-70-1.) Adding Fluid on Page 10-120-1. )
Replace the fluid if it becomes contaminated or after

major repair.
Always replace the hydraulic / hydrostatic filter, the case

drain filters and the hydraulic charge filter whenever the
hydraulic fluid is replaced. (See Removing And
Replacing Hydraulic / Hydrostatic Filter on Page 10-120-
3. )
Open the rear door and raise the rear grill. Remove the
fill cap.
Raise the operator cab. (See Raising on Page 10-30-2.)
Figure 10-120-4

1
P-37661
Remove the plug (Item 1) [Figure 10-120-4] and remove

the fluid.
Recycle or dispose of used fluid in an environmentally

safe manner.
WARNING
explosion or fire.
W-2103-0508
Install the plug (Item 1) [Figure 10-120-4].

60 of 888
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D)
Removing And Replacing Hydraulic / Hydrostatic

Filter
For the correct service interval (See SERVICE

SCHEDULE on Page 10-70-1.)
Open the rear door.
Figure 10-120-5

P-48470
Remove the filter (Item 1) [Figure 10-120-5].
Clean the surface of the filter housing where the filter

seal contacts the housing.
Put clean oil on the seal of the new filter element. Install
and hand tighten the filter element.
WARNING
explosion or fire.
W-2103-0508
Close the rear door.
Start the engine and operate the loader hydraulic

controls.
Stop the engine and check for leaks at the filter.

Check the fluid level in the reservoir and add as needed.
(See Checking And Adding Fluid on Page 10-120-1. )

61 of 888
HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-120-7
Right Side
Removing And Replacing Case Drain Filters
For the correct service interval (See SERVICE

1
Figure 10-120-6
Left Side
P-24682
Disconnect the hoses and fittings from the filter (Item 1)

[Figure 10-120-7]. Remove and discard the filter.
1
Install fittings on new filter, install new filter, connect and
tighten the hoses.

P-24734
Disconnect the hoses and fittings from the hydrostatic

WARNING
motor case drain filter (Item 1) [Figure 10-120-6].
Remove the mounting clamp and discard the filter. AVOID INJURY OR DEATH
Install fittings on new filter, install new filter, install the sparks or lighted tobacco away from fuel and oil.
mounting clamp, connect and tighten the hoses. Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
Lower the operator cab. (See Lowering on Page 10-30-

3.)

controls.
Stop the engine and check for leaks at the filters.


62 of 888
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D) AVOID INJURY OR DEATH
Removing And Replacing Hydraulic Charge Filter penetrate skin or eyes, causing serious injury or
The hydraulic charge filter is located under the cab. For
the correct service interval (See SERVICE SCHEDULE
on Page 10-70-1.) not use your bare hand. Wear safety goggles. If fluid
Raise the operator cab. (See Raising on Page 10-30-2.) from a physician familiar with this injury.
W-2072-0807
Figure 10-120-8
Stop the engine and check for leaks at the filter.


P-64239
Remove the filter (Item 1) [Figure 10-120-8].
Clean the surface of the filter housing where the filter

seal contacts the housing.
Put clean oil on the seal of the new filter.
Install and hand tighten the new filter.
WARNING
explosion or fire.
W-2103-0508

3.)

controls.
WARNING

63 of 888
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)
Breather Cap
See the SERVICE SCHEDULE for the correct

replacement interval. (See SERVICE SCHEDULE on
Page 10-70-1.)
Figure 10-120-9

P-76673
Remove the breather cap (Item 1) [Figure 10-120-9] and

discard. (Blower housing removed for clarity.)
Install new breather cap.

3.)

64 of 888
BOB-TACH (HAND LEVER) The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
Inspection And Maintenance 130-2].
Figure 10-130-1 If the wedge does not contact the lower edge of the hole
[Figure 10-130-2], the attachment will be loose and can
come off the Bob-Tach.
Figure 10-130-3
P-31693
Move the Bob-Tach levers to engage the wedges [Figure

10-130-1].

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 10-130-2
2 B-17460
Inspect the mounting frame on the attachment and Bob-

Tach, linkages and wedges for excessive wear or
Wedge must contact damage [Figure 10-130-3]. Replace any parts that are
lower edge of hole in the damaged, bent or missing. Keep all fasteners tight.
attachment.
Look for cracked welds. Contact your Bobcat dealer for
P-31233 B-15177 repair or replacement parts.
Lubricate the wedges. (See LUBRICATING THE

The wedges (Item 1) [Figure 10-130-2] must extend LOADER on Page 10-140-1.)
through the holes in the attachment mounting frame.

65 of 888

66 of 888
BOB-TACH (POWER) The spring loaded wedge (Item 1) must contact the lower
edge of the hole in the attachment (Item 2) [Figure 10-
This machine may be equipped a Power Bob-Tach. 131-2].
Inspection And Maintenance If the wedge does not contact the lower edge of the hole
[Figure 10-131-2], the attachment will be loose and can
Figure 10-131-1 come off the Bob-Tach.
Figure 10-131-3
1
.B-15993Q
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
10-131-1] until the wedges are fully down.
The 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 10-131-2
B-17460
Wedge must contact

lower edge of hole in the Inspect the mounting frame on the attachment and the
attachment. Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-131-3]. Replace any parts that are
P-31233 B-15177 damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

The wedges (Item 1) [Figure 10-131-2] must extend repair or replacement parts.
through the holes in the attachment mounting frame.
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-70-1) (See LUBRICATING THE LOADER on
Page 10-140-1.)

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LUBRICATING THE LOADER Figure 10-140-2
Lubrication Locations
Lubricate the loader as specified for the best 3

performance of the loader. (See SERVICE SCHEDULE
on Page 10-70-1.)
Record the operating hours each time you lubricate the

Bobcat Loader.
Always use a good quality lithium based multi-purpose 2

grease when you lubricate the loader. Apply lubricant
until extra grease shows.
Lubricate the following:
Figure 10-140-1
1 Access 4
Hole

Access
Hole
N-18506
P-24698A
P-24697 2. Stabilizer Rod - Rear (Both Sides) (2) [Figure 10-140-

2].
3. Lift Cylinder Rod End (Both Sides) (2) [Figure 10-
1. Stabilizer Rod - Front (Both Sides) (2) [Figure 10-
140-2].
140-1]
4. Lift Cylinder Base End (Both Sides) (2) [Figure 10-
140-2].
Figure 10-140-3
N-18510
5. Tilt Cylinder Base End (Both Sides) (2) [Figure 10-

140-3].

69 of 888
LUBRICATING THE LOADER (CONT’D) Figure 10-140-6
Lubrication Locations (Cont’d)
Figure 10-140-4 10
P-24700
10. Lift Arm Pivot Pin (Both Sides) (2) [Figure 10-140-6].
Figure 10-140-7
P-48104
6. Tilt Cylinder Rod End (2). [Figure 10-140-4].

7. Bob-Tach Pivot Pin (Both Sides) (2) [Figure 10-140-
4]. 11
Figure 10-140-5
P-24701
P-24699
11. Lift Arm Link Pivot Pin (Both Sides) (2) [Figure 10-
140-7].
Figure 10-140-8
9
P-16045
8. Bob-Tach Wedge (Both Sides) (2) [Figure 10-140-5].
9. Power Bob-Tach Cylinder (Both Sides) (2) [Figure

10-140-5]. (If Equipped) 12
P-24703
NOTE: SJC equipped machines do not have a

steering lever shaft.
12. 250 Hours: Steering Lever Shaft (2) [Figure 10-140-
8].

70 of 888
SPARK ARRESTOR MUFFLER
Cleaning Procedure
WARNING
See the SERVICE SCHEDULE for service interval for
cleaning the spark arrestor muffler. (See SERVICE
When the engine is running during service, the
steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
Do not operate the loader with a defective exhaust
death.
system. W-2006-0284
Start the engine and run for about 10 seconds while a

second person, wearing safety glasses, holds a piece of
IMPORTANT wood over the outlet of the muffler.
This will force contaminants out through the cleanout

This loader is factory equipped with a U.S.D.A.
hole.
Forestry Service approved spark arrestor muffler. It
is necessary to do maintenance on this spark Stop the engine.
arrestor muffler to keep it in working condition. The
spark arrestor muffler must be serviced by dumping Install and tighten the plug.
the spark chamber every 100 hours of operation.
If this machine is operated on flammable forest,

brush or grass covered land, it must be equipped
with a spark arrestor attached to the exhaust system
and maintained in working order. Failure to do so will WARNING
be in violation of California State Law, Section 4442
PRC. AVOID INJURY OR DEATH
When an engine is running in an enclosed area, fresh
Consult local laws and regulations for spark arrestor air must be added to avoid concentration of exhaust
requirements fumes. If the engine is stationary, vent the exhaust
I-2022-0807
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
Stop the engine. Open the rear door. W-2050-0807
Figure 10-150-1
WARNING
Stop engine and allow the muffler to cool before
1 cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
WARNING
P-48476
Never use machine in atmosphere with explosive
dust or gases or where exhaust can contact
Remove the plug (Item 1) [Figure 10-150-1] from the flammable material. Failure to obey warnings can
bottom of the muffler. cause injury or death.
W-2068-1285

71 of 888

72 of 888
PIVOT PINS
Inspection And Maintenance
Figure 10-160-1
P-31309
All lift arm and cylinder pivots have a large pin held in
position with a retainer bolt and lock nut (Item 1) [Figure

10-160-1].
Check that the lock nuts are tightened to 35 - 40 ft.-lb. (48

- 54 N•m) torque.

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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
• Install a fully charged battery.
compartment.
• Remove grease from exposed cylinder rods.
• Lubricate the loader.
• Check all belt tensions.
• Replace worn or damaged parts.
• Be sure all shields and guards are in place.
• Park the loader in a dry protected shelter.
• Lubricate the loader.
• Lower the lift arms all the way and put the bucket flat
on the ground. • Check track condition and remove blocks from under
frame.
• Put blocks under the frame to remove weight from the • Remove cover from exhaust pipe opening.
tracks.
• Start the engine and let run for a few minutes while
• Put grease on any exposed cylinder rods. observing the instrument panels and systems for
correct operation.
• Put fuel stabilizer in the fuel tank and run the engine
• Operate machine, check for correct function.
a few minutes to circulate the stabilizer to the pump
• Stop the engine and check for leaks. Repair as

and fuel injectors.
needed.
If biodiesel blend fuel has been used, perform the
following:
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, hyd. / hydro.).

• 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.

75 of 888

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STOPPING THE ENGINE AND LEAVING THE NOTE: Activating the Password Lockout Feature on
LOADER machines with the Deluxe Instrumentation
Panel allows operation of the loader without
Procedure using a password. (See Password Lockout
Stop the Bobcat Loader on level ground. Feature on Page 60-190-2.)
Fully lower the lift arms and put the attachment flat on the Figure 10-180-3
ground.
Figure 10-180-1
P-66659A P-66666

Exit the loader using grab handles, safety tread and
P-31864
steps (maintaining a 3-point contact) [Figure 10-180-3].
Pull the engine speed control fully backward [Figure 10-

180-1] to decrease the engine speed.
Engage the parking brake.

WARNING
Figure 10-180-2 Before you leave the operator’s seat:
• Lower the lift arms, put the attachment flat on the
ground.
• Stop the engine.
1 • Engage the parking brake.
• Raise seat bar.
• (Foot Pedal Controls) Move pedals until both
lock.
• (Advanced Control System-ACS) Move the
hydraulic controls to the NEUTRAL POSITION to
2 make sure that both lift and tilt functions are
deactivated.
P-76603 B-15553L The seat bar system must deactivate the lift and
tilt control functions when the seat bar is up.
Service the system if hand controls do not
Turn the key switch to the STOP position (Item 1) deactivate.
(Standard Key Panel) or press the STOP button (Item 2) • (Selectable Joystick Controls-SJC) Move the
(Deluxe Instrumentation Panel) [Figure 10-180-2]. joysticks to the NEUTRAL POSITION to make
sure that travel and hydraulic functions are
Lift the seat bar and make sure the lift and tilt functions deactivated.
are deactivated. The seat bar system must deactivate these
functions when the seat bar is up. Service the
Unbuckle the seat belt.
system if controls do not deactivate.
W-2463-0603
Remove the key from the switch (Standard Key Panel) to
prevent operation of the loader by unauthorized
personnel.

77 of 888
STOPPING THE ENGINE AND LEAVING THE Front Door (If Equipped)
LOADER (CONT’D)
NOTE: When an Operator Cab Enclosure Kit is
Emergency Exit installed, the window of the front door can be
used as an emergency exit. [Figure 10-180-6]
The front opening on the operator cab and rear window
provide exits. NOTE: If the loader has a Special Application Door
Kit installed, the window of the front door is
Rear Window (If Equipped) NOT an emergency exit.
Figure 10-180-4 Figure 10-180-6

P-64994
N-20171
Pull on the tag on the top of the rear window to remove Pull the plastic loop at the top of the window in the front
the rubber cord [Figure 10-180-4]. door to remove the rubber cord [Figure 10-180-6].
Push the rear window out of the rear of the operator cab. Figure 10-180-7
Figure 10-180-5
X X
X X
S0363
P-31269A
Push the window out with your foot at any corner of the
window [Figure 10-180-7].
Exit through the rear of the operator cab [Figure 10-180-
5]. Exit through the front door.

78 of 888
HYDRAULIC SYSTEM
BOB-TACH (POWER) BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-3 HYDRAULIC
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1 SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-4
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-3
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-2 DRIVE
SYSTEM
CYLINDER (BOB-TACH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-4
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22-1
CYLINDER (LIFT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

ELECTRICAL
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6 SYSTEM &
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5 ANALYSIS
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
ENGINE
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1 SERVICE
Base End Pivot Pin Removal And Installation. . . . . . . . . . . . . . . . . . . . 20-21-4
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-6
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-5
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-2 SPECIFICATIONS
Rod End Pivot Pin Bushing And Seal Removal And Installation. . . . . . 20-21-4
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21-1
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK . . . . . . . . . . . . . . 20-140-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1
HIGH FLOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
High Flow Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-3
High Flow Relief Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-4
79 of 888 20-01 T190 Service Manual

HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) . . . . . . . . . . . . . 20-41-1

Actuator Removal And Installation (Out of Loader) . . . . . . . . . . 20-41-6
Anti-Cavitation Valve Removal And Installation (Lift, Rod End) 20-41-12
Auxiliary Spool Removal And Installation. . . . . . . . . . . . . . . . . 20-41-24
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . 20-41-25
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . 20-41-32
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
End Cap Block Removal And Installation . . . . . . . . . . . . . . . . 20-41-16
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-9
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . 20-41-30
Lift Load Check Valve Removal And Installation . . . . . . . . . . . 20-41-10
Lift Spool And Detent Removal And Installation . . . . . . . . . . . 20-41-17
Load Check Valve Removal And Installation (Tilt & Auxiliary) . 20-41-11
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-41-28
Main Relief Valve Removal And Installation. . . . . . . . . . . . . . . 20-41-31
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . 20-41-10
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-15
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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-13
Port Relief / Anti-Cavitation Valve Removal And Installation (Tilt, Rod
End) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-14
Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . 20-41-14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-41-1
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-41-26
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-41-22

HYDRAULIC CONTROL VALVE (STANDARD) . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Anti-Cavitation Valve Removal And Installation (Lift, Rod End) . . . . . . . . . . 20-40-9
Auxiliary Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-28
Auxiliary Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-27
Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-34
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
End Cap / Spool Lock Block Removal And Installation . . . . . . . . . . . . . . . . 20-40-14
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Lift Arm Bypass Orifice Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-40-33
Lift Load Check Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Lift Spool And Detent Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-40-15
Load Check Valve Removal And Installation (Tilt & Auxiliary). . . . . . . . . . . . 20-40-8
Lock Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-31
Main Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 20-40-33
Mount Bracket Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-7
Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Port Relief / Anti-Cavitation Valve Removal And Installation (Lift, Base End)20-40-10
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) 20-40-11

Port Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Rubber Boot Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Solenoid Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-29
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-25
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Hydraulic Fluid Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-3
HYDRAULIC/HYDROSTATIC FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Charge Filter Housing Removal And Installation. . . . . . . . . . . . . . . . . . . . . . 20-80-3
Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
HYDRAULIC PUMP (STANDARD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Direct Pump Test (Charge Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
Direct Pump Test (Standard Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-2
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-10
Hydraulic Pump Startup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-8
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-9
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

HYDRAULIC PUMP (STANDARD) (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Direct Pump Test (Charge Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-6
Direct Pump Test (Standard Section). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-2
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-12
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-11
Pump Test At Quick Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-61-8
HYDRAULIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-8
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-9

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-6
HYDRAULIC PUMP (SJC) (HIGH FLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
Direct Pump Test (High Flow Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-6
Hydraulic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-10
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-11
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-8
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT ARM BYPASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-50-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
REAR AUXILIARY DIVERTER VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-5
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.

SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.


HYDRAULIC/HYDROSTATIC SCHEMATIC
T190 (S/N 531660001 AND ABOVE)
(S/N 531760001 AND ABOVE)
Printable Version Click Here
(PRINTED MAY 2008)

V-1264legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 47 RELIEF VALVE - 2000 PSI (137 Bar)
Capacity . . . . . . . 19.2 Qts. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
2 SPRING LOADED FILTER BY-PASS 33 FILTER - BICS CONTROL VALVE 48 RELIEF VALVE - 1200 PSI (83 Bar)
17 PILOTED ACTIVATED DIRECTIONAL
VALVE: 45-55 PSI (3,1-3,8 Bar) CONTROL VALVE - TILT CONTROL (SCREEN)
49 SOLENOID ACTIVATED DIRECTIONAL
3 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE (TWO COIL)
18 PILOTED ACTIVATED DIRECTIONAL 34 CHECK VALVE - BUCKET POSITION
36-44 PSI (2,5-3,0 Bar)
CONTROL VALVE - LIFT CONTROL VALVE 50 FIXED CAPACITY DISPLACEMENT
Normally Closed
19 PULL BUTTON ACTIVATED HYDRAULIC MOTOR
4 DRIVE MOTOR SHUTTLE VALVE 35 RESTRICTION
DIRECTIONAL CONTROL VALVE - LIFT 51 ANTICAVITATION VALVE
5 RELIEF/REPLENISHING VALVE - HIGH ARM BY-PASS
36 VARIABLE CAPACITY DISPLACEMENT 52 PROPORTIONAL RELIEF VALVE –
PRESSURE: 5000 PSI (345 Bar) 20 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP (Fan Speed Regulator):
CONTROL VALVE - UNLOADING
6 RELIEF VALVE - CHARGE INLET: 37
SHUTTLE RELIEF VALVE 1566 - 1784 PSI (108 - 123 bar)
SPOOL 53 FILTER - BOB-TACH VALVE
360 PSI (24,8 Bar) (Not Adjustable - Factory Set)
at High Engine Idle 21 PILOTED ACTIVATED DIRECTIONAL Dealer Copy -- Not for Resale
65 PSI (4,5 Bar) RESTRICTION - 0.343 inch (8,73 mm)
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - FLOW CONTROL 54
SPOOL
38 FIXED CAPACITY DISPLACEMENT 55 CHECK VALVE
7 FRONT AUXILIARY MANUAL PRESSURE 22 FLOW DIVIDER ADJUSTMENT VALVE BIDIRECTIONAL HYDROSTATIC
BLEED-OFF VALVE MOTOR 56 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BRAKE
8 HYDRAULIC PUMP . . . . . . . Gear Type 23 SOLENOID ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
16.3 GPM (61,6 L/min.) at High Engine Idle CONTROL VALVE - BASE
57 HYDRAULIC BRAKE - SPRING APPLIED
24 SOLENOID ACTIVATED DIRECTIONAL 40 SOLENOID ACTIVATED DIRECTIONAL - PRESSURE RELEASE
9 RELIEF VALVE - MAIN:
3250-3350 PSI (224-231 Bar) CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION
at Front Quick Couplers VALVE (ON/OFF)
25 LOAD SHUTTLE VALVE - BLEED OFF
10 RELIEF/ANTICAVITATION VALVE - 41 CHECK VALVE - BICS CONTROL VALVE
PORT 3500 PSI (241,3 Bar) 26 SOLENOID ACTIVATED DIRECTIONAL
42 CHARGE PUMP -
CONTROL VALVE - TWO COIL
11 ANTICAVITATION VALVE 12.8 GPM (48,5 L/min) at High Engine Idle
27 PILOT ACTIVATED DIRECTIONAL
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 43 CHECK VALVE - With 300 PSI (20,7 Bar)
CONTROL VALVE - AUXILIARY 28 RESTRICTOR - 0.140 inch (3,6 mm) Spring And With 0.016 inch (0,40 mm) Orifice
13 RELIEF/ANTICAVITATION VALVE - 44 PILOT ACTIVATED DIRECTIONAL
PORT (OPTIONAL) 3500 PSI (241,3 Bar) 29 RESTRICTOR - 0.031 inch (0,8 mm)
CONTROL VALVE - HYDRAULIC
RELIEF VALVE: 3300 PSI (228 Bar) POWERED BOB-TACH
30
14 LOAD CHECK VALVE
45 RESTRICTION - 0.089 inch (2,26 mm) NOTE: Unless otherwise specified
15 LIFT CYLINDER SPOOL - MADE TO 31 FILTER - HYDRAULIC (CANISTER) springs have NO significant
RESTRICT FLOW DURING BOOM 46 RESTRICTION - 0.025 inch (0,6 mm)
pressure value.
DOWN BUT NOT DURING BOOM UP
Printed in U.S.A. V-1264legend (4-30-08)

85 of 888
(REAR QUICK
FEMALE COUPLERS) MALE
T190 (S/N 531660001 AND ABOVE)
BASE ROD REAR AUX VALVE (OPTIONAL)
INTEGRATED QUICK
(PRINTED MAY 2008) 23 24 COUPLER BLOCK
V-1264 25 MALE
26
28 7 (FRONT AUXILIARY
MALE
7 LEFT SIDE LIFT ARM)
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
57
P-OUT P-IN T
32 BUCKET POSITION VALVE (OPTIONAL)
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
HYDRAULIC CONTROL VAVLE
6 3 40 C
21
Dealer Copy -- Not13for Resale

20
AUXILIARY
CHARGE
SPOOL
INLET 12 12
13 B
B A
54
31
2
14
36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5
D C
3 8
50 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
(OPTIONAL) 11
HYDRAULIC
52 51 POWERED 14
BOB-TACH LIFT CYLINDERS
(OPTIONAL) 10
18
39
DRIVE MOTOR DR B A
13 LIFT
CYLINDER
38 43 SPOOL
48 46 15 33 33
55 47 41 35
49 45
56
PP
57 14
9 16 WORKING CIRCUITS
53
PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
4 37
44
32
LIFT ARM BY PASS VALVE
19
86 of 888
Printed in U.S.A. V-1264 (4-30-08)
WITH HIGH FLOW OPTION
T190 (S/N 531660001 AND ABOVE)
(PRINTED MAY 2008)

V-1265legend
LEGEND
1 RESERVOIR: 16 SOLENOID ACTIVATED DIRECTIONAL 32 FILTER - CASE DRAIN (SINTERED 47 RELIEF VALVE - 2000 PSI (137 Bar)
Capacity . . . . . . . 19.2 Qts. (18,2 L) CONTROL VALVE - BICS CONTROL BRONZE)
2 SPRING LOADED FILTER BY-PASS 33 FILTER - BICS CONTROL VALVE 48 RELIEF VALVE - 1200 PSI (83 Bar)
VALVE: 45-55 PSI (3,1-3,8 Bar) CONTROL VALVE - TILT CONTROL (SCREEN)
3 DIFFERENTIAL PRESSURE SWITCH: CONTROL VALVE (TWO COIL)
36-44 PSI (2,5-3,0 Bar)
CONTROL VALVE - LIFT CONTROL VALVE 50
Normally Closed RELIEF VALVE - 3300 PSI (228 Bar)
19 PULL BUTTON ACTIVATED
4 DRIVE MOTOR SHUTTLE VALVE 35 RESTRICTION 51 DUMP VALVE - (ON/OFF)
DIRECTIONAL CONTROL VALVE - LIFT
5 RELIEF/REPLENISHING VALVE - HIGH ARM BY-PASS
36 VARIABLE CAPACITY DISPLACEMENT 52 CHECK VALVE
PRESSURE: 5000 PSI (345 Bar) 20 PILOTED ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC PUMP 53
CONTROL VALVE - UNLOADING FILTER - BOB-TACH VALVE
6 RELIEF VALVE - CHARGE INLET: 37
SHUTTLE RELIEF VALVE
SPOOL
360 PSI (24,8 Bar) (Not Adjustable - Factory Set) 54 AUXILIARY HYDRAULIC PUMP -
at High Engine Idle 21 PILOTED ACTIVATED DIRECTIONAL Dealer Copy -- Not for Resale 9.2 GPM (34,8 L/min) at High Engine Idle
65 PSI (4,5 Bar)
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - FLOW CONTROL
SPOOL 55 FIXED CAPACITY DISPLACEMENT
38 FIXED CAPACITY DISPLACEMENT
7 FRONT AUXILIARY MANUAL PRESSURE 22 FLOW DIVIDER ADJUSTMENT VALVE BIDIRECTIONAL HYDROSTATIC HYDRAULIC MOTOR
BLEED-OFF VALVE MOTOR 56 ANTICAVITATION VALVE
8 HYDRAULIC PUMP . . . . . . . Gear Type 23 SOLENOID ACTIVATED DIRECTIONAL 39 CHECK VALVE - With 80 PSI (5,5 Bar) Spring
CONTROL VALVE - BASE 57 PROPORTIONAL RELIEF VALVE –
16.3 GPM (61,6 L/min.) at High Engine Idle
(Fan Speed Regulator):
9 24 SOLENOID ACTIVATED DIRECTIONAL 40 SOLENOID ACTIVATED DIRECTIONAL 1566 - 1784 PSI (108 - 123 bar)
RELIEF VALVE - MAIN:
3250-3350 PSI (224-231 Bar) CONTROL VALVE - ROD CONTROL VALVE - BUCKET POSITION 58 RESTRICTION - 0.343 inch (8,73 mm)
at Front Quick Couplers VALVE (ON/OFF)
25 LOAD SHUTTLE VALVE - BLEED OFF 59 CHECK VALVE
10 RELIEF/ANTICAVITATION VALVE - 41 CHECK VALVE - BICS CONTROL VALVE
PORT 3500 PSI (241,3 Bar) 26 SOLENOID ACTIVATED DIRECTIONAL
42 CHARGE PUMP - 60 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - TWO COIL CONTROL VALVE - BRAKE
11 ANTICAVITATION VALVE 12.8 GPM (48,5 L/min) at High Engine Idle
27 PILOT ACTIVATED DIRECTIONAL 61 HYDRAULIC BRAKE - SPRING APPLIED
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY 43 CHECK VALVE - With 300 PSI (20,7 Bar) - PRESSURE RELEASE
CONTROL VALVE - AUXILIARY 28 RESTRICTOR - 0.140 inch (3,6 mm) Spring And With 0.016 inch (0,40 mm) Orifice
13 RELIEF/ANTICAVITATION VALVE - 44 PILOT ACTIVATED DIRECTIONAL
PORT (OPTIONAL) 3500 PSI (241,3 Bar) 29 RESTRICTOR - 0.031 inch (0,8 mm)
CONTROL VALVE - HYDRAULIC
RELIEF VALVE: 3300 PSI (228 Bar) POWERED BOB-TACH
30
14 LOAD CHECK VALVE
45 RESTRICTION - 0.089 inch (2,26 mm) NOTE: Unless otherwise specified
15 LIFT CYLINDER SPOOL - MADE TO 31 FILTER - HYDRAULIC (CANISTER) springs have NO significant
RESTRICT FLOW DURING BOOM 46 RESTRICTION - 0.025 inch (0,6 mm)
pressure value.
DOWN BUT NOT DURING BOOM UP
Printed in U.S.A. V-1265legend (4-30-08)

87 of 888
(REAR QUICK
WITH HIGH FLOW OPTION
T190 (S/N 531660001 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)

Printable Version Click Here INTEGRATED QUICK
23 24 COUPLER BLOCK
(PRINTED MAY 2008) MALE
25
V-1265 26
MALE
DRIVE MOTOR
29
1 30
FEMALE
27
4 37
61
P-OUT P-IN T
38
D
HYDRAULIC FILTER 34
31
OIL
2 22
COOLER
B HYDROSTATIC PUMPS A
5 36
5
A
HYDRAULIC CONTROL VAVLE
6 3 40 C
21
Dealer Copy -- Not13for Resale

20
AUXILIARY
CHARGE
SPOOL
INLET 12 12
13 B
B A
58
31
2
14
36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 5 HIGH FLOW VALVE
D C
3 51
8
50
52
55 INLET OUTLET
B A 17
TILT
42 13 10 CYLINDER
BOB-TACH SPOOL
CYLINDER
54 (OPTIONAL) 11
HYDRAULIC
57 56 POWERED 14
BOB-TACH LIFT CYLINDERS
(OPTIONAL) 10
18
39
DRIVE MOTOR DR B A
13 LIFT
CYLINDER
38 43 SPOOL
48 46 15 33 33
59 47 41 35
49 45
60
PP
61 14
9 16 WORKING CIRCUITS
53
PILOT CIRCUITS
DRAIN CIRCUITS
P1 P2
COMPONENTS
4 37
44
32
LIFT ARM BY PASS VALVE
19
88 of 888
Printed in U.S.A. V-1265 (4-30-08)
WITH SJC OPTION
T190 (S/N 531660001 AND ABOVE)
(PRINTED MAY 2008)

V-1266legend
LEGEND
1 RESERVOIR: 16 33 FILTER - BICS CONTROL VALVE 50 FIXED CAPACITY DISPLACEMENT
SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - BICS CONTROL (SCREEN) HYDRAULIC MOTOR
51
2 SPRING LOADED FILTER BY-PASS ANTICAVITATION VALVE
VALVE: 45-55 PSI (3,1-3,8 bar) VALVE 52 PROPORTIONAL RELIEF VALVE –
CONTROL VALVE - TILT CONTROL
3 DIFFERENTIAL PRESSURE SWITCH: (Fan Speed Regulator):
18 PILOTED ACTIVATED DIRECTIONAL 35 RESTRICTION 1566 - 1784 PSI (108 - 123 bar)
36-44 PSI (2,5-3,0 bar)
Normally Closed CONTROL VALVE - LIFT CONTROL
53 CHARGE PUMP -
19 PULL BUTTON ACTIVATED 36 VARIABLE CAPACITY DISPLACEMENT 12.8 GPM (48,5 L/min) at High Engine Idle
4 DRIVE MOTOR SHUTTLE VALVE
DIRECTIONAL CONTROL VALVE - BI-DIRECTIONAL HYDROSTATIC PUMP
54 CHECK VALVE - With 300 PSI (20,7 bar) Spring
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS 37 SHUTTLE RELIEF VALVE with 0.016 inch (0,40 mm) orifice
PRESSURE: 5075 PSI (350 bar) 20 PILOTED ACTIVATED DIRECTIONAL (Not Adjustable - Factory Set) 55 SOLENOID ACTIVATED CONTROL
CONTROL VALVE - UNLOADING 65 PSI (4,5 bar) VALVE - FORWARD/REVERSE
6 RELIEF VALVE - CHARGE INLET: SPOOL 56 SERVO PISTON -Swash Plate
360 PSI (24,8 bar) 38 FIXED CAPACITY DISPLACEMENT
at High Engine Idle Dealer Copy -- NotBI-DIRECTIONAL
for Resale HYDROSTATIC 57 POSITION SENSOR -Swash Plate
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - FLOW CONTROL MOTOR
SPOOL
58 CHARGE PRESSURE SENSOR
7 FRONT AUXILIARY MANUAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring
22 FLOW DIVIDER ADJUSTMENT VALVE
PRESSURE BLEED-OFF VALVE 59 CHECK VALVE
8 HYDRAULIC PUMP . . . . . . . Gear Type 40 SOLENOID ACTIVATED DIRECTIONAL
23 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION 60 SOLENOID ACTIVATED DIRECTIONAL
CONTROL VALVE - BASE VALVE (ON/OFF) CONTROL VALVE - BRAKE
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL 61 HYDRAULIC BRAKE - SPRING APPLIED
41 CHECK VALVE - BICS CONTROL VALVE
3250-3350 PSI (224-231 bar) CONTROL VALVE - ROD - PRESSURE RELEASE
at Front Quick Couplers
42 RESTRICTION - 0.343 inch (8,7 mm)
10 PORT RELIEF/ANTICAVITATION VALVE
3500 PSI (241,3 bar) 43 FILTER - Bob-Tach Valve
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL 44 PILOT ACTIVATED DIRECTIONAL
27 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY POWERED BOB-TACH
CONTROL VALVE - AUXILIARY 45
28 RESTRICTOR - 0.140 inch (3,6 mm) RESTRICTION - 0.089 inch (2,26 mm)
13 PORT RELIEF/ANTICAVITATION VALVE:
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm) 46 RESTRICTION - 0.025 inch (0,6 mm)
3500 PSI (241,3 bar)
14 LOAD CHECK VALVE 30 RELIEF VALVE: 3300 PSI (228 bar) 47 RELIEF VALVE - 2000 PSI (137 bar)
15 LIFT CYLINDER SPOOL - MADE TO 48 RELIEF VALVE - 1200 PSI (83 bar) NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER)
RESTRICT FLOW DURING BOOM NO significant pressure value.
DOWN BUT NOT DURING BOOM UP 32 FILTER - CASE DRAIN (SINTERED 49 SOLENOID ACTIVATED DIRECTIONAL
BRONZE) CONTROL VALVE (TWO COIL) V-1266legend (4-30-08)
Printed in U.S.A.
89 of 888
(REAR QUICK
WITH SJC OPTION
T190 (S/N 531660001 AND ABOVE) BASE ROD REAR AUX VALVE (OPTIONAL)
(PRINTED MAY 2008) INTEGRATED QUICK
(V-1266) 23 24 COUPLER BLOCK
Printable Version Click Here 25 MALE

26
MALE
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
61
P-OUT P-IN T
D
34
38 HYDRAULIC FILTER
31
B HYDROSTATIC PUMPS A OIL

COOLER 22
2
55
56 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
57
21

6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
58
42
31
57 14
2 36
10 TILT CYLINDERS
BICS CONTROL VALVE
5 56 5
55
3
TILT
B A 17
SPOOL
D C
8
10 11
INLET OUTLET 14
50 LIFT CYLINDERS
52 51 53 10
FAN MOTOR 18
HYDRAULIC
POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
38
35
39 47
15
DR
59
14
60 54
48 33 41
61 46 33
9 16
49 45
37 PP
4 43
32 LIFT ARM BY PASS VALVE
P1 P2
44 19
Printed in U.S.A. DRIVE MOTOR
90 of 888
V-1266 (4-30-08)
WITH SJC AND HIGH FLOW OPTION
T190 (S/N 531660001 AND ABOVE)
(PRINTED MAY 2008)

V-1267legend
LEGEND
1 RESERVOIR: 16 33 FILTER - BICS CONTROL VALVE 50 RELIEF VALVE - 3300 PSI (228 bar)
SOLENOID ACTIVATED DIRECTIONAL
Capacity . . . . . . . 19.2 qt. (18,2 L) CONTROL VALVE - BICS CONTROL (SCREEN)
51 DUMP VALVE - (ON/OFF)
2 SPRING LOADED FILTER BY-PASS 34 CHECK VALVE - BUCKET POSITION
VALVE: 45-55 PSI (3,1-3,8 bar) 17 PILOTED ACTIVATED DIRECTIONAL
VALVE 52 CHECK VALVE
CONTROL VALVE - TILT CONTROL
3 DIFFERENTIAL PRESSURE SWITCH:
18 PILOTED ACTIVATED DIRECTIONAL 35 RESTRICTION 53
36-44 PSI (2,5-3,0 bar) AUXILIARY HYDRAULIC PUMP -
Normally Closed CONTROL VALVE - LIFT CONTROL 9.2 GPM (34,8 L/min) at High Engine Idle
19 PULL BUTTON ACTIVATED 36 VARIABLE CAPACITY DISPLACEMENT 54
4 DRIVE MOTOR SHUTTLE VALVE CHECK VALVE - With 300 PSI (20,7 bar) Spring
DIRECTIONAL CONTROL VALVE - BI-DIRECTIONAL HYDROSTATIC PUMP with 0.016 inch (0,40 mm) orifice
5 RELIEF/REPLENISHING VALVE - HIGH LIFT ARM BY-PASS 37 SHUTTLE RELIEF VALVE 55 SOLENOID ACTIVATED CONTROL
PRESSURE: 5075 PSI (350 bar) 20 PILOTED ACTIVATED DIRECTIONAL (Not Adjustable - Factory Set) VALVE - FORWARD/REVERSE
CONTROL VALVE - UNLOADING 65 PSI (4,5 bar) 56 SERVO PISTON -Swash Plate
6 RELIEF VALVE - CHARGE INLET: SPOOL
360 PSI (24,8 bar) 38 FIXED CAPACITY DISPLACEMENT 57 POSITION SENSOR -Swash Plate
at High Engine Idle Dealer Copy -- NotBI-DIRECTIONAL
for Resale HYDROSTATIC
With 140 degrees F. (60 degrees C.) Fluid CONTROL VALVE - FLOW CONTROL MOTOR 58 CHARGE PRESSURE SENSOR
SPOOL
7 FRONT AUXILIARY MANUAL 39 CHECK VALVE - With 80 PSI (5,5 bar) Spring 59
22 FLOW DIVIDER ADJUSTMENT VALVE CHARGE PUMP -
PRESSURE BLEED-OFF VALVE 12.8 GPM (48,5 L/min) at High Engine Idle
8 HYDRAULIC PUMP . . . . . . . Gear Type 40 SOLENOID ACTIVATED DIRECTIONAL
23 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION 60 FIXED CAPACITY DISPLACEMENT
CONTROL VALVE - BASE VALVE (ON/OFF) HYDRAULIC MOTOR
9 RELIEF VALVE - MAIN: 24 SOLENOID ACTIVATED DIRECTIONAL 61
41 CHECK VALVE - BICS CONTROL VALVE ANTICAVITATION VALVE
3250-3350 PSI (224-231 bar) CONTROL VALVE - ROD
at Front Quick Couplers 62 PROPORTIONAL RELIEF VALVE –
42 RESTRICTION - 0.343 inch (8,7 mm)
10 PORT RELIEF/ANTICAVITATION VALVE (Fan Speed Regulator):
3500 PSI (241,3 bar) 43 FILTER - Bob-Tach Valve 1566 - 1784 PSI (108 - 123 bar)
11 ANTICAVITATION VALVE CONTROL VALVE - TWO COIL 44 63 CHECK VALVE
PILOT ACTIVATED DIRECTIONAL
27 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - HYDRAULIC
POWERED BOB-TACH 64 SOLENOID ACTIVATED DIRECTIONAL
12 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - REAR AUXILIARY
CONTROL VALVE - BRAKE
CONTROL VALVE - AUXILIARY 45
28 RESTRICTOR - 0.140 inch (3,6 mm) RESTRICTION - 0.089 inch (2,26 mm) 65 HYDRAULIC BRAKE - SPRING APPLIED
13 PORT RELIEF/ANTICAVITATION VALVE: - PRESSURE RELEASE
. . . . . (Optional) 29 RESTRICTOR - 0.031 inch (0,8 mm) 46 RESTRICTION - 0.025 inch (0,6 mm)
3500 PSI (241,3 bar)
14 LOAD CHECK VALVE 30 RELIEF VALVE: 3300 PSI (228 bar) 47 RELIEF VALVE - 2000 PSI (137 bar)
15 LIFT CYLINDER SPOOL - MADE TO 48 RELIEF VALVE - 1200 PSI (83 bar) NOTE: Unless otherwise specified, springs have
31 FILTER - HYDRAULIC (CANISTER)
RESTRICT FLOW DURING BOOM NO significant pressure value.
DOWN BUT NOT DURING BOOM UP 32 FILTER - CASE DRAIN (SINTERED 49 SOLENOID ACTIVATED DIRECTIONAL
BRONZE) CONTROL VALVE (TWO COIL) V-1267legend (4-30-08)
Printed in U.S.A.
91 of 888
(REAR QUICK
FEMALE
HYDRAULIC/HYDROSTATIC SCHEMATIC COUPLERS) MALE
WITH SJC AND HIGH FLOW OPTION

T190 (S/N 531660001 AND ABOVE)
BASE ROD REAR AUX VALVE (OPTIONAL)
(PRINTED MAY 2008) INTEGRATED QUICK
23 24 COUPLER BLOCK
(V-1267)
25 MALE
26
MALE
DRIVE MOTOR 29
1 30
FEMALE
27
4 37
65
P-OUT P-IN T
D
34
38 HYDRAULIC FILTER
31
B HYDROSTATIC PUMPS A OIL

COOLER 22
2
55
56 A
HYDRAULIC CONTROL VALVE
5 5 3 40 C
57
21

6 36 13
20
12
12 AUXILIARY
CHARGE
SPOOL B
INLET B A
58
42
31
57 14
2 36
10 TILT CYLINDERS
BICS CONTROL VALVE
HIGH FLOW VALVE
5 56 5
55 51
50
3 52
TILT
B A 17
SPOOL
D C
8
10 11
INLET 14
60 LIFT CYLINDERS
62 61 59 10
FAN MOTOR 18
HYDRAULIC
OUTLET
53 POWERED B A LIFT
BOB-TACH
(OPTIONAL) SPOOL
38
35
39 47
15
DR
63
14
64 54
48 33 41
65 46 33
9 16
49 45
37 PP
4 43
32 P2 LIFT ARM BY PASS VALVE
P1
44 19
Printed in U.S.A. DRIVE MOTOR
92 of 888
V-1267 (4-30-08)
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.

93 of 888
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).

94 of 888

NON-RETURN VALVE, SHUTTLE VALVE: Valve which DIRECTIONAL CONTROL VALVE: Valve providing for
allows free flow in one direction only. the 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
open the valve by pilot pressure. DIRECTION CONTROL VALVE
T
OUT IN
(Variable Position) Joystick
P
Controlled, variable pressure to shift
the pilot activated directional control
SHUTTLE VALVE - The Inlet port
valve spool.
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.

95 of 888

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).

96 of 888
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
PROBLEM CAUSE
The hydraulic system will not operate. 1, 2, 3, 5, 8
The transmission warning light come ON when hydraulics are operating. 1, 3
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 with the pedal is in neutral position 4, 9, 10, 11
Bypass valve stuck 12
Bypass valve stem bent or broke 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. Using the loader for more than its rated 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 manual spool cartridge.

97 of 888

98 of 888
CYLINDER (LIFT) Figure 20-20-2
Testing
WARNING 2
1
penetrate skin or eyes, causing serious injury or
enters skin or eyes, get immediate medical attention N-18786
W-2072-0807
Install a plug in the hose (Item 1) [Figure 20-20-2] and
tighten.
Figure 20-20-1
Connect the negative ground cable to the battery.
Engage the parking brake. Lower the seat bar. Start the

engine. Press the PRESS TO OPERATE BUTTON. Push
the top (toe) of the lift pedal.
1 If there is any leakage from the base end cylinder port

(Item 2) [Figure 20-20-2], remove the lift cylinder for
repair.
Repeat the procedure to check the other lift cylinder.
N-18785
WARNING
Lower the lift arms. Stop the engine. Pull up on the lift AVOID INJURY OR DEATH
arm bypass control and move the lift pedal to release the Always clean up spilled fuel or oil. Keep heat, flames,
hydraulic pressure. Raise the seat bar. sparks or lighted tobacco away from fuel and oil.
Check only one cylinder at a time. Open the rear door. explosion or fire.
W-2103-0508
Disconnect the negative ground cable to the battery.
Disconnect the hose (Item 1) [Figure 20-20-1] from the

lift cylinder base end port.

99 of 888
CYLINDER (LIFT) (CONT’D) Figure 20-20-4
Removal And Installation

1
Figure 20-20-3
2
N-18806
Remove the retainer bolt (Item 1) [Figure 20-20-4] and

N-18785 nut from the lift arm pin (both sides).
Installation: Tighten the bolt and nut to standard torque.

Stop the engine. Pull up on the lift arm bypass control to
release the hydraulic pressure. Use a drift pin and hammer, remove the lift arm pivot pin

(Item 2) [Figure 20-20-4] (both sides).
Open the rear door.
Roll the lift arm link back.
Disconnect the negative ground cable to the battery.
Figure 20-20-5
lift cylinder base end port.
Install a plug in the hose and tighten.

1
P-34048A

nut from the lift cylinder rod end pivot pin (both sides).

100 of 888
Removal And Installation (Cont’d)
Figure 20-20-6
1
1 2
N-18782

P-34049A nut from the lift cylinder pivot pin.

Use a slide hammer, remove the lift cylinder rod end pivot
pin (Item 1) [Figure 20-20-6]. Use a drift pin and hammer, remove the lift arm pivot pin

(Item 2) [Figure 20-20-8].
Figure 20-20-7
P-34047A
Install a smaller pin (Item 1) [Figure 20-20-7] to hold the

cylinder in place.

lift cylinder rod end port.
Install a plug in the hose and tighten.

101 of 888
CYLINDER (LIFT) (CONT’D)
Figure 20-20-9

P-24721A
Remove the smaller pin (Item 1) [Figure 20-20-7] and lift

the lift cylinder (Item 1) [Figure 20-20-9] out from the
loader.

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CYLINDER (LIFT) (CONT’D)
Parts Identification
1. Plug 9. Spacer
2. O-ring 10. Seal
3. Cylinder 11. O-ring
4. O-ring 12. Head
5. Nut 13. Rod Seal
6. Piston 14. Wiper Seal
7. Seal 15. Rod
8. O-ring
7 8

1 6
15
2
5
4
14
1 13
2 12
3
11
10
B-13593

103 of 888
Disassembly And Assembly

4
Use the following tools to service the cylinder:
3
2
MEL1074 - O-ring Seal Hook
Spanner Wrench 1
MEL1033 - Rod Seal Installation Tool
MEL1396 - Seal Installation Tool
Piston Ring Compressor
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts. P-48036
Always install new O-rings and seals during assembly.

Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
Lubricate all O-rings and seals with hydraulic oil during and head (Item 4) [Figure 20-20-11].
installation.
Assembly: Tighten the nut (Item 1) [Figure 20-20-11] to
Hold the hydraulic cylinder over a drain pan and move 600 ft.-lb. (814 N•m) torque.
the rod in and out slowly to remove the fluid from the

cylinder. NOTE: Clean and dry the threads before installing the
nut. Install the new nut from the kit.
Put the base end of the cylinder in a vise.
Figure 20-20-12
Figure 20-20-10
2 2
1
P-48038
P-48033
Remove the seal (Item 1) and O-ring (Item 2) [Figure 20-

Use a spanner wrench to loosen the head (Item 1) 20-12] from the piston.
[Figure 20-20-10] from the cylinder case.
NOTE: If the fiber surface (Item 3) [Figure 20-20-12]
Assembly: Tighten the head with a spanner wrench until on the piston head, becomes damaged, the
the head is seated all of the way into the cylinder (Item 2) complete piston head must be replaced.
[Figure 20-20-10].

104 of 888
CYLINDER (LIFT) (CONT'D) Figure 20-20-15
Disassembly And Assembly (Cont'd)
Figure 20-20-13
1
P-48040
Remove the wiper seal (Item 1) [Figure 20-20-15] from

P7424 the cylinder head.
Figure 20-20-16
Assembly: Install the new seal on the tool and slowly
stretch it until it fits the piston [Figure 20-20-13]. Allow

the seal to stretch for 30 seconds before installing it on
the piston. 2
Once the seal is installed on the piston, a piston ring

compressor can be used on the piston for 3 minutes to
compress the seal into place.
1
Figure 20-20-14
P-48041A 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-
2 16].
P-48039
Remove the two O-rings (Item 1) and the back-up washer

(Item 2) [Figure 20-20-14] from the cylinder head.

105 of 888
CYLINDER (LIFT) (CONT'D) Figure 20-20-19
Figure 20-20-17
P7425
Assembly: Install the rod seal in the head. Rotate the

P-48042 handles to collapse the rod seal.
Reverse the disassembly procedure to assemble the lift

Remove the rod seal (Item 1) [Figure 20-20-17] from the cylinder.
cylinder head.

Figure 20-20-18
P-48043A P7427
Assembly: Install the rod seal on the rod seal tool

[Figure 20-20-18].
NOTE: During installation the spring side of the seal

(Item 1) [Figure 20-20-18] must be installed
toward the inside of the cylinder.

106 of 888
CYLINDER (TILT) Figure 20-21-2
Testing
WARNING 1
Hydraulic fluid escaping under pressure can have

sufficient force to enter a person’s body by
penetrating the skin. This can cause serious injury
and possible death if proper medical treatment by a
physician familiar with this injury is not received
immediately.
W-2145-0290
N-18802
Remove the attachment. Roll the Bob-Tach fully back.

Stop the engine. Raise the seat bar. Install a cap (Item 1) [Figure 20-21-2] on the fitting and
tighten.
Figure 20-21-1
Engage the parking brake. Lower the seat bar.
Start the engine and push the Press to Operate button.

Push the bottom (heel) of the tilt pedal.
If there is leakage from the open port, remove the tilt

cylinder for repair.
N-18801
Disconnect the hose (Item 1) [Figure 20-21-1] which

goes to the base end of the tilt cylinder.

107 of 888
CYLINDER (TILT) (CONT'D) Figure 20-21-4
WARNING 1

explosion or fire.
W-2103-0508
N-18545
Figure 20-21-3
Use a drift pin and hammer, remove the rod end pivot pin
(Item 1) [Figure 20-21-4].
Figure 20-21-5

1
N-18544 3 2
Remove the attachment. Roll the Bob-Tach forward. Stop

the engine. Raise the seat bar.
Remove the retainer bolt (Item 1) [Figure 20-21-3] and P-34137

nut from the rod end pin.
Installation: Tighten the bolt and nut to standard torque. Remove the retainer bolt (Item 1) [Figure 20-21-5] from
the tilt cylinder rod end pivot pin.
Installation: Tighten the bolt and nut to 125 - 140 ft.-lb.

(170 - 190 N•m) torque.
Remove the step (Item 2) [Figure 20-21-5].

cylinders.

108 of 888
CYLINDER (TILT) (CONT'D)
Figure 20-21-6
P-34228

cylinder.

Remove the cylinder (Item 2) [Figure 20-21-6] from the
rod end pivot pin.
Remove the cylinder from the loader.

109 of 888
Rod End Pivot Pin Bushing And Seal Removal And

Installation
Figure 20-21-7
1
1 N-18554
Reverse the removal procedure to install the pivot pin

bushing and seal.
N-18556
Base End Pivot Pin Removal And Installation
Remove the rod end of the tilt cylinder from the Bob- Figure 20-21-10

Tach. (See Removal And Installation Page 20-21-2.)
Use a seal pick to remove the seals (Item 1) [Figure 20-

21-7] on both sides of the pivot bushing.
Figure 20-21-8
1
P-24709
Remove the tilt cylinder from the Bob-Tach. (See

Removal And Installation Page 20-21-2.)
N-18555 Loosen the retainer bolt (Item 1) [Figure 20-21-10] from

the tilt cylinder rod base end pin.
Remove and replace bushing with a driver tool and Installation: Tighten the retainer bolt to 175 - 190 ft.-lb.
hammer [Figure 20-21-8]. (240 - 260 N•m) torque.
Strike the head of the bolt (Item 1) [Figure 20-21-10] to

push the pivot pin out.
Reverse the removal procedure to install the pivot pin.

110 of 888
CYLINDER (TILT) (CONT'D)
1. Case 9. Washer
2. Plug 10. O-ring
3. O-ring 11. Head
4. Nut 12. Seal
5. Piston 13. Seal
6. Seal 14. Rod
7. O-ring 15. Seal MC-1688B
8. O-ring 16. Bushing
3
MC-01688A

9
4
10
7
12
6 13
5 11
MC-01688D
14
MC-01688C
15
16
15
PE-1056A

111 of 888

3
Use the following tools to service the cylinder: 2

1
Spanner Wrench

damage. Replace any damaged parts.
P-48071
Lubricate all O-rings and seals with hydraulic oil during Remove the nut (Item 1), piston (Item 2) and head (Item
installation. 3) [Figure 20-21-12].
Hold the hydraulic cylinder over a drain pan and move Assembly: Tighten the nut (Item 1) [Figure 20-21-12] to
the rod in and out slowly to remove the fluid from the 100 ft.-lb. (136 N•m) torque.
cylinder.

NOTE: Clean and dry the threads before installing the
Put the base end of the cylinder in a vise. nut. Install the new nut from the kit.
Figure 20-21-11 Figure 20-21-13
P-48034 P-48088 P-48089
Use a spanner wrench to loosen the head (Item 1) Assembly: Mark the end of the shaft and nut. Tighten
[Figure 20-21-11] from the cylinder case. the nut an additional 135 degrees or 2-1/4 flats [Figure
20-21-13].
Assembly: Tighten the head with a spanner wrench until
the head is seated all of the way into the cylinder (Item 2)
[Figure 20-21-11].

112 of 888

1
Figure 20-21-14
2
2
P-48039

P-48073 (Item 2) [Figure 20-21-16] from 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
1
P-48040


stretch it until it fits the piston [Figure 20-21-15]. Allow
the seal to stretch for 30 seconds before installing it on
the piston.


113 of 888
Figure 20-21-18
1
P-48043 P7427

P-48041 P-48042 [Figure 20-21-20].

Install the wiper seal, with the wiper side of the seal (Item (Item 1) [Figure 20-21-20] must be installed
1) toward the outside of the head (Item 2) [Figure 20-21- toward the inside of the cylinder.

18].
Figure 20-21-21
Figure 20-21-19
P7425
P-48042

Remove the rod seal (Item 1) [Figure 20-21-19] from the handles to collapse the rod seal [Figure 20-21-21].
cylinder head.

114 of 888
CYLINDER (BOB-TACH) Figure 20-22-2
Testing
WARNING
explosion or fire.
W-2103-0508 1
P16330
WARNING Disconnect the hose (Item 1) [Figure 20-22-2] from the

Bob-Tach cylinder base end port.
AVOID INJURY OR DEATH Figure 20-22-3


from a physician familiar with this injury. 2
W-2072-0807
Figure 20-22-1
1 P16332
Install a plug in the hose (Item 1) [Figure 20-22-3] and

tighten.
Engage the parking brake. Lower the seat bar. Start the
engine.
Push and hold the BOB-TACH “WEDGES UP” Switch

(Front Accessory Panel).
N-21401
If there is any leakage from the base end cylinder port
(Item 2) [Figure 20-22-3], remove the Bob-Tach cylinder
Tilt the Bob-Tach forward, so it is parallel to the floor
for repair.
[Figure 20-22-1].

115 of 888
CYLINDER (BOB-TACH) (CONT’D)
Figure 20-22-4
1 2
N-21401
Disconnect the hoses from the cylinder fittings (Item 1 &

2) [Figure 20-22-4].

Install plugs and cap on fittings.
NOTE: Connect the hose with the 45 degree end (Item

1) [Figure 20-22-4] to the base end fitting on
the cylinder.
Figure 20-22-5
1
1
N-21400
Remove the bolts (Item 1) [Figure 20-22-5].
Installation: Tighten the bolts to 25 - 28 ft.-lb. (34 - 38

N•m) torque.
Remove the washers and cylinder from the lever pivots.

116 of 888
CYLINDER (BOB-TACH) (CONT’D)
1. Cylinder
2. Plug
3. O-Ring
4. Nut
5. Piston
6. O-Ring
7. Ring
8. Spacer
9. O-Ring
10. Ring
11. O-Ring
12. Head
13. Seal
14. Seal
15. Rod

3
2
14
13 12
11
10
9
8 7 6
5
4
15
PE1064

117 of 888
CYLINDER (BOB-TACH) (CONT’D) Figure 20-22-7

4 3 2
Use the following tools to service the cylinder:
1
Spanner Wrench

damage. Replace any damaged parts.
P16294

Remove the head and rod assembly from the cylinder
Lubricate all O-rings and seals with hydraulic oil during [Figure 20-22-7]. Put the rod end in a vise.
installation.
Remove the nut (Item 1), piston (Item 2), spacer (Item 3)
Hold the hydraulic cylinder over a drain pan and move and head (Item 4) [Figure 20-22-7] from the rod.
the rod in and out slowly to remove the fluid from the

cylinder. Assembly: Grease the piston where the nut contacts the
piston. do not get grease on the threads. Install the new
Put the base end of the cylinder in a vise. nut (Item 1) [Figure 20-22-7].
Figure 20-22-6 Assembly: Tighten the nut to 90 ft.-lb. (122 N•m) torque.
Figure 20-22-8
2
3
2
1
4
1
P-43212
P16295
Use a spanner wrench to loosen the head (Item 1)
[Figure 20-22-6].
Remove the O-ring (Item 1), and seal (Item 2) from the
Assembly: Tighten the head with a spanner wrench until piston (Item 3) [Figure 20-22-8].
the head is seated all of the way into the cylinder (Item 2)
[Figure 20-22-6]. NOTE: The piston center hole (Item 4) [Figure 20-22-
8] has a bevel on one end. The bevel goes
toward the rod when assembling.

118 of 888
Disassembly And Assembly (Cont’d)
Figure 20-22-9
1
P-48040

Figure 20-22-12
stretch it until it fits the piston [Figure 20-22-9]. Allow the

seal to stretch for 30 seconds before installing it on the
piston. 2

1
Figure 20-22-10
P-48041A P-48042
Install the wiper seal, with the wiper side of the seal (Item
1), toward the outside of the head (Item 2) [Figure 20-22-
2 12].
P-48039

(Item 2) [Figure 20-22-10] from the cylinder head.

119 of 888
Figure 20-22-13
P7425

P-48042 handles to collapse the rod seal [Figure 20-22-15].
Reverse the disassembly procedure to assemble the

Remove the rod seal (Item 1) [Figure 20-22-13] from the Bob-Tach cylinder.
cylinder head.

Figure 20-22-14
P-48043A P7427

[Figure 20-22-14].

(Item 1) [Figure 20-22-14] must be installed
toward the inside of the cylinder.

120 of 888
MAIN RELIEF VALVE Figure 20-30-1
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 2
hydraulic control valve near the bottom, facing the front of 1
the loader.
Testing
IMPORTANT P-34480
Connect the IN port (Item 1) [Figure 20-30-1] of the

The hydraulic tester must be in the fully open
hydraulic tester to the bottom (female) quick coupler on
position before you start the engine.
I-2024-0284
the loader.
Connect the OUT port (Item 2) [Figure 20-30-1] of the

hydraulic tester to the top (male) quick coupler on the

loader.
WARNING Figure 20-30-2
When the engine is running during service, the

steering levers must be in neutral and the parking
brake engaged. Failure to do so can cause injury or
death.
W-2006-0284
2
1
WARNING
P-76460C
W-2017-0286 Start the engine and run at low idle.
The tools listed will be needed to do the following • Press the AUXILIARY HYDRAULICS Button (Item 1)
procedure: [Figure 20-30-2] once to engage the auxiliary
hydraulics.
MEL10003 - Hydraulic Tester
NOTE: The light (Item 2) [Figure 20-30-2] will be on.
MEL10006 - Hydraulic Test Kit
Turn the key switch to the OFF position. To release the

hydraulic pressure at the front auxiliary quick couplers
push the couplers into the coupler block and hold for
three seconds.
Lift and block the loader. (See Procedure on Page 10-10-

1.)

121 of 888
MAIN RELIEF VALVE (CONT’D)
Testing (Cont’d)
Figure 20-30-3
Right
Steering
Lever
Control
1
P-31833
Figure 20-30-4

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

[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] & [Figure 20-30-4] a
second time.
Refer to Specifications, (See Hydraulic System on Page

SPEC-10-3.) for both flow and pressure specifications of
the hydraulic system.
Check the free flow specification.
Turn the restrictor control, on the tester, until the main

relief valve opens. Check the relief pressure.
If the relief pressure is not correct, stop the engine and

adjust the main relief valve.

122 of 888
MAIN RELIEF VALVE (CONT’D)
Adjusting
Figure 20-30-5
O-ring
Back-up
B-6764
If the pressure is not correct, adjust the main relief valve.

Remove the end cap (Item 1) [Figure 20-30-5].

Turn the adjusting screw in or out until the pressure is
correct.
NOTE: If the correct pressure can not be reached,

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

123 of 888
MAIN RELIEF VALVE (CONT’D) Figure 20-30-7
Figure 20-30-6
P-48874
1
Clean the area around the control valve. Loosen and

P-68159 remove the main relief valve (Item 1) [Figure 20-30-6]
and [Figure 20-30-7].
Remove the O-rings and back-up washers [Figure 20-

30-5].

Clean the main relief valve in clean solvent. Use air
pressure to dry the valve.
Install new O-rings and back-up washers. Install the main

relief valve (Item 1) [Figure 20-30-7] and tighten. Check
the pressure again. (See Testing on Page 20-30-1.)
Installation: Tighten the main relief valve to 35 - 40 ft.-lb.

(47 - 54 N•m) torque.
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

124 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Removal And Installation
Description
Figure 20-40-1
DANGER
P-90328
AVOID DEATH
P-68012
The hydraulic control valve is located inside the main support. Replace if damaged.
frame on the right hand side, below the operators cab. D-1009-0409

The hydraulic control valve [Figure 20-40-1] 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 are operated using mechanical
linkages to connect the foot pedals to the lift and tilt Never work on a machine with the lift arms up unless
spools. the lift arms are secured by an approved lift arm
The auxiliary function is operated by pilot pressure. support device can allow the lift arms or attachment
There is one solenoid located by each side of the spool. to fall and cause injury or death.
Only one solenoid at a time is activated by the switch on W-2059-0598
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 contains a main relief valve

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

1.)
Raise the lift arms and install an approved lift arm support
device (See Installing on Page 10-20-1.)

125 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Disconnect and cap the tubelines (Item 1) [Figure 20-40-
(CONT’D) 3] from the lift arm bypass valve to the hydraulic control
valve.
Disconnect and cap the hose (Item 2) [Figure 20-40-3]
Clean the area around the control valve. from the lift arm bypass valve to the drive motor case
drain.
Drain the hydraulic reservoir. (See Removing And
Replacing Hydraulic Fluid on Page 10-120-2.) and (See Figure 20-40-4
Removing And Replacing Case Drain Filters on Page 10-
120-4.)
Remove the control panel. (See Removal And Installation

on Page 50-100-2.)
Figure 20-40-2
1
2
P-68328

1
Remove the brake hose (Item 1) [Figure 20-40-4] from
1 the hydraulic control valve.
Figure 20-40-5
P-68329
1
Mark and disconnect the five electric solenoid connectors
for correct installation (Item 1) [Figure 20-40-2].
Disconnect and cap the supply hose (Item 2). Remove

the supply hose clamp (Item 3) [Figure 20-40-2].
Figure 20-40-3
1
1
P-66967A
1
Remove the connector pins (Item 1) [Figure 20-40-5].
P-66964

126 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Figure 20-40-8
(CONT’D)
Removal And Installation (Cont'd)
Figure 20-40-6 1
1
P-66968
Remove tubeline clamp screw (Item 1) [Figure 20-40-8]

from the auxiliary tubelines in the left rear upright.
P-68317
Installation: Tighten screw to 15 - 20 ft.-lb. (20 - 27 N•m)
torque.
Remove the crossbar linkage bolt (Item 1) [Figure 20-40-
6].

Figure 20-40-9
Remove the control pedal crossbar linkage and tilt

linkage. (See Linkage Removal And Installation on Page
50-90-2.) 3
5
Figure 20-40-7
4
2 1
1
1
P-66970
Remove and cap both tubelines (Item 1) [Figure 20-40-

9] from the auxiliary section of the control valve.
P-66965 Disconnect and cap the drain hose (Item 2) [Figure 20-
40-9] from the control valve.
Remove the two lift arm bypass valve bracket mounting Remove and cap the outlet tubeline (Item 3) [Figure 20-
bolts (Item 1) [Figure 20-40-7]. 40-9] from the control valve to the hydraulic oil cooler.
Remove the lift arm bypass valve and mounting bracket. Remove and cap the charge tubeline (Item 4) [Figure 20-
40-9] from the control valve to the charge filter.
Remove the throttle rod (Item 5) [Figure 20-40-9] from

the engine, then pull the throttle rod out of the loader from
the rear.

127 of 888
(CONT’D)
Figure 20-40-10 1
1
3
P-66971
Disconnect and cap the tubelines (Item 1) and (Item 2)

[Figure 20-40-12] from the tilt section of the control
P-68319 valve.
Disconnect and cap the tubeline (Item 3) [Figure 20-40-

Disconnect and cap the supply tubeline (Item 1) [Figure 12] from the lift section of the control valve.

20-40-10] from the hydraulic control valve.
Figure 20-40-13
Figure 20-40-11
1
2
P-66957
P-66973
Mark all tubelines and hoses for correct installation.

Remove the supply tubeline clamp screw (Item 1)
[Figure 20-40-11]. The fixed end main valve hose (Item 1) [Figure 20-40-
13] is connected to a fixed end fitting on the control valve.
Installation: Tighten screw to 15 - 20 ft.-lb. (20 - 27 N•m) The hose is routed to the back upright where the hose is
torque. connected to a tee fitting that feeds the base end of both
lift cylinders. The hose must be removed at the back tee
Remove supply tubeline (Item 2) [Figure 20-40-11] from fitting, located in the right side upright.
loader.
NOTE: Remember the hose routing for ease of
control valve installation.

128 of 888
(CONT'D)
Figure 20-40-14
1
1
P-66974
Connect a hoist to the lifting brackets (Item 1) [Figure 20-

40-16] on the control valve.
P-66962
Figure 20-40-17
Remove any tie-straps (Item 1) [Figure 20-40-14]

securing the fixed end main valve hose.

Figure 20-40-15 1
P-68327P-
P-68327
P-51713
66972P-
1 34004P-
Remove the two mounting bolts (Item 1) [Figure 20-40-

17] fastening the control valve and bracket to the side of
P-68318 the loader.
Remove the control valve from the loader.

Remove the fixed-end main valve hose (Item 1) [Figure
20-40-15] from the main control valve fitting. Reverse removal procedure to install the hydraulic
control valve.

129 of 888
HYDRAULIC CONTROL VALVE (STANDARD) (CONT'D)
Identification Chart
Figure 20-40-18
J2
C2 J4 C3
D5 E3 B3
E3
G1 G2
F2 B2 A3 D3
D4 F4 E2
C4
A2
D1
D2
A1
E1
F1 H2 B1
F3

H3
MR C1
H1 J3
J1 MS1937
ITEM T190 LOADER ITEM T190 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 Lift 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 Valve Solenoid
D1 Anti-Cavitation Valve H2 BICS Lock Valve (Tilt)
Lift (Rod End)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI H3 BICS Lock Valve (Lift)
Lift (Base End) J1 Inlet Fluid Flow (From Pump)
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI J2 Outlet Fluid Flow (Return to Tank)
Tilt (Base End) J3 Lift Arm Bypass Orifice
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI J4 Drain (Case)
Tilt (Rod End)
MR Main Relief Valve – 3300 PSI
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)

130 of 888
(CONT'D)
Mount Bracket Removal And Installation
Remove the control valve and mount bracket from the

loader. 1
Figure 20-40-19
2
1
2
P-68014
Remove the fitting (Item 1) [Figure 20-40-21] from the

check valve.
Remove the lift load check valve (Item 2) [Figure 20-40-

3 21].
P-68011

Installation: Lubricate the O-ring and tighten the valve to
55 - 65 ft.-lb. (75 - 88 N•m) torque.
Remove the two mount bolts (Item 1) and lift eyes (Item
2) [Figure 20-40-19] from the hydraulic control valve. Figure 20-40-22
Remove the mount bracket (Item 3) [Figure 20-40-19]

from the hydraulic control valve.
Lift Load Check Valve Removal And Installation

1
Figure 20-40-20
1
P-51439
Remove and install new O-rings (Item 1) and back-up

ring (Item 2) [Figure 20-40-22].
P-68013
Remove the tubeline (Item 1) [Figure 20-40-20] from the

control valve.

131 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Load Check Valve Removal And Installation (Tilt &
(CONT'D) Auxiliary)
Lift Load Check Valve Removal And Installation Figure 20-40-24

(Cont’d)
Figure 20-40-23
1
1
P-68007
P-51440 At the front side of the control valve locate the tilt section
load check valve (Item 1) [Figure 20-40-24].
Check for free movement of the load check valve (Item 1)

At the front side of the control valve locate the auxiliary
[Figure 20-40-23]. section load check valve (Item 2) [Figure 20-40-24].
NOTE: The tilt and auxiliary load check valves are

interchangeable.
Figure 20-40-25
1
3
2
P-51453
Remove the spring (Item 1) and poppet (Item 2) [Figure

20-40-25].
Check the orifice (Item 3) [Figure 20-40-25] in the

poppet to be sure it is not plugged.
Installation: Install a new O-ring (Item 4) [Figure 20-40-

25] on the plug and lightly lubricate with oil before
installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m)
torque.

132 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Installation: Always use new O-ring (Item 1) [Figure 20-
(CONT'D) 40-27] on the anti-cavitation valve plug. Tighten the plug
to 35 - 40 ft.-lb. (47 - 54 N•m) torque.
Anti-Cavitation Valve Removal And Installation
(Lift, Rod End) Figure 20-40-28
Figure 20-40-26
1
3
2
P-51453
P-68015
20-40-28].
At the back side of the control valve, remove the lift

section anti-cavitation valve (Item 1) [Figure 20-40-26]. Check the orifice (Item 3) [Figure 20-40-28] in the

IMPORTANT installing. Tighten the plug to 38 - 45 ft.-lb. (52 - 61 N•m)
torque.
damage the system.
I-2003-0888
Figure 20-40-27
P-51693

133 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Port Relief / Anti-Cavitation Valve Removal And
(CONT'D) Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-40-31

Installation (Lift, Base End)
Figure 20-40-29
P-68015
P-68015 Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-40-31] from the base end of the tilt section.
Loosen the lift circuit port relief/anti-cavitation valve (Item

Figure 20-40-32
1) [Figure 20-40-29].
Figure 20-40-30
P-51454
1
P-51451 Replace the O-ring (Item 1) [Figure 20-40-32] before

installation.
Replace the O-ring (Item 1) [Figure 20-40-30] before Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m)
installation. torque.
Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m)

torque.

134 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Port Relief Valve Removal And Installation
(CONT'D)
Figure 20-40-35
Port Relief / Anti-Cavitation Valve Removal And
Installation (Tilt, Rod End)
Figure 20-40-33
P-68015
Remove the port relief plug (Item 1) [Figure 20-40-35]

P-68015 from the auxiliary circuit of the control valve.
Figure 20-40-36
Remove the tilt port relief/anti cavitation valve (Item 1)

[Figure 20-40-33] from the rod end of the tilt section.
Figure 20-40-34
P-51695
1
Installation: Always use new O-rings (Item 1) [Figure

P-51694 20-40-36]. Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.
Replace the O-ring (Item 1) [Figure 20-40-34] before

installation.
Installation: Tighten to 38 - 45 ft.-lb. (52 - 61 N•m)

torque.

135 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Plug Removal And Installation
(CONT'D)
Figure 20-40-39
Port Relief Valve Removal And Installation (Cont’d)
Figure 20-40-37
1
1
P-68016
P-51696 At the top side of the control valve, remove the plug (Item
1) [Figure 20-40-39].
The control valve may be equipped with an optional Figure 20-40-40

auxiliary port relief valve (Item 1) [Figure 20-40-37].

Remove the auxiliary port relief valve.
Figure 20-40-38
P-51460

20-40-40]. Tighten to 40 ft.-lb. (54 N•m) torque.
P-51640

20-40-38]. Tighten to 38 - 45 ft.-lb. (52 - 61 N•m) torque.

136 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Rubber Boot Removal And Installation
(CONT'D)
Figure 20-40-43
Plug Removal And Installation (Cont’d)
1
Figure 20-40-41
P-51506
1
P-51461 Remove the three screws (Item 1) [Figure 20-40-43] on
the rubber boot retainer plate.
At the bottom side of the control valve remove the plug Installation: Tighten the screws to 90 - 100 in.-lb. (10 -
(Item 1) [Figure 20-40-41].

11,3 N•m) torque.
Figure 20-40-42 Figure 20-40-44
1
2
1
P-51462
P-51701
Installation: Always use new O-rings (Item 1) [Figure Remove the rubber boots (Item 1) from the retainer plate
20-40-42]. Tighten to 40 ft.-lb. (54 N•m) torque. (Item 2) [Figure 20-40-44].

137 of 888
(CONT'D)
End Cap / Spool Lock Block Removal And

Installation
Figure 20-40-45
1 1
2
1
P-51699A
1
Remove the four end cap/spool lock block mount screws
(Item 1) [Figure 20-40-47].
P-51697 Installation: Tighten the screws to 90 - 100 in.-lb. (10 -

11,3 N•m) torque.
Remove the lift spool lock solenoid (Item 1) and the tilt

Remove the rubber boots and retainer plate from the lift
spool lock solenoid (Item 2) [Figure 20-40-45] from the and tilt spools.
end cap/spool lock block.
Figure 20-40-48
Figure 20-40-46
1
1
P-51700
P-68017
Remove the end cap/spool lock block (Item 1) [Figure

Disconnect the tube line (Item 1) [Figure 20-40-46] from 20-40-48] from the control valve.
the end cap/spool lock block.

138 of 888
(CONT'D)
Lift Spool And Detent Removal And Installation

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool 1
Remove the end cap/spool lock block from the control

valve.
Figure 20-40-49
P-51513
Remove the end cap (Item 1) [Figure 20-40-51].
Figure 20-40-52
1

P-51511A
1
Remove the O-ring (Item 1) [Figure 20-40-49]. 2
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap/spool lock block.
P-51514
Figure 20-40-50
Use a screwdriver to remove the snap ring (Item 1)
[Figure 20-40-52].
Remove the washer (Item 2) [Figure 20-40-52].
P-51512A
Remove the spacer (Item 1) and O-ring (Item 2) [Figure

20-40-50] from the lift spool.

139 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Put a rag around the detent assembly [Figure 20-40-54].
(CONT'D) This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
(Cont'd) Figure 20-40-55
Figure 20-40-53
2 1
3
1
1 2 P-51517
2
P-51515
Remove the detent sleeve (Item 1), detent balls (Item 2)

Remove the screws (Item 1) [Figure 20-40-53] from the and spring (Item 3) [Figure 20-40-55].

detent bonnet.
Remove the detent bonnet (Item 2) [Figure 20-40-53].
Installation: Lubricate the screws and tighten to 90 - 100

in.-lb. (10 - 11,3 N•m) torque.
IMPORTANT
The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-54
P-51516

140 of 888
(CONT'D)

(Cont'd)
Figure 20-40-56
P-8988
Clamp the linkage end of the spool in a vise [Figure 20-

1 40-58].
P-51518 NOTE: Protect spool before clamping in vise.
Figure 20-40-59
Remove the lift spool assembly and seal (Item 1) [Figure

20-40-56] from the control valve. 2
Figure 20-40-57
1
3
N-18915
1
Install the spring tool (Item 1) [Figure 20-40-59] over the

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

Remove the lift spool seal (Item 1) [Figure 20-40-57] (Item 2) [Figure 20-40-59] from the centering
from the linkage end of the valve. spring, as it is under spring pressure.
NOTE: The centering spring (Item 3) [Figure 20-40-59]

is white on all medium frame loaders.

141 of 888
(CONT'D)
Lift Spool And Detent Removal And Installation 1

(Cont'd)
Figure 20-40-60
N-19009
Remove spring tool (Item 1) [Figure 20-40-62] from the

1 spring assembly.
2
N-18916 Figure 20-40-63
Put a rag around the detent assembly [Figure 20-40-60]. 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 20-40-60].
Figure 20-40-61
1
N-18919A
Inspect the adapter (Item 1), collar (Item 2), spring (Item
3) and washer (Item 4) [Figure 20-40-63].
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-61]

from the spring assembly.

142 of 888
(CONT'D)

(Cont'd)
2
Figure 20-40-64
1
N-18961
Install the O-ring (Item 1) over the nipple on the plastic

plug (Item 2) [Figure 20-40-66].
N-18918 NOTE: Check the O-ring for damage. The lift spool
will have an internal leak if there is damage to
this O-ring. Always replace the o-ring and
Remove the stud from the end of the spool [Figure 20-

recheck the lift spool before the control valve
40-64]. is replaced.
Figure 20-40-65 Figure 20-40-67
N-18920
N-18963
Removal of the plastic plug: Install the plastic plug and O-ring in the spool [Figure 20-
40-67].
Make a center point in the plug using a 1/16 in. drill.
Drill a hole all the way through the plug using a 7/64 in.
tap drill
Turn a 6-32 tap (Item 1) [Figure 20-40-65] 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.

143 of 888
(CONT'D)

(Cont'd)
2
Figure 20-40-68
O-Ring
1 3
2
N-18958
Plastic
Plug
0.60 in. Apply grease on all the detent component surfaces
(15,2 mm)
before assembly [Figure 20-40-70].
B-14712 Install the spring (Item 1) and detent balls (Item 2) into
the adapter (Item 3) [Figure 20-40-70] and compress
with the detent pliers (Item 1) [Figure 20-40-71].
Install the stud and tighten until the other end of the stud

is out about 0.600 in. (15,2 mm) from the spool [Figure Figure 20-40-71
20-40-68].
Figure 20-40-69
N-18968
N-18967 Install the detent adapter to the collar [Figure 20-40-71].
NOTE: The collar and the detent adapter are held

Clamp the collar (Item 1) [Figure 20-40-69] in a vice. 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.

144 of 888
(CONT'D)

(Cont'd)
Figure 20-40-72
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-40-74].
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 90 - 100 in.-lb. (10 - 11,3 N•m).
Figure 20-40-73
NOTE: The adapter must fit in the center of the
washer (Item 1) [Figure 20-40-74].
Figure 20-40-75
2
N-18917
Install the spool seal (Item 1) and back-up washer (Item

2) [Figure 20-40-73].
CD-15051
Install the detent balls and spring [Figure 20-40-75].

145 of 888
(CONT'D)

(Cont'd)
Figure 20-40-76
2
P-51515
Install the lift spool assembly in the spool bore [Figure

20-40-78].
N-19007 Install the detent bonnet (Item 1) [Figure 20-40-78].
Install the mounting screws (Item 2) [Figure 20-40-78].

Hold the detent balls in place with the detent pliers

[Figure 20-40-76]. Installation: Lubricate the screws and tighten to 90 - 100
in.-lb. (10 - 11,3 N•m) torque.
Figure 20-40-77
Figure 20-40-79
1
N-19008
P-51514
Install the detent sleeve (Item 1) [Figure 20-40-77] to the

detent adapter. Install the washer (Item 1) and snap ring (Item 2) [Figure
20-40-79].

146 of 888
(CONT'D)

(Cont'd)
Figure 20-40-80
2
1
P-51512A
Install the O-ring (Item 1) and bushing (Item 2) [Figure

20-40-82] on the lift spool.
P-51513 Figure 20-40-83
Install the end cap (Item 1) [Figure 20-40-80].

Figure 20-40-81
1
P-51511A
Install the O-ring (Item 1) [Figure 20-40-83] on the

control valve.
P-51520
Install the spool seal (Item 1) [Figure 20-40-81] on the

linkage end of the valve.

147 of 888
(CONT'D)

(Cont'd)
Figure 20-40-84
2
1
P-51697
3
Use an Ohm meter to measure the lock solenoid coils
resistance.
4
P-51701 The correct resistance for the coil is 5.5 ± 0.28 Ohms.
Installation: Install the lift spool (Item 1) and tilt spool

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

(Item 2) [Figure 20-40-86] lock solenoids and tighten to
mount bolt (Item 2) [Figure 20-40-84]. 35 - 45 ft.-lb. (52 - 61 N•m) torque.
Install the lift and tilt spool rubber boots and mount plate
(Item 3) and install the three mounting screws (Item 4)
[Figure 20-40-84].
Installation: Tighten the screws to 90 - 100 in.-lb. (10 -

11,3 N•m) torque.
Figure 20-40-85
P-68017
Connect the tubeline (Item 1) [Figure 20-40-85].

148 of 888
(CONT'D)
Tilt Spool Removal And Installation
Remove the lift and tilt end cap/spool lock block. (See
End Cap / Spool Lock Block Removal And Installation on
Page 20-40-14.)
2
Figure 20-40-87
1
P-68023
Remove the spool centering block (Item 1) [Figure 20-

1 2 40-89] from the control valve.
Check and replace the O-ring (Item 2) [Figure 20-40-89]

before replacing the spool centering block.

P-51521A Figure 20-40-90

20-40-87] from the tilt spool.
Figure 20-40-88
1
1 P-51544A
Remove the tilt spool, centering spring, back-up washer

2
and spool seal [Figure 20-40-90].
P-68019 Installation: Always use a new spool seal.
Remove the two tubelines (Item 1) [Figure 20-40-88].
Remove the three bolts (Item 2) [Figure 20-40-88] from

the spool centering block.
Installation: Tighten the bolts to 90 - 100 in.-lb. (10 - 11,3

N•m) torque.

149 of 888
(CONT'D)
Tilt Spool Removal And Installation (Cont'd)

2 1
Figure 20-40-91
3
4
1
N-18944A
N-18942
Figure 20-40-94
Put the linkage end of the spool in the vice [Figure 20-
40-91]. 2

1
Install the spool tool (Item 1) [Figure 20-40-91] over the
centering spring.
Figure 20-40-92
1
1
P-51545 N-18943
Remove the spool seal(s) (Item 1) and the back-up

Installation: Always use a new spool seal.
N-19014
Remove the bolt (Item 1) [Figure 20-40-92] holding the

centering spring to the spool.
Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3

N•m) torque.
Remove spring tool from the spring assembly.

150 of 888
(CONT'D)
Auxiliary Spool Removal And Installation
Figure 20-40-95
2
2
1
1
P-68022

1
20-40-97] from the auxiliary spool.
P-68020
Figure 20-40-98
Remove the three screws (Item 1) [Figure 20-40-95]

from the spool centering block.

N•m) torque.

2 1
Figure 20-40-96
P-51549A
Remove the spring (Item 1) and center spring retainer

2 (Item 2) [Figure 20-40-98] from the auxiliary spool.
1 NOTE: If the centering spring retainer (Item 2) [Figure

20-40-98] must be replaced, replace the
retainer on the opposite end also.
P-68021

(Item 2) [Figure 20-40-96] from the auxiliary spool.
NOTE: If the centering spring retainer (Item 2) [Figure

retainer on the opposite end also.

151 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Auxiliary Solenoid Removal And Installation
(CONT'D)
Figure 20-40-101
Auxiliary Spool Removal And Installation (Cont’d)
Figure 20-40-99
1
1
1 2
P-68007
P-51550A Remove the nut (Item 1) [Figure 20-40-101] from both

solenoids.
Remove the spacer (Item 1) and O-ring (Item 2) [Figure Installation: Tighten the nut to 48 - 72 in.-lb. (5 - 8 N•m)

torque.
Figure 20-40-100 Figure 20-40-102
1
2
P-51551A
P-51553
Remove the spool (Item 1) [Figure 20-40-100]. Remove the nut (Item 1) and solenoid coil (Item 2)
[Figure 20-40-102].
Use an Ohm meter to measure the solenoid coil

resistance.
The correct resistance for the coil is 4.9 ± 0.25 Ohms.

152 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Solenoid Removal And Installation
(CONT'D)
Figure 20-40-105
Auxiliary Solenoid Removal And Installation (Cont’d)
Figure 20-40-103
1
2
P-68006
P-68008 Remove the nut (Item 1) [Figure 20-40-105] from the

solenoid stem.
Remove the solenoid stem (Item 1) [Figure 20-40-103]. Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.

Installation: Tighten the stem to 10 - 14 ft.-lb. (14 - 19 Remove the solenoid coil (Item 2) [Figure 20-40-105].
N•m) torque.
Figure 20-40-106
Figure 20-40-104
N-18693A
P-51555
Remove the O-rings (Item 1) [Figure 20-40-106] from

Remove the O-rings (Item 1) [Figure 20-40-104] from both ends of the solenoid coil.
the solenoid stem.
Check and clean the screen (Item 2) [Figure 20-40-104]. resistance.

153 of 888
(CONT'D)
Solenoid Removal And Installation (Cont’d)
Figure 20-40-107 3
2
1
1
N-18694
Remove the O-rings (Item 1) and back-up rings (Item 2)

[Figure 20-40-108] from the cartridge.
P-68009
Clean all parts in solvent and dry with compressed air.
Remove the solenoid stem (Item 1) [Figure 20-40-107]. Inspect all parts for wear and replace any showing

excessive wear.
Installation: Lubricate the O-rings and tighten the stem
to 20 - 24 ft.-lb. (27 - 33 N•m) torque. NOTE: The screen (Item 3) [Figure 20-40-108] may be
cleaned with solvent. If it is torn or worn it
needs to be replaced.
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-40-106] &

[Figure 20-40-108] and new back-up rings (Item 2)
[Figure 20-40-108] on the solenoid stem.

154 of 888
(CONT'D)
Lock Valve Removal And Installation
Figure 20-40-109 1
1
1
1 2
1
2
2
2
P-51564

[Figure 20-40-111] from the lift lock valve, and replace
P-68010 with new.
Locate the two BICS lock valves, (Item 1) is for the tilt
circuit and (Item 2) [Figure 20-40-109] is for the lift

circuit.
Figure 20-40-110
P-51443
Remove the lift lock valve (Item 1) [Figure 20-40-110]

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

tighten to 20 - 24 ft.-lb. (27 - 33 N•m) torque.

155 of 888
(CONT'D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-40-112
1
1
P-51706
Remove the tilt lock valve (Item 1) [Figure 20-40-114]

from the front of the control valve.
P-51705
Installation: Lightly lubricate the lock valve O-rings and
Locate the tilt circuit lock valve (Item 1) [Figure 20-40-
112].

Figure 20-40-115
Figure 20-40-113
2 1
1
1
1 2
2
2
P-51564
P-51697
[Figure 20-40-115] from the tilt lock valve, and replace
Remove the lift spool lock solenoid (Item 1) [Figure 20- with new.
40-113].
Remove the tilt spool lock solenoid (Item 2) [Figure 20-

40-113].
Installation: Lubricate the O-rings and tighten the spool

lock solenoids to 38 - 45 ft.-lb. (52 - 61 N•m) torque.

156 of 888
HYDRAULIC CONTROL VALVE (STANDARD) Main Relief Valve Removal And Installation
(CONT'D)
Figure 20-40-118
Lift Arm Bypass Orifice Removal And Installation
Figure 20-40-116
1
P-51707
2
P-68010 Remove the main relief valve (Item 1) [Figure 20-40-
118].
Remove the tubeline (Item 1) and fitting (Item 2) [Figure Figure 20-40-119
20-40-116] from the valve.

Figure 20-40-117
P-51463
P-51437 Remove the O-rings (Item 1) [Figure 20-40-119] from the

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

casting.

157 of 888
(CONT'D)
Check Valve Removal And Installation
Figure 20-40-120
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-40-

122] and tighten the fitting to 20 - 24 ft.-lb. (27 - 33 N•m)
P-68013 torque.
Figure 20-40-123
Remove the tubeline (Item 1) [Figure 20-40-120].

Figure 20-40-121
P-68870
P-68010 Inspect the screen (Item 1) [Figure 20-40-123].
Remove the BICS check valve fitting (Item 1) [Figure 20-

40-121] from the top of the lift load check valve.
Installation: Lubricate the O-ring and tighten the fitting to

20 - 24 ft.-lb. (27 - 33 N•m) torque.

158 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Removal And Installation
Description
Figure 20-41-1
DANGER
P-90328
AVOID DEATH
P-68027
The hydraulic control valve is located inside the main support. Replace if damaged.
frame on the right hand side, below the operators cab. D-1009-0409

The hydraulic control valve [Figure 20-41-1] 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 ACS or the SJC hydraulic
control valve are operated using electronic control Never work on a machine with the lift arms up unless
handle/levers or foot pedals that send an electronic the lift arms are secured by an approved lift arm
signal to the electronic actuators to move the lift and tilt support device. Failure to use an approved lift arm
spools in the control valve. support device can allow the lift arms or attachment
The auxiliary function is operated by pilot pressure. W-2059-0598
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.
IMPORTANT
The hydraulic control valve also contains a main relief
valve which is adjustable. When repairing hydrostatic and hydraulic systems,
damage the system.
I-2003-0888

1.)
device (See Installing on Page 10-20-1.)

159 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Disconnect and cap the tubelines (Item 1) [Figure 20-41-
(CONT’D) 3] from the lift arm bypass valve to the hydraulic control
valve.
Clean the area around the control valve. from the lift arm bypass valve to the drive motor case
drain.
Replacing Hydraulic Fluid on Page 10-120-2.) and (See Figure 20-41-4
120-4.)

on Page 50-100-2.)
Figure 20-41-2
3 1
2 P-68328

1 Remove the brake hose (Item 1) [Figure 20-41-4] from
the hydraulic control valve.
1
Figure 20-41-5
P-68204
Mark and disconnect the three electric solenoid

connectors for correct installation (Item 1) [Figure 20-41-
2].
Disconnect and cap the supply hose (Item 2). Remove
the supply hose clamp (Item 3) [Figure 20-41-2].
1
Figure 20-41-3
1
P-51983A
1
Disconnect the connectors for the hydraulic control valve

actuators (Item 1) [Figure 20-41-5].
P-68206

160 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Figure 20-41-8
(CONT’D)
Removal And Installation (Cont'd) 3

5
Figure 20-41-6
2
1 1 4
P-68203
Remove and cap both tubelines (Item 1) [Figure 20-41-

8] from the auxiliary section of the control valve.
P-66965
Disconnect and cap the drain hose (Item 2) [Figure 20-
Remove the two lift arm bypass valve bracket mounting
bolts (Item 1) [Figure 20-41-6].

Remove and cap the outlet tubeline (Item 3) [Figure 20-
41-8] from the control valve to the hydraulic oil cooler.
Remove the lift arm bypass valve and mounting bracket.
Remove and cap the charge tubeline (Item 4) [Figure 20-
Figure 20-41-7 41-8] from the control valve to the charge filter.
Remove the throttle rod (Item 5) [Figure 20-41-8] from

the engine, then pull the throttle rod out of the loader from
the rear.
1
P-66968
Remove tubeline clamp screw (Item 1) [Figure 20-41-7]

from the auxiliary tubelines in the left rear upright.

torque.

161 of 888
(CONT’D)
Figure 20-41-9 1
3
2
1
P-66971
Disconnect and cap the tubelines (Item 1) and (Item 2)

[Figure 20-41-11] from the tilt section of the control
P-68319 valve.
Disconnect and cap the tubeline (Item 3) [Figure 20-41-

Disconnect and cap the supply tubeline (Item 1) [Figure 11] from the lift section of the control valve.

20-41-9] from the hydraulic control valve.
Figure 20-41-12
Figure 20-41-10
1
2
P-66957
P-66973
Mark all tubelines and hoses for correct installation.

Remove the supply tubeline clamp screw (Item 1)
[Figure 20-41-10]. The fixed end main valve hose (Item 1) [Figure 20-41-
12] is connected to a fixed end fitting on the control valve.
Installation: Tighten screw to 15 - 20 ft.-lb. (20 - 27 N•m) The hose is routed to the back upright where the hose is
torque. connected to a tee fitting that feeds the base end of both
lift cylinders. The hose must be removed at the back tee
Remove supply tubeline (Item 2) [Figure 20-41-10] from fitting, located in the right side upright.
loader.
NOTE: Remember the hose routing for ease of
control valve installation.

162 of 888
(CONT’D)
Figure 20-41-13
1 1
P-68202
Connect a hoist to the lifting brackets (Item 1) [Figure 20-

41-15] on the control valve.
P-66962
Figure 20-41-16
Remove any tie-straps (Item 1) [Figure 20-41-13]

securing the fixed end main valve hose.

1
Figure 20-41-14
P-68327
P-51713
1

16] fastening the control valve and bracket to the side of
P-68318 the loader.

Remove the fixed-end main valve hose (Item 1) [Figure
20-41-14] from the main control valve fitting. Reverse removal procedure to install the hydraulic
control valve.

163 of 888
(CONT’D)
Actuator Removal And Installation (Out of Loader)
Figure 20-41-17
P-68030
Using a drift pin and a hammer, remove the actuator

linkage pin (Item 1) [Figure 20-41-19] from the actuator
1 and the lift spool.
P-68028 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 lift actuator.
Installation: Tighten the mounting bolts to 90 - 100 in.-lb.

(10 - 11,3 N•m) torque.
1
Figure 20-41-18
P-68031
1
Inspect the O-ring (Item 1) [Figure 20-41-20] on the nose

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

P-68029 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].

164 of 888
(CONT’D)

(Cont’d)
Figure 20-41-21
P-68034
Using a drift pin and a hammer, remove the actuator

linkage pin (Item 1) [Figure 20-41-23] from the actuator
1 and the tilt spool.
P-68032
Remove the actuator and linkage pin from the valve.

Figure 20-41-24
from the tilt actuator.

(10 - 11,3 N•m) torque.
Figure 20-41-22 1
P-68031
Inspect the O-ring (Item 1) [Figure 20-41-24] on the nose

of the actuator, and replace as needed.
P-68033 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].

165 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC)
(CONT’D)

(Cont’d)
Figure 20-41-25
1
2
P-68035
NOTE: The two longer bolts (Item 1) are used to

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

(10 - 11,3 N•m) torque (Item 1) [Figure 20-41-25]

166 of 888
(CONT’D)
Figure 20-41-26
J2 C3
C2
J4
D5 B3
E3
E3
G1 G2
F2 A3
B2 D3
D4 E2
C4
A2
D1
D2
A1
E1
F1 H2 B1
H3

MR C1
H1 J3
J1 MS1972
ITEM T190 LOADER ITEM T190 LOADER

A1 Lift Cylinder Base End E1 Lift Spool Centering Spring
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 G1 Auxiliary Solenoid Stem
C1 Load Check/BICS Valve G2 Auxiliary Solenoid Stem
Lift H1 BICS Valve Solenoid
C2 Lift Load Check
H2 BICS Lock Valve (Tilt)
C3 Load Check Valve Auxiliary Function
C4 Check Valve H3 BICS Lock Valve (Lift)
D1 Anti-Cavitation Valve J1 Inlet Fluid Flow (From Pump)
Lift (Rod End) J2 Outlet Fluid Flow (Return to Tank)
D2 Port Relief/Anti-Cavitation Valve – 3500 PSI J3 Lift Arm Bypass Orifice
Lift (Base End) J4 Drain (Case)
D3 Port Relief/Anti-Cavitation Valve – 3500 PSI Main Relief Valve – 3300 PSI
MR
Tilt (Base End)
D4 Port Relief/Anti-Cavitation Valve – 3500 PSI
Tilt (Rod End)
D5 Port Relief/Anti-Cavitation Valve (Auxiliary)
3500 PSI (Optional)

167 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Lift Load Check Valve Removal And Installation
(CONT’D)
Mount Bracket Removal And Installation Figure 20-41-28
Remove the control valve and mount bracket from the

loader.
Figure 20-41-27
1 1
P-68013
Remove the tubeline (Item 1) [Figure 20-41-28] from the

3 control valve.
P-68011
Figure 20-41-29

and lift eyes (Item 2) from the hydraulic control valve.
Remove the mount bracket (Item 3) from the hydraulic 1

control valve.
P-68014

check valve.
Remove the lift load check valve (Item 2) [Figure 20-41-

29].
Installation: Lubricate the O-ring and tighten the valve to

55 - 65 ft.-lb. (75 - 88 N•m) torque.

168 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Load Check Valve Removal And Installation (Tilt &
(CONT’D) Auxiliary)
Lift Load Check Valve Removal And Installation
(Cont’d) Figure 20-41-32
Figure 20-41-30
1
2
2
P-68007
P-51439
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

ring (Item 2) [Figure 20-41-30]. At the front side of the control valve locate the auxiliary
section load check valve (Item 2) [Figure 20-41-32].
NOTE: The tilt and auxiliary load check valves are

Figure 20-41-31 interchangeable.
Figure 20-41-33
1
1
3
2
P-51440
P-51453
Check for free movement of the load check valve (Item 1)
[Figure 20-41-31].
20-41-33].
Check the orifice (Item 3) [Figure 20-41-33] in the


torque.

169 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Always use new O-ring (Item 1) [Figure 20-41-35] on the
(CONT’D) anti-cavitation valve plug.
Anti-Cavitation Valve Removal And Installation (Lift,
Rod End) Figure 20-41-36
Figure 20-41-34
1
3
2
1
P-51453
P-68037
20-41-36].
At the back side of the control valve, remove the lift

section anti-cavitation valve (Item 1) [Figure 20-41-34]. Check the orifice (Item 3) [Figure 20-41-36] in the

IMPORTANT torque.

damage the system.
I-2003-0888
Figure 20-41-35
P-51452

170 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief / Anti-Cavitation Valve Removal And
(CONT’D) Installation (Tilt, Base End)
Port Relief / Anti-Cavitation Valve Removal And
Installation (Lift, Base End) Figure 20-41-39
Figure 20-41-37
P-68037
P-68037
Remove the tilt port relief/anti cavitation valve (Item 1)
[Figure 20-41-39] from the base end of the tilt section.
Loosen the lift circuit port relief/anti cavitation valve (Item

1) [Figure 20-41-37]. Figure 20-41-40
Figure 20-41-38
1
1
P-68039
P-68038
installation.
installation. Installation: Lightly lubricate with oil and tighten to 38 -
45 ft.-lb. (52 - 61 N•m) torque.
Installation: Lightly lubricate with oil and tighten to 38 -
45 ft.-lb. (52 - 61 N•m) torque.

171 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Port Relief Valve Removal And Installation
(CONT’D)
Port Relief / Anti-Cavitation Valve Removal And Figure 20-41-43
Installation (Tilt, Rod End)
Figure 20-41-41 1
P-68037
Remove the port relief plug (Item 1) [Figure 20-41-43]

P-68037
from the auxiliary circuit of the control valve.
Remove the tilt port relief/anti cavitation valve (Item 1) Figure 20-41-44

[Figure 20-41-41] from the rod end of the tilt section.
Figure 20-41-42
P-51801
1

P-51455 20-41-44]. Lightly lubricate with oil and tighten to 38 - 45
ft.-lb. (52 - 61 N•m) torque.
installation.
Installation: Lightly lubricate with oil and tighten to 38 -

45 ft.-lb. (52 - 61 N•m) torque.

172 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Plug Removal And Installation
(CONT’D)
Port Relief Valve Removal And Installation (Cont’d) Figure 20-41-47
Figure 20-41-45
1
1
P-68016
P-51743
At the top side of the control valve, remove the plug (Item
1) [Figure 20-41-47].
The control valve may be equipped with an optional
auxiliary port relief valve (Item 1) [Figure 20-41-45]. Figure 20-41-48

Remove the auxiliary port relief valve.
Figure 20-41-46
1
P-51460

P-51640

20-41-46]. Lightly lubricate with oil and tighten to 38 - 45

173 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) End Cap Block Removal And Installation
(CONT’D)
Plug Removal And Installation (Cont’d) Remove the lift and tilt actuators from the control valve.
(See Actuator Removal And Installation (Out of Loader)
Figure 20-41-49 on Page 20-41-6.)
Figure 20-41-51
1 P-51461
P-68040
At the bottom side of the control valve remove the plug
(Item 1) [Figure 20-41-49].

Disconnect the tube line (Item 1) [Figure 20-41-51] from
Figure 20-41-50 the end cap block.
Remove the two end cap block mount screws (Item 2)

[Figure 20-41-51].

11,3 N•m) torque.
1 Figure 20-41-52
P-51462
1

P-68041
Remove the end cap block (Item 1) [Figure 20-41-52]

from the control valve.

174 of 888
(CONT’D)
Lift Spool And Detent Removal And Installation 1

procedure:
MEL 1285 - Spring Tool
Remove the end cap block from the control valve.
Figure 20-41-53
1
P-68043
1
Remove the two screws (Item 1) [Figure 20-41-55] from
the lift spool end cap.

in.-lb. (10 - 11,3 N•m) torque.

Figure 20-41-56
P-68042
Remove the O-ring (Item 1) [Figure 20-41-53].
Installation: Replace the O-ring, and lubricate lightly

with oil before installation of the end cap block.
Figure 20-41-54 1
P-68044
2 Remove the lift spool end cap (Item 1) [Figure 20-41-56]

1 from the control valve.
P-68047

20-41-54] from the lift spool.

175 of 888
(CONT’D)
(Cont'd)
Figure 20-41-57
P-51772
1
Clamp the linkage end of the spool in a vise [Figure 20-
41-59].
P-68045
NOTE: Protect spool before clamping in vise.
Remove the lift spool assembly and seal (Item 1) [Figure Figure 20-41-60

20-41-57] from the control valve.
Figure 20-41-58
1
P-51773

P-68046
centering spring.
Remove the lift spool seal (Item 1) [Figure 20-41-58]

from the linkage end of the valve.

176 of 888
(CONT’D)
(Cont'd)
Figure 20-41-61
1
1
N-18920
Removal of the plastic plug:
Make a center point in the plug using a 1/16 in. drill.
N-190146
Drill a hole all the way through the plug using a 7/64 in.
tap drill

centering spring to the spool. Turn a 6 - 32 tap (Item 1) [Figure 20-41-63] into the plug.
Pull the tap and plug out of the spool. Be careful, do not
Installation: Tighten the bolt to 90 - 100 in.-lb. (10 - 11,3 break the tap.
N•m) torque.
Clean all the debris from inside the spool bore.
NOTE: DO NOT USE Loctite® ON THE STUD
Figure 20-41-62 THREADS.
Figure 20-41-64
3
2 2
1 1
4
P-51776
P-74183
Install the O-ring (Item 1) over the nipple on the plastic
plug (Item 2) [Figure 20-41-64].
NOTE: Check the O-ring for damage. The lift spool

will have an internal leak if there is damage to
this O-ring. Always replace the O-ring and
recheck the lift spool before the control valve
is replaced.

177 of 888
(CONT’D)
(Cont'd)
1
Figure 20-41-65
2
3
3
P-68044
Install the lift spool assembly (Item 1) [Figure 20-41-67]

in the spool bore.
P-74184
Install the end cap (Item 2) [Figure 20-41-67].
Install the plastic plug and O-ring in the spool [Figure 20- Install the mounting screws (Item 3) [Figure 20-41-67].

41-65].
Figure 20-41-66 in.-lb. (10 - 11,3 N•m) torque.
2
1
P-51771 P-51775


178 of 888
(CONT’D)
(Cont'd) 1
Figure 20-41-68
P-68042
Install the O-ring (Item 1) [Figure 20-41-70] on the

control valve.
P-68048
Figure 20-41-71
Install the spool seal (Item 1) [Figure 20-41-68] on the

actuator end of the valve.
Figure 20-41-69 3
1
P-68040
2 Install the end cap block (Item 1) and the two mount bolts
(Item 2) [Figure 20-41-71].
P-68049
11,3 N•m) torque.
Install the O-ring (Item 1) and spacer (Item 2) [Figure 20-
41-69] on the lift spool. Connect the tube line (Item 3) [Figure 20-41-71] to the
end cap block.
Install the lift and tilt actuators to the control valve.

179 of 888
(CONT’D)
Tilt Spool Removal And Installation
Remove the end cap block. (See End Cap Block

Removal And Installation on Page 20-41-16.)
Figure 20-41-72
2
P-68051

1 2
Check and replace the O-ring (Item 2) [Figure 20-41-74]
before replacing the spool centering block.
P-68049

Figure 20-41-75
20-41-72] from the tilt spool.
Figure 20-41-73
1
1
2 1
P-68052
2 Remove the tilt spool, centering spring, back-up washer

and spool seal (Item 1) [Figure 20-41-75].
P-68050

Disconnect the tubeline (Item 1) [Figure 20-41-73].


N•m) torque.

180 of 888
(CONT’D)
Tilt Spool Removal And Installation (Cont'd)
2 1
Figure 20-41-76
3
4
1
N-18944A
N-18942
Figure 20-41-79
Put the linkage end of the spool in the vice [Figure 20-
41-76]. 2

1
centering spring.
Figure 20-41-77
1
1
P-51545 N-18943

N-19014

centering spring to the spool.

N•m) torque.

181 of 888
(CONT’D)
Auxiliary Spool Removal And Installation
Figure 20-41-80
1 1
2
P-68054
2 Remove the spacer (Item 1) and O-ring (Item 2) [Figure

P-68050
Figure 20-41-83
Disconnect the tubelines (Item 1) [Figure 20-41-80] from
the spool centering block.


N•m) torque.
2
Remove the spool centering block from the control valve. 1
Figure 20-41-81
P-68076

2 NOTE: If the centering spring retainer (Item 2) [Figure

retainer on the opposite end of the spool,
also.
1
P-68053

NOTE: If the centering spring retainer (Item 2) [Figure

retainer on the opposite end of the spool also.

182 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Auxiliary Solenoid Removal And Installation
(CONT’D)
Auxiliary Spool Removal And Installation (Cont’d) Figure 20-41-86
Figure 20-41-84
1 1
2
P-68082
P-68077
Remove the nut (Item 1) [Figure 20-41-86] from both
solenoids.
20-41-84] from the auxiliary spool. Installation: Tighten the nut to 48 - 72 in.-lb. (5 - 8 N•m)

torque.
Figure 20-41-85
Figure 20-41-87
P-68078
P-51553
Remove the auxiliary spool (Item 1) [Figure 20-41-85].

Remove the nut (Item 1) and solenoid coil (Item 2)
[Figure 20-41-87].

resistance.

183 of 888
HYDRAULIC CONTROL VALVE (ACS) OR (SJC) Solenoid Removal And Installation
(CONT’D)
Auxiliary Solenoid Removal And Installation (Cont’d) Figure 20-41-90
Figure 20-41-88
1
2
P-68084
P-68083
Remove the nut (Item 1) [Figure 20-41-90] from the
solenoid stem.
Remove the solenoid stem (Item 1) [Figure 20-41-88].
Installation: Tighten the nut to 53 in.-lb. (6 N•m) torque.

Installation: Tighten the stem to 10 - 14 ft.-lb. (14 - 19
N•m) torque. Remove the solenoid coil (Item 2) [Figure 20-41-90].
Figure 20-41-89 Figure 20-41-91
N-18693A
P-51555
Remove the O-rings (Item 1) [Figure 20-41-89] from the Remove the O-rings (Item 1) [Figure 20-41-91] from
solenoid stem. both ends of the solenoid coil.
Check and clean the screen (Item 2) [Figure 20-41-89]. Use an Ohm meter to measure the solenoid coil
resistance.

184 of 888
(CONT’D)
Solenoid Removal And Installation (Cont’d)
Figure 20-41-92
3
2
1
1
N-18694

[Figure 20-41-93] from the stem.
P-68085
Clean all parts in solvent and dry with compressed air.

Inspect all parts for wear and replace any showing

excessive wear.
Installation: Lubricate the O-rings and tighten the stem
to 20 - 24 ft.-lb. (27 - 33 N•m) torque. NOTE: The screen (Item 3) [Figure 20-41-93] may be
cleaned with solvent. If it is torn or worn it
Use only new O-rings and apply oil to all O-rings and
back-up rings before installation.
Install new O-rings (Item 1) [Figure 20-41-91] & [Figure

20-41-93] and new back-up rings (Item 2) [Figure 20-41-
93] on the solenoid stem.

185 of 888
(CONT’D)
Lock Valve Removal And Installation
Figure 20-41-94
1
1
1
2
1
1
2
2
2
P-51564

[Figure 20-41-96] from the lift lock valve, and replace
P-68079
with new.
Locate the two BICS lock valves, (Item 1) is for the tilt Figure 20-41-97
circuit, and (Item 2) [Figure 20-41-94] is for the lift circuit.

Figure 20-41-95
1
P-68080
Remove the tilt lock valve (Item 1) [Figure 20-41-97]

P-68081
from the back of the control valve.
Remove the lift lock valve (Item 1) [Figure 20-41-95] Installation: Lightly lubricate the lock valve o-rings and
from the back of the control valve. tighten to 20 - 24 ft.-lb. (27 - 33 N•m) torque.
Installation: Lightly lubricate the lock valve o-rings and


186 of 888
(CONT’D)
Lock Valve Removal And Installation (Cont’d)
Figure 20-41-98
1
1
1
1
2
2
2
P-51564

[Figure 20-41-98] from the tilt lock valve, and replace

with new.

187 of 888
(CONT’D)
Lift Arm Bypass Orifice Removal And Installation
Figure 20-41-99
P-68087

valve.

Figure 20-41-100
P-51437
Check the lift arm bypass orifice (Item 1) [Figure 20-41-

100].
NOTE: This orifice is not removable from the valve

casting.

188 of 888
(CONT’D)
Main Relief Valve Removal And Installation
Figure 20-41-101
P-68088
Remove the main relief valve (Item 1) [Figure 20-41-

101].

Figure 20-41-102
1
P-51463
Remove the O-rings from the main relief valve (Item 1)

[Figure 20-41-102].
Installation: Always use new O-rings. Tighten to 38 - 45


189 of 888
(CONT’D)
Check Valve Removal And Installation
Figure 20-41-103
P-68869
Installation: Lubricate the O-ring (Item 1) [Figure 20-41-

105] and tighten the fitting to 20 - 24 ft.-lb. (27 - 33 N•m)
P-68081
torque.
Remove the tubeline (Item 1) [Figure 20-41-103]. Figure 20-41-106

Figure 20-41-104
P-68870
P-68010
Inspect the screen (Item 1) [Figure 20-41-106].
Remove the BICS check valve fitting (Item 1) [Figure 20-

41-104] from the top of the lift load check valve.
Installation: Lubricate the O-ring and tighten the fitting to

20 - 24 ft.-lb. (27 - 33 N•m) torque.

190 of 888
LIFT ARM BYPASS CONTROL VALVE Removal And Installation
Description
The lift arm bypass control valve is located on the right

side of the machine close to the engine speed control.
DANGER
The lift arm bypass control valve is manually operated by
pulling up on the valve knob (Item 1) [Figure 20-50-1]
and turning the knob clockwise a 1/4 turn. 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 P-90328
Figure 20-50-1 AVOID DEATH

1 unless supported by an approved lift arm
D-1009-0409

WARNING
P-68159 the lift arms are secured by an approved lift arm
Raise the lift arms 6 feet (2 m) off the ground. Stop the to fall and cause injury or death.
engine. Turn the Lift Arm Bypass Control Knob (Item 1) W-2059-0598
[Figure 20-50-1] clockwise 1/4 turn. Then pull up and
hold the Lift Arm Bypass Control Knob until the lift arms
Install jack stands under the rear corners of the loader.
slowly lower.
Start the engine. Raise the lift arms and install an
The knob should return to its original position.
approved lift arm support device. (See Installing on Page
10-20-1.)
Raise the operator cab.(See Raising on Page 10-30-2.)

191 of 888
LIFT ARM BYPASS CONTROL VALVE (CONT'D) Remove the two mounting bolt/nuts (Item 4) [Figure 20-
50-3].
Installation: Tighten the mounting bolts to 180 - 200 in.-
Figure 20-50-2 lb. (21 - 23 N•m) torque.
Remove the lift arm bypass control valve.
1 Disassembly And Assembly
3 Figure 20-50-4
2
P-68160
Hold the Lift Arm Bypass Control knob (Item 1) and

loosen the jam nut (Item 2) on the Lift Arm Bypass valve

shaft [Figure 20-50-2].
P-26065
Remove the Lift Arm Bypass Control knob (Item 1) and
the jam nut (Item 2) from the Lift Arm Bypass valve shaft
[Figure 20-50-2]. Remove the bypass valve (Item 1) [Figure 20-50-4] from
the valve block. Inspect the bypass valve for damage and
Remove the rubber washer (Item 3) [Figure 20-50-2]. replace if necessary.
Figure 20-50-3 Installation: Tighten the valve to 33 - 37 ft.-lb. (45 - 50

N•m) torque.
Inspect the hydraulic fittings on the valve block for

damage and replace if necessary.
2
3
1
P-68160
Disconnect the base end lift tubeline (Item 1) [Figure 20-

50-3] from the Lift Arm Bypass valve.
Disconnect the drain hose (Item 2) [Figure 20-50-3] from

the Lift Arm Bypass valve.
Disconnect the motor case drain hose (Item 3) [Figure

20-50-3].

192 of 888
HYDRAULIC PUMP (STANDARD) Install a hydraulic tester (Item 1) [Figure 20-60-1] onto
the front auxiliary quick couplers.
Description
This procedure will require a operator in the cab and one
The hydraulic gear pump is attached to the end of the 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 Front
engine. Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
The hydraulic gear pump is a combination of gear pumps connected correctly. If no flow is indicated on the tester,
that provide hydraulic flow to several hydraulic systems. the hoses are connected wrong. With the hoses
connected correctly, increase the engine speed to full
The hydraulic gear pump has a dedicated charge pump. RPM*.
This supplies flow to the hydraulic fan motor and charge
pressure to the hydrostatic pump. Warm the fluid to 140° F (60° C) by turning the restrictor
control clockwise on the tester so it reads about a 1000
A seal kit is available to service the hydraulic pump. If PSI (69 bar).
any of the main components of the pump are damaged,
the entire pump must be replaced. NOTE: DO NOT EXCEED 3300 PSI.
Pump Test At Quick Couplers Turn the restrictor control (Item 2) [Figure 20-60-1] on
the tester counterclockwise to obtain free flow, the flow
The tools listed will be needed to do the following should be approximately 16 - 17 GPM. Start turning the
procedure: restrictor clockwise, causing more restriction on the flow.

The GPM should drop off slightly until the pressure
MEL10003 - In-Line Hydraulic Tester reaches approximately 2800 PSI. At approximately 2800
MEL10006 - Flow Meter Fitting Kit PSI the flow should start decreasing rapidly until the
pressure reaches 3250 - 3300 PSI. At 3250 - 3300 PSI
Figure 20-60-1 the flow should be at 0 GPM. Turn the restrictor (Item 2)
[Figure 20-60-1] counterclockwise to free flow. Shut the
front auxiliary hydraulics off.
1
If flow and pressure specs 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.
P-16903 P-66894
NOTE: When testing the hydraulic flow of a machine,

hoses must be at least 3/4 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 50
GPM.

193 of 888
HYDRAULIC PUMP (STANDARD) (CONT'D) Figure 20-60-2
Direct Pump Test (Standard Section)
The tools listed will be needed to do the following

procedure: 2
MEL1563 or 6689779 - Remote Start Tool

WARNING 1
P-68163
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
tubeline on the control valve.
Lift and block the loader. (See Procedure on Page 10-10- Figure 20-60-3
1.)

device. (See Installing on Page 10-20-1.)
WARNING 2
1

P-48256
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]
Open the rear door of the loader. of the pump. Connect the OUTLET hose (Item 2) [Figure
20-60-3] from the tester to the tubeline (Item 2) [Figure
Connect the remote start tool. (See REMOTE START 20-60-2] on the control valve.
TOOL KIT-MEL1563 on Page 10-60-1.)
IMPORTANT
I-2024-0284

194 of 888
HYDRAULIC PUMP (STANDARD) (CONT'D)
Direct Pump Test (Standard Section) (Cont'd)
Figure 20-60-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Out In Hydraulic Control
Valve

BH-196
Sample tester connection shown [Figure 20-60-4].
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
RPM*.
Warm the fluid to 140° F (60° C) by turning the restrictor

control (Item 1) [Figure 20-60-4] on the tester to about
1000 PSI (6895 kPa). DO NOT exceed system relief
pressure. Open the restrictor control and record the free
flow (GPM) at full RPM*.
Push the maximum/variable flow switch (on the remote

start tool) to engage the front auxiliary hydraulics, the
light will come ON. Push the button (on the right control
lever) 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 (GPM) X 100

FREE FLOW (GPM)
A low percentage may indicate a failed pump.


195 of 888
Direct Pump Test (Charge Section)

procedure:

MEL10103 - Hydraulic Tester 2
MEL10106 - Hydraulic Test Kit 1
WARNING
P-69182
Failure to use jackstands can allow the machine to Disconnect the proportioning valve electrical connector
fall or move and cause injury or death. (Item 1) [Figure 20-60-5].
W-2017-0286
Remove the tie-strap (Item 2) [Figure 20-60-5] from the

Lift and block the loader. (See Procedure on Page 10-10- electrical harness.
1.)

Figure 20-60-6
WARNING
the lift arms are secured by an approved lift arm 1
W-2059-0598
P-69184
NOTE: The fluid from the charge pump must be
filtered after it passes through the Hydraulic
Tester, to prevent any contamination to the Disconnect the filter inlet hose (Item 1) [Figure 20-60-6].
Hydrostatic Pumps.
Connect the remote start tool. (See REMOTE START


196 of 888
Direct Pump Test (Charge Section) (Cont’d)
Figure 20-60-7
4 3
P-48256A
2 1 Be sure all connections are tight and that the hoses are
P-69185 not touching any moving parts before starting the loader
[Figure 20-60-8].
Connect the filter inlet hose (Item 1) to the inlet side of

the tester (Item 2) [Figure 20-60-7].

Connect the OUTLET hose (Item 3) from the hydraulic
tester to the inlet fitting (Item 4) of the charge filter
IMPORTANT
[Figure 20-60-7].
I-2024-0284
RPM*.

600 PSI (41,4 bar). DO NOT exceed 1200 PSI (82,7 bar).
Open the restrictor control and record the free flow
(GPM) at full RPM*.
Turn the restrictor down to system operating pressure

approximately 1000 PSI (69 bar). DO NOT EXCEED
1200 PSI (82,7 bar). Refer to Hydraulic Schematics for
flow. The high pressure flow must be at least 80% of free
flow.
HIGH PRESSURE FLOW (GPM)
%= X 100
FREE FLOW (GPM)
*Refer to the Hydraulic Schematics for pump flow and

RPM.

197 of 888
DANGER
1
P-66880
P-90328
AVOID DEATH Disconnect and cap the outlet hoses (Item 1) [Figure 20-
• Disconnecting or loosening any hydraulic 60-9] from the back of the hydraulic pump.
can cause lift arms to drop. Remove the Power Bob-Tach block if equipped. (See
• Keep out of this area when lift arms are raised Removal And Installation on Page 20-130-1.)

D-1009-0409
WARNING
IMPORTANT the lift arms are secured by an approved lift arm
When repairing hydrostatic and hydraulic systems, to fall and cause injury or death.
clean the work area before disassembly and keep all W-2059-0598
Figure 20-60-10
damage the system.
I-2003-0888
Lift and block the rear of the loader. (See Procedure on

Page 10-10-1.)
device. (See Installing on Page 10-20-1.) 1
Drain the hydraulic fluid from the reservoir. (See

Removing And Replacing Hydraulic Fluid on Page 10-
120-2.) and (See Removing And Replacing Case Drain
Filters on Page 10-120-4.) P-66882

Disconnect and cap the inlet hoses (Item 1) [Figure 20-
60-10] from the front of the hydraulic pump.

198 of 888
Figure 20-60-11
P-43940 P-43938A
Replace the O-ring (Item 1) [Figure 20-60-13] on the

P-66897 hydraulic pump.
Reverse the removal procedure to install the hydraulic

Figure 20-60-12 pump.

1
P-66898

11] and [Figure 20-60-12] from the hydraulic pump.
Installation: Tighten the mounting bolts to 55 - 60 ft.-lb.

(75 - 85 N•m) torque.
Remove the hydraulic pump from the loader.

199 of 888
Hydraulic Pump Startup
NOTE: This procedure to prevent a dry start up of the

hydraulic pump.
Figure 20-60-14
Starter
Solenoid
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-66897
P-59356

Disconnect the pump inlet hose connection at the front of
the hydrostatic pump. Fill the pump inlet and hose Connect the starter bypass tool to the starter solenoid
completely with hydraulic fluid. Reconnect the hose battery terminal and S terminal. Crank the engine for 15
[Figure 20-60-14]. seconds, then stop for at least 30 seconds. Again, crank
the engine for 15 seconds. Remove the starter bypass
Figure 20-60-15 tool [Figure 20-60-16].
Momentary Switch
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.
Starter Bypass Tool Check for hydraulic leaks.
P-59354
[Figure 20-60-15] 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.

200 of 888
HYDRAULIC PUMP (STANDARD) (CONT'D)
15
14
7 5
13
8
5 6
4
12 3

9
8
7
11
5
6
10
9
7
3 4 5 6
1 1. Shaft Seal
2 2. Pump Flange Section
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
10. Auxiliary Pump Section
11. Spline Shaft
12. Pump Center Section
13. Charge Pump Section
14. Pump End Section
15. Bolt (8)
B-21259A

201 of 888
Disassembly And Assembly 1
Figure 20-60-17
P-26352
P-64507
1
1 P-64509
1
Remove the pump end section (Item 1) [Figure 20-60-
P-64508 18].
Mark the pump sections for correct assembly [Figure 20-

60-17].

Remove the eight pump housing bolts (Item 1) [Figure
20-60-17].
Installation: Tighten the bolts (Item 2) [Figure 20-60-17]

to 54 ft.-lb. (73,2 N•m) torque.
IMPORTANT
damage the system.
I-2003-0888

202 of 888
Figure 20-60-19 1
P-64511
2
Figure 20-60-22
P-64509
1
Figure 20-60-20

3
4
1
P-64512
2 Remove the charge pump section (Item 1) [Figure 20-

P-64510 60-21] & [Figure 20-60-22] from the pump center
section.
Remove the wear plate (Item 1) and section seal (Item 2) NOTE: Inspect the pump section (Item 1) [Figure 20-
[Figure 20-60-19] & [Figure 20-60-20] from the pump 60-22]. If excessive wear or damage is visible,
end section. the pump must be replaced.
NOTE: Position wear plate (Item 1) [Figure 20-60-20]

inlets and traps as shown with bronze side
toward gears.
NOTE: Inspect the pump end section (Item 3) [Figure

20-60-20] and bushings (Item 4) [Figure 20-60-
20]. If excessive wear or damage is visible, the
pump must be replaced.

203 of 888
Figure 20-60-23
P-64515
Figure 20-60-26
P-64513
Figure 20-60-24

1
P-64516
Remove the idler gear (Item 1) [Figure 20-60-25] &

P-64514 [Figure 20-60-26] from the pump center section.
NOTE: Inspect the idler gear (Item 1) [Figure 20-60-

Remove the drive gear (Item 1) [Figure 20-60-23] & 26]. If excessive wear or damage is visible, the
[Figure 20-60-24]. pump must be replaced.
NOTE: Inspect the drive gear (Item 1) [Figure 20-60-


204 of 888
Figure 20-60-27
1
P-64519
1
2 Figure 20-60-30
P-64517
2
Figure 20-60-28

1
2 1
P-64520
Remove the load seal (Item 1) [Figure 20-60-29] &

P-64518 [Figure 20-60-30]. Inspect for damage and replace as
needed.
Remove the wear plate (Item 1) and O-ring (Item 2) Remove the pre-load seal (Item 2) [Figure 20-60-30].
[Figure 20-60-27] & [Figure 20-60-28] from the pump
center section. Inspect for damage and replace as
needed.

toward gears.

205 of 888
Figure 20-60-31
2
1
1
P-64526
Figure 20-60-34
P-64521
3
Inspect the pre-load seal (Item 1) [Figure 20-60-31] for

damage and replace as needed. 4

NOTE: Inspect the pump center section (Item 2) and
bushings (Item 3) [Figure 20-60-31]. If
excessive wear or damage is visible, the
pump must be replaced. 1
Figure 20-60-32
2
1
P-64527
Remove the wear plate (Item 1) and O-ring (Item 2)

needed.

toward gears.
P-64525 NOTE: Inspect the pump center section (Item 3) and

Remove the pump center section (Item 1) [Figure 20-60- pump must be replaced.
32].

206 of 888
Figure 20-60-35
1
P-64530
1
Remove the drive gear (Item 1) [Figure 20-60-37] from
P-64528 the pump flange section.
Figure 20-60-38
Figure 20-60-36

1
P-64531
P-64529

Remove the auxiliary pump section (Item 1) [Figure 20- 38]. If excessive wear or damage is visible, the
60-35] & [Figure 20-60-36] from the pump flange pump must be replaced.
section.
NOTE: Inspect the pump section (Item 1) [Figure 20-

60-36]. If excessive wear or damage is visible,
the pump must be replaced.

207 of 888
Figure 20-60-39
2
P-64535
Figure 20-60-42
P-64532
Remove the spline shaft (Item 1) [Figure 20-60-39] from

the end of the drive gear.

Remove the idler gear (Item 2) [Figure 20-60-39].
Figure 20-60-40
2
P-64536

1 [Figure 20-60-41] & [Figure 20-60-42] from the pump
flange section. Inspect for damage and replace as
needed.

P-64534 inlets and traps as shown with bronze side
toward gears.


208 of 888
Figure 20-60-43
3
2
1
P-64540

P-64537 damage and replace as needed.
NOTE: Inspect the pump flange section (Item 2) and

Figure 20-60-44 bushings (Item 3) [Figure 20-60-45]. If

Figure 20-60-46
1
2
2
1 P-30188A
P-64538

[Figure 20-60-44]. Inspect for damage and replace as
P-64541
needed.
Remove the pre-load seal (Item 2) [Figure 20-60-44]. Remove the shaft seal (Item 1) [Figure 20-60-46] from
the pump flange section.
Installation: The shaft seal flush surface (Item 2)

[Figure 20-60-46] must be facing out away from the
pump.

209 of 888

210 of 888
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) NOTE: When testing the hydraulic flow of a machine,
Description connected directly to the hydraulic tester
The hydraulic gear pump is attached to the end of the the connection to the tester. Also make sure
hydrostatic pumps and is located on the right side of the your hydraulic tester is capable of at least 50
loader between the hydraulic control valve and the GPM.
engine.
Install a hydraulic tester (Item 1) [Figure 20-61-47] onto
The hydraulic gear pump is a combination of gear pumps the front auxiliary quick couplers.
that provide hydraulic flow to several hydraulic systems.
The hydraulic gear pump has a dedicated charge pump. operator running the tester.
pressure to the hydrostatic pump. Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
The high flow hydraulic pump has an additional pump trigger on the right handle. Make sure the tester is
section that provides an additional amount of flow that is connected correctly. If no flow is indicated on the tester,
controlled by an external valve. The valve is switched the hoses are connected wrong. With the hoses
from a button on the panel in the cab. connected correctly, increase the engine speed to full
RPM*.
A seal kit is available to service the hydraulic pump. If
any of the main components of the pump are damaged, Warm the fluid to 140° F (60° C) by turning the restrictor
the entire pump must be replaced. control clockwise on the tester so it reads about a 1000

PSI (69 bar).
Pump Test At Quick Couplers
NOTE: DO NOT EXCEED 3300 PSI.
procedure: Turn the restrictor control (Item 2) [Figure 20-61-47] on
MEL10003 - In-Line Hydraulic Tester should be approximately 16 - 17 GPM. Start turning the
MEL10006 - Flow Meter Fitting Kit restrictor clockwise, causing more restriction on the flow.
Figure 20-61-47 reaches approximately 2800 PSI. At approximately 2800
PSI the flow should start decreasing rapidly until the
1 the flow should be at 0 GPM. Turn the restrictor (Item 2)

on Page 20-61-2.)

P-16903 P-66894

211 of 888
HYDRAULIC PUMP (STANDARD) (HIGH FLOW) Figure 20-61-48
(CONT'D)
The tools listed will be needed to do the following 2

procedure:

1
WARNING
P-68163

Disconnect the OUTLET hose (Item 1) [Figure 20-61-48]
that comes from the gear pump, and connects to the
W-2017-0286
Figure 20-61-49

1.)
2
WARNING 1

to fall and cause injury or death. P-48256
W-2059-0598
Connect the INLET hose (Item 1) [Figure 20-61-49] from

Raise the operator cab. (See Raising on Page 10-30-2.) the tester to the OUTLET hose (Item 1) [Figure 20-61-
48] of the pump. Connect the OUTLET hose (Item 2)
Open the rear door of the loader. [Figure 20-61-49] from the tester to the tubeline (Item 2)
[Figure 20-61-48] on the control valve.

212 of 888
HYDRAULIC PUMP (STANDARD) (HIGH FLOW)
(CONT'D)
Figure 20-61-50
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Valve

BH-196
RPM*.


80% of free flow.

%= X 100
FREE FLOW (GPM)


213 of 888
(CONT'D)

procedure:
MEL1563 or 6689779 - Remote Start Tool 2

WARNING
P-69182

Disconnect the proportioning valve electrical connector
(Item 1) [Figure 20-61-51].
W-2017-0286
electrical harness.

1.) Figure 20-61-52
WARNING
Never work on a machine with the lift arms up unless 1
W-2059-0598
P-69184

filtered after it passes through the Hydraulic Disconnect the filter inlet hose (Item 1) [Figure 20-61-
Tester, to prevent any contamination to the 52].
Hydrostatic Pumps.


214 of 888
(CONT'D)
Figure 20-61-53
4 3
P-48256A
Be sure all connections are tight and that the hoses are
2 1 not touching any moving parts before starting the loader
P-69185 [Figure 20-61-54].


IMPORTANT
[Figure 20-61-53]. The hydraulic tester must be in the fully open
I-2024-0284
RPM*.

(GPM) at full RPM*.

flow.
%= X 100
FREE FLOW (GPM)

RPM.

215 of 888
(CONT'D)
Direct Pump Test (High Flow Section)
WARNING
W-2017-0286
P-48463
WARNING Install a jumper hose (Item 1) [Figure 20-61-55] onto the

front auxiliary quick couplers.
the lift arms are secured by an approved lift arm Raise the lift arms and install an approved lift arm support
support device. Failure to use an approved lift arm device. (See Installing on Page 10-20-1.)

W-2059-0598
IMPORTANT
I-2024-0284

procedure:


1.)


216 of 888
(CONT'D)
EXAMPLE: TESTER
Direct Pump Test (High Flow Section) (Cont'd) CONNECTION
Reservoir
Figure 20-61-56
Hydraulic Pump
Out In
High Flow Valve
1
1 B-16277

2
P-48235 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
Disconnect the high flow pump OUTLET hose (Item 1) coupler. Make sure the tester is connected correctly. If no
from the high flow valve INLET fitting (Item 2) [Figure 20-

flow is indicated on the tester, the hoses are connected
61-56]. wrong. With the hoses connected correctly, increase the
engine speed to full RPM*.
Figure 20-61-57
1000 PSI (6895 kPa).
2 1 Open the restrictor control and record the free flow

(GPM) at full RPM. Turn the restrictor control on the
tester to 3300 PSI and the flow should go to zero GPM.
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Adjustment on Page 20-150-3.)
P-48256
Record the highest pressure (PSI) and flow (GPM). The
high pressure flow must be at least 80% of free flow.
the tester, to the high flow pump OUTLET hose (Item 1) %= HIGH PRESSURE FLOW (GPM) X100
[Figure 20-61-56]. Connect the OUTLET hose (Item 2) FREE FLOW (GPM)
[Figure 20-61-57] from the tester, to the high flow valve
INLET fitting (Item 2) [Figure 20-61-56] on the High Flow A low percentage may indicate a failed pump.
valve.
*Refer to Hydraulic Schematics Legend for system relief
Lower the cab. pressure and full RPM.

217 of 888
(CONT'D)
DANGER
1
P-64545
P-90328
Disconnect and cap the outlet hoses (Item 1) [Figure 20-
AVOID DEATH 61-59] from the back of the hydraulic pump.
tubeline, hose, fitting, component or a part failure Remove the Power Bob-Tach block if equipped. (See
can cause lift arms to drop. Removal And Installation on Page 20-130-1.)

D-1009-0409
WARNING
IMPORTANT support device. Failure to use an approved lift arm
When repairing hydrostatic and hydraulic systems, W-2059-0598
tubelines and ports to keep dirt out. Dirt can quickly Figure 20-61-60
damage the system.
I-2003-0888

Page 10-10-1.)
Raise the lift arms and install an approved lift arm support 1
Drain the hydraulic fluid from the reservoir. (See

120-2.) and (See Removing And Replacing Case Drain
P-66882
Filters on Page 10-120-4.)
Open the rear door of the loader. Disconnect and cap the inlet hoses (Item 1) [Figure 20-
61-60] from the front of the hydraulic pump.

218 of 888
(CONT'D)
Figure 20-61-61
P-43940 P-43938A
Replace the O-ring (Item 1) [Figure 20-61-63] on the

hydraulic pump.
P-66897
pump.
Figure 20-61-62

1
P-66898

61] and [Figure 20-61-62] from the hydraulic pump.

(75 - 85 N•m) torque.
Remove the hydraulic pump from the loader.

219 of 888
(CONT'D)

hydraulic pump.
Figure 20-61-64 Starter

Solenoid
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-66897
P-59356

Connect the starter bypass tool to the starter solenoid
the hydrostatic pump. Fill the pump inlet and hose
battery terminal and S terminal. Crank the engine for 15
completely with hydraulic fluid. Reconnect the hose
seconds, then stop for at least 30 seconds. Again, crank
[Figure 20-61-64].
tool [Figure 20-61-66].
Figure 20-61-65
Momentary Switch Start the loader from the operators cab and run the
hydraulics.
of cylinder stroke.

Check for hydraulic leaks.
Starter Bypass Tool
P-59354

without starting.


220 of 888
(CONT'D)
17
16
8 4
12 15 2
7
14 3 4 5
7
8 13 6 5
9
6
7

12
7
8
7
9 6
5
3 4
6 5 11
6 9
5 10
1 3 4
1. Shaft Seal
2. Pump Flange Section
2
3. Pre-Load Seal
4. Load Seal
5. O-Ring
6. Valve Plate
7. Pin
8. Drive Gear
9. Idler Gear
11. Auxiliary Center Section
12. Splined Shaft
14. Charge Center Section
15. High Flow Pump Section
16. High Flow End Section
17. Bolt
B-18248

221 of 888
(CONT'D)
1
Figure 20-61-67
1
P-64553
P-64554
1
1 Remove the high flow end section (Item 1) [Figure 20-
61-68].
P-64552

61-67].

20-61-67].

IMPORTANT
damage the system.
I-2003-0888

222 of 888
(CONT'D)

1
Figure 20-61-69
P-64556
2 Figure 20-61-72
P-64554
1
Figure 20-61-70

3
4
1 P-64557
2 Remove the high flow pump section (Item 1) [Figure 20-

61-71] & [Figure 20-61-72] from the charge center
P-64555 section.
NOTE: Inspect the high flow pump section (Item 1)

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-61-72]. If excessive wear or
[Figure 20-61-69] & [Figure 20-61-70] from the high flow damage is visible, the pump must be
end section. replaced.

toward gears.
NOTE: Inspect the high flow end section (Item 3) and


223 of 888
(CONT'D)
Figure 20-61-73
P-64560
Figure 20-61-76
P-64558
Figure 20-61-74

1
P-64561

[Figure 20-61-76] from the charge center section.
P-64559
Remove the drive gear (Item 1) [Figure 20-61-73] & pump must be replaced.
[Figure 20-61-74].


224 of 888
(CONT'D)
Figure 20-61-77
1
P-64564
2 Figure 20-61-80
P-64562
2
Figure 20-61-78

1
2 1
P-64565

P-64563 needed.
Remove the pre-load seal (Item 2) [Figure 20-61-80].

[Figure 20-61-77] & [Figure 20-61-78] from the charge
needed.

toward gears.

225 of 888
(CONT'D)

2
Figure 20-61-81
3
1
1 P-64569
Figure 20-61-84
P-64567 3

4
damage and replace as needed.

NOTE: Inspect the charge center section (Item 2) and
Figure 20-61-82
2
P-64571
1

needed.

toward gears.

P-64568 bushings (Item 4) [Figure 20-61-84]. If
Remove the charge center section (Item 1) [Figure 20-
61-82].

226 of 888
(CONT'D)
Figure 20-61-85
1
1
P-64574

the auxiliary center section.
P-64572
Figure 20-61-88
Figure 20-61-86

1
P-64575
P-64573
Remove the charge pump section (Item 1) [Figure 20- pump must be replaced.
61-85] & [Figure 20-61-86] from the auxiliary pump
center section.
NOTE: Inspect the charge pump section (Item 1)

[Figure 20-61-86]. If excessive wear or
damage is visible, the pump must be
replaced.

227 of 888
(CONT'D)
Figure 20-61-89
1
2
1
2
P-64578
Figure 20-61-92
P-64576

the end of the drive gear. Inspect for damage and replace

as needed.
1
2
Figure 20-61-90
P-64579
1 Remove the wear plate (Item 1) and O-ring (Item 2)

[Figure 20-61-91] & [Figure 20-61-92] from the auxiliary
needed.

toward gears.
P-64577


228 of 888
(CONT'D)
2
Figure 20-61-93
1 1
P-64521

P-64519
NOTE: Inspect the auxiliary center section (Item 2)
and bushings (Item 3) [Figure 20-61-95]. If
Figure 20-61-94 excessive wear or damage is visible, the

2 Figure 20-61-96
1
P-64520

P-64525
needed.
Remove the auxiliary center section (Item 1) [Figure 20-
Remove the pre-load seal (Item 2) [Figure 20-61-94]. 61-96].

229 of 888
(CONT'D)
Figure 20-61-97
P-64528
1
Figure 20-61-100
P-64526
Figure 20-61-98

3
4 1
1 P-64529
Remove the auxiliary pump section (Item 1) [Figure 20-

2
61-99] & [Figure 20-61-100] from the pump flange
P-64527 section.
NOTE: Inspect the auxiliary pump section (Item 1)

Remove the wear plate (Item 1) and O-ring (Item 2) [Figure 20-61-100]. If excessive wear or
[Figure 20-61-97] & [Figure 20-61-98] from the auxiliary damage is visible, the pump must be
center section. Inspect for damage and replace as replaced.
needed.

toward gears.


230 of 888
(CONT'D)
Figure 20-61-101
1
2
P-64532
Remove the spline shaft (Item 1) [Figure 20-61-103]

from the end of the drive gear.
P-64530
Remove the drive gear (Item 1) [Figure 20-61-101] from Figure 20-61-104

Figure 20-61-102
1
1
P-64534
P-64531 Remove the idler gear (Item 1) [Figure 20-61-104] from

NOTE: Inspect the drive gear (Item 1) [Figure 20-61- NOTE: Inspect the idler gear (Item 1) [Figure 20-61-
102]. If excessive wear or damage is visible, 104]. If excessive wear or damage is visible,
the pump must be replaced. the pump must be replaced.

231 of 888
(CONT'D)
Figure 20-61-105
P-64537
Figure 20-61-108
P-64535
Figure 20-61-106

2
P-64538
1

2 [Figure 20-61-108]. Inspect for damage and replace as
P-64536 needed.
Remove the pre-load seal (Item 2) [Figure 20-61-108].

Remove the wear plate (Item 1) and section seal (Item 2)
needed.

toward gears.

232 of 888
(CONT'D)
Figure 20-61-109
3
2
1
P-64540


Figure 20-61-110
2
P-30188A
P-64541
Remove the shaft seal (Item 1) [Figure 20-61-110] from


pump.

233 of 888

234 of 888
HYDRAULIC PUMP (SJC) Install a hydraulic tester (Item 1) [Figure 20-70-1] onto
the front auxiliary quick couplers.
Description
The hydraulic gear pump is attached to the end of the 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 Front
engine. Auxiliary button. Engage the front auxiliary with the
trigger on the right handle. Make sure the tester is
The hydraulic gear pump is a combination of gear pumps connected correctly. If no flow is indicated on the tester,
that provide hydraulic flow to several hydraulic systems. the hoses are connected wrong. With the hoses
The hydraulic gear pump has a dedicated charge pump. RPM*.
pressure to the hydrostatic pump. Warm the fluid to 140° F (60° C) by turning the restrictor
control clockwise on the tester so it reads about a 1000
A seal kit is available to service the hydraulic pump. If PSI (69 bar).
any of the main components of the pump are damaged,
the entire pump must be replaced. NOTE: DO NOT EXCEED 3300 PSI.
Pump Test At Quick Couplers Turn the restrictor control (Item 2) [Figure 20-70-1] on
The tools listed will be needed to do the following should be approximately 16 - 17 GPM. Start turning the
procedure: restrictor clockwise, causing more restriction on the flow.

MEL10003 - In-Line Hydraulic Tester reaches approximately 2800 PSI. At approximately 2800
MEL10006 - Flow Meter Fitting Kit PSI the flow should start decreasing rapidly until the
Figure 20-70-1 the flow should be at 0 GPM. Turn the restrictor (Item 2)
1
on Page 20-70-2.)

P-16903 P-66894
NOTE: When testing the hydraulic flow of a machine,

connected directly to the hydraulic tester
the connection to the tester. Also make sure
your hydraulic tester is capable of at least 50
GPM.

235 of 888
HYDRAULIC PUMP (SJC) (CONT'D) Figure 20-70-2

procedure: 2

WARNING 1
P-68163
W-2017-0286
1.)

WARNING 2
1

P-48256
W-2059-0598

236 of 888
HYDRAULIC PUMP (SJC) (CONT'D)
Figure 20-70-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Valve

BH-196
RPM*.


80% of free flow.

FREE FLOW (GPM)


237 of 888

procedure:

WARNING
P-69182
W-2017-0286

1.)

Figure 20-70-6
WARNING
W-2059-0598
P-69184
Tester, to prevent any contamination to the Disconnect the filter inlet hose (Item 1)[Figure 20-70-6].
Hydrostatic Pumps.


238 of 888
Figure 20-70-7
4 3
P-48256A
[Figure 20-70-8].


IMPORTANT
[Figure 20-70-7].
I-2024-0284
RPM*.

(GPM) at full RPM*.

flow.
%= X 100
FREE FLOW (GPM)

RPM.

239 of 888
HYDRAULIC PUMP (SJC) (CONT'D) Raise the operator cab. (See Raising on Page 10-30-2.)
Removal And Installation Drain the hydraulic fluid from the reservoir. (See
120-2.)
DANGER Open the rear door of the loader.

Figure 20-70-9
1
P-90328
2
AVOID DEATH
unless supported by an approved lift arm P-64546

D-1009-0409
Disconnect and cap the outlet hose (Item 1) [Figure 20-
70-9] from the back of the hydraulic pump.
Remove the Power Bob-Tach block (Item 2) [Figure 20-

70-9] if equipped. (See Removal And Installation on
IMPORTANT Page 20-130-1.)
Figure 20-70-10
damage the system.
I-2003-0888
1
Page 10-10-1.)
WARNING P-64547
Disconnect and cap the inlet hoses (Item 1) [Figure 20-

Never work on a machine with the lift arms up unless 70-10] from the front of the hydraulic pump.
W-2059-0598

240 of 888
Figure 20-70-11
3
1
1
2
P-64343
Remove the bracket mounting bolt (Item 1) from the

P-64549 pump mounting bracket (Item 2) [Figure 20-70-12].
Note: The mounting bolt is a special purpose bolt.

Remove the two mounting bolts (Item 1) [Figure 20-70- Only replace with original Bobcat Parts.
11] from the hydraulic pump.

Installation: Apply a medium strength threadlocker to
Installation: Tighten the mounting bolts to 55 - 60 ft.-lb. mounting bolt and tighten to 90 - 100 ft.-lb. (122 - 136
(75 - 85 N•m) torque. N•m) torque.
Remove the mounting bracket (Item 2) [Figure 20-70-

12].
Remove the hydraulic pump (Item 3) [Figure 20-70-12]

from the hydrostatic pump.
Figure 20-70-13
P-64446
Replace the O-ring (Item 1) [Figure 20-70-13] in the

hydrostatic pump.

pump.

241 of 888

hydraulic pump.
Figure 20-70-14
Starter
Solenoid
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-66897
P-59356

Momentary Switch
hydraulics.
of cylinder stroke.

P-59354

without starting.


242 of 888
HYDRAULIC PUMP (SJC) (CONT'D)
15
14
7 5
13
8
5 6
4
12 3

9
8
7
11
5
6
10
9
7
3 4 5 6
1 1. Shaft Seal
2 2. Pump Flange Section
3. Pre-Load Seal
4. Load Seal
5. O-ring
6. Wear Plate
7. Pins
8. Drive Gear
9. Idler Gear
11. Spline Shaft
12. Pump Center Section
14. Pump End Section
15. Bolt (8)
B-21259A

243 of 888
Figure 20-70-17
P-26352
P-64507
1
1 P-64509
1
Remove the pump end section (Item 1) [Figure 20-70-
P-64508 18].

70-17].

20-70-17].

IMPORTANT
damage the system.
I-2003-0888

244 of 888
Figure 20-70-19 1
P-64511
2
Figure 20-70-22
P-64509
1
Figure 20-70-20

3
4
1
P-64512
2 Remove the charge pump section (Item 1) [Figure 20-

P-64510 70-21] & [Figure 20-70-22] from the pump center
section.
Remove the wear plate (Item 1) and section seal (Item 2) NOTE: Inspect the pump section (Item 1) [Figure 20-
[Figure 20-70-19] & [Figure 20-70-20] from the pump 70-22]. If excessive wear or damage is visible,
end section. the pump must be replaced.

toward gears.
NOTE: Inspect the pump end section (Item 3) [Figure

20-70-20] and bushings (Item 4) [Figure 20-70-

245 of 888
Figure 20-70-23
P-64515
Figure 20-70-26
P-64513
Figure 20-70-24

1
P-64516

P-64514 [Figure 20-70-26] from the pump center section.



246 of 888
Figure 20-70-27
1
P-64519
1
2 Figure 20-70-30
P-64517
2
Figure 20-70-28

1
2 1
P-64520

needed.
needed.

toward gears.

247 of 888
Figure 20-70-31
2
1
1
P-64526
Figure 20-70-34
P-64521
3


NOTE: Inspect the pump center section (Item 2) and
Figure 20-70-32
2
1
P-64527

needed.

toward gears.
P-64525 NOTE: Inspect the pump center section (Item 3) and

Remove the pump center section (Item 1) [Figure 20-70- pump must be replaced.
32].

248 of 888
Figure 20-70-35
1
P-64530
1
P-64528 the pump flange section.
Figure 20-70-38
Figure 20-70-36

1
P-64531
P-64529

Remove the auxiliary pump section (Item 1) [Figure 20- 38]. If excessive wear or damage is visible, the
70-35] & [Figure 20-70-36] from the pump flange pump must be replaced.
section.
NOTE: Inspect the pump section (Item 1) [Figure 20-

70-36]. If excessive wear or damage is visible,
the pump must be replaced.

249 of 888
Figure 20-70-39
2
P-64535
Figure 20-70-42
P-64532

the end of the drive gear.

Figure 20-70-40
2
P-64536

1 [Figure 20-70-41] & [Figure 20-70-42] from the pump
needed.

P-64534 inlets and traps as shown with bronze side
toward gears.


250 of 888
Figure 20-70-43
3
2
1
P-64540


Figure 20-70-44 bushings (Item 3) [Figure 20-70-45]. If

Figure 20-70-46
1
2
2
1 P-30188A
P-64538

P-64541
needed.
Remove the pre-load seal (Item 2) [Figure 20-70-44]. Remove the shaft seal (Item 1) [Figure 20-70-46] from

pump.

251 of 888

252 of 888
HYDRAULIC PUMP (SJC) (HIGH FLOW) NOTE: When testing the hydraulic flow of a machine,
Description connected directly to the hydraulic tester
The hydraulic gear pump is attached to the end of the the connection to the tester. Also make sure
hydrostatic pumps and is located on the right side of the your hydraulic tester is capable of at least 50
loader between the hydraulic control valve and the GPM.
engine.
Install a hydraulic tester (Item 1) [Figure 20-71-1] onto
The hydraulic gear pump is a combination of gear pumps the front auxiliary quick couplers.
that provide hydraulic flow to several hydraulic systems.
The hydraulic gear pump has a dedicated charge pump. operator running the tester.
pressure to the hydrostatic pump. Start the engine and run at low idle RPM. Press the Front
Auxiliary button. Engage the front auxiliary with the
The high flow hydraulic pump has an additional pump trigger on the right handle. Make sure the tester is
section that provides an additional amount of flow that is connected correctly. If no flow is indicated on the tester,
controlled by an external valve. The valve is switched the hoses are connected wrong. With the hoses
from a button on the panel in the cab. connected correctly, increase the engine speed to full
RPM*.
A seal kit is available to service the hydraulic pump. If
any of the main components of the pump are damaged, Warm the fluid to 140° F (60° C) by turning the restrictor
the entire pump must be replaced. control clockwise on the tester so it reads about a 1000

PSI (69 bar).
Pump Test At Quick Couplers
procedure: Turn the restrictor control (Item 2) [Figure 20-71-1] on
MEL10003 - In-Line Hydraulic Tester should be approximately 16 - 17 GPM. Start turning the
MEL10006 - Flow Meter Fitting Kit restrictor clockwise, causing more restriction on the flow.
Figure 20-71-1 reaches approximately 2800 PSI. At approximately 2800
PSI the flow should start decreasing rapidly until the
1 the flow should be at 0 GPM. Turn the restrictor (Item 2)

on Page 20-71-2.)

P-16903 P-66894

253 of 888
HYDRAULIC PUMP (SJC) (HIGH FLOW) (CONT'D) Figure 20-71-2

procedure: 2

WARNING 1
P-68163
W-2017-0286
1.)

WARNING 2
1

P-48256
W-2059-0598

254 of 888
HYDRAULIC PUMP (SJC) (HIGH FLOW) (CONT'D)
Figure 20-71-4
EXAMPLE: TESTER
CONNECTION
Reservoir
Hydraulic Pump
Valve

BH-196
RPM*.


80% of free flow.

FREE FLOW (GPM)


255 of 888

procedure:

WARNING
P-69182
W-2017-0286

1.)

Figure 20-71-6
WARNING
W-2059-0598
P-69184
Tester, to prevent any contamination to the Disconnect the filter inlet hose (Item 1)[Figure 20-71-6].
Hydrostatic Pumps.


256 of 888
Figure 20-71-7
4 3
P-48256A
[Figure 20-71-8].


IMPORTANT
[Figure 20-71-7].
I-2024-0284
RPM*.

(GPM) at full RPM*.

flow.
%= X 100
FREE FLOW (GPM)

RPM.

257 of 888
Direct Pump Test (High Flow Section)
1
WARNING
W-2017-0286
P-48463
WARNING Install a jumper hose (Item 1) [Figure 20-71-9] onto the

front auxiliary quick couplers.
device. (See Raising on Page 10-30-2.)

W-2059-0598
IMPORTANT
I-2024-0284

procedure:


1.)


258 of 888
Direct Pump Test (High Flow Section) (Cont'd) EXAMPLE: TESTER

CONNECTION
Reservoir
Figure 20-71-10
Hydraulic Pump
Out In
High Flow Valve
1 1
B-16277
2 Sample tester connection shown [Figure 20-71-12].

P-48235
Start the engine and run at low idle RPM. Press the front
auxiliary button. Press the High Flow button. Push the
Disconnect the high flow pump OUTLET hose (Item 1) button (on the right control lever) for fluid flow to the quick
from the high flow valve INLET fitting (Item 2) [Figure 20- coupler. Make sure the tester is connected correctly. If no

71-10]. flow is indicated on the tester, the hoses are connected
wrong. With the hoses connected correctly, increase the
Figure 20-71-11 engine speed to full RPM*.

1000 PSI (6895 kPa).

2 1
(GPM) at full RPM. Turn the restrictor control on the
tester to 3300 PSI and the flow should go to zero GPM.
If pressure readings are not obtained go to the High Flow

Valve, relief valve adjustment procedure.(See High Flow
Relief Valve Adjustment on Page 20-150-3.)
P-48256
Record the highest pressure (PSI) and flow (GPM). The

high pressure flow must be at least 80% of free flow.
the tester, to the high flow pump OUTLET hose (Item 1)
[Figure 20-71-10]. Connect the OUTLET hose (Item 2) %= HIGH PRESSURE FLOW (GPM) X100
[Figure 20-71-11] from the tester, to the high flow valve FREE FLOW (GPM)
INLET fitting (Item 2) [Figure 20-71-10] on the High Flow
valve. A low percentage may indicate a failed pump.
Lower the cab. *Refer to Hydraulic Schematics Legend for system relief
pressure and full RPM.

259 of 888
DANGER
P-64545
P-90328
AVOID DEATH Figure 20-71-14


D-1009-0409
1
2
Page 10-10-1.)
P-64546
Drain the hydraulic fluid from the reservoir. (See Disconnect and cap the outlet hoses (Item 1) [Figure 20-
Removing And Replacing Hydraulic Fluid on Page 10- 71-13] and [Figure 20-71-14] from the back of the
120-2.) and(See Removing And Replacing Case Drain hydraulic pump.
Filters on Page 10-120-4.)
Remove the Power Bob-Tach block (Item 2) [Figure 20-
Open the rear door of the loader. 71-14] if equipped. (See Removal And Installation on
Page 20-130-1.)
WARNING
W-2059-0598

260 of 888
Figure 20-71-15
3
1
1
2
1 P-64343
Remove the bracket mounting bolt (Item 1) from the

P-64544 pump mounting bracket (Item 2) [Figure 20-71-17].
NOTE: The mounting bolt is a special purpose bolt.
Disconnect and cap the inlet hoses (Item 1) [Figure 20- Only replace with original Bobcat Parts.
71-15] from the front of the hydraulic pump. Installation: Apply a medium strength threadlocker to

mounting bolt and tighten to 90 - 100 ft.-lb. (122 - 136
Figure 20-71-16 N•m) torque.
Remove the mounting bracket (Item 2) [Figure 20-71-
17].
Remove the hydraulic pump (Item 3) [Figure 20-71-17]
from the hydrostatic pump.
Figure 20-71-18
1
P-64549

16] from the hydraulic pump.

(75 - 85 N•m) torque.
P-64446
Replace the O-ring (Item 1) [Figure 20-71-18] in the

hydrostatic pump.

pump.

261 of 888

hydraulic pump.
Figure 20-71-19
Starter
Solenoid
P-59355
S Terminal
Inlet Hose
Battery Terminal
P-66897
P-59356

Momentary Switch
hydraulics.
of cylinder stroke.

P-59354

without starting.


262 of 888
17
16
8 4
12 15 2
7
14 3 4 5
7
8 13 6 5
9
6
7
12

7
8
7
9 6
5
3 4
6 5 11
6 9
5 10
1 3 4
1. Shaft Seal
2. Pump Flange Section
2
3. Pre-Load Seal
4. Load Seal
5. O-Ring
6. Valve Plate
7. Pin
8. Drive Gear
9. Idler Gear
11. Auxiliary Center Section
12. Splined Shaft
14. Charge Center Section
15. High Flow Pump Section
16. High Flow End Section
17. Bolt
B-18248

263 of 888
Figure 20-71-22
1
P-64553
P-64554
1
1
Remove the high flow end section (Item 1) [Figure 20-
P-64552 71-23].

71-22].

20-71-22].

IMPORTANT
damage the system.
I-2003-0888

264 of 888
Figure 20-71-24 1
P-64556
2
Figure 20-71-27
P-64554
1
Figure 20-71-25

3
4
1
P-64557
2
Remove the high flow pump section (Item 1) [Figure 20-
P-64555 71-26] & [Figure 20-71-27] from the charge center
section.
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the high flow pump section (Item 1)
[Figure 20-71-24] & [Figure 20-71-25] from the high flow [Figure 20-71-27]. If excessive wear or
end section. damage is visible, the pump must be
replaced.
toward gears.
NOTE: Inspect the high flow end section (Item 3) and


265 of 888
Figure 20-71-28
P-64560
Figure 20-71-31
P-64558
Figure 20-71-29

1
P-64561

P-64559 [Figure 20-71-31] from the charge center section.



266 of 888
Figure 20-71-32
P-64564
2
Figure 20-71-35
P-64562
2
Figure 20-71-33

1
2
1
P-64565

needed.
needed.

toward gears.

267 of 888
Figure 20-71-36 2
3
1
1
P-64569
Figure 20-71-39
P-64567
3


1
Figure 20-71-37
2
1 P-64571

needed.

toward gears.
P-64568 NOTE: Inspect the charge center section (Item 3) and

Remove the charge center section (Item 1) [Figure 20- pump must be replaced.
71-37].

268 of 888
Figure 20-71-40
1 1
P-64574

P-64572 the auxiliary center section.
Figure 20-71-43
Figure 20-71-41

1
P-64575
P-64573

Remove the charge pump section (Item 1) [Figure 20- 43]. If excessive wear or damage is visible, the
71-40] & [Figure 20-71-41] from the auxiliary pump pump must be replaced.
center section.
NOTE: Inspect the charge pump section (Item 1)

[Figure 20-71-41]. If excessive wear or
damage is visible, the pump must be
replaced.

269 of 888
Figure 20-71-44
1 2
2
P-64578
Figure 20-71-47
P-64576

the end of the drive gear. Inspect for damage and replace

as needed.
Remove the idler gear (Item 2) [Figure 20-71-44]. 1
Figure 20-71-45 2
P-64579
1
[Figure 20-71-46] & [Figure 20-71-47] from the auxiliary
needed.

P-64577 toward gears.


270 of 888
Disassembly And Assembly (Cont'd) 2
Figure 20-71-48
1
1
P-64521


Figure 20-71-49 and bushings (Item 3) [Figure 20-71-50]. If

2
Figure 20-71-51
1
P-64520

P-64525
needed.
Remove the pre-load seal (Item 2) [Figure 20-71-49]. Remove the auxiliary center section (Item 1) [Figure 20-
71-51].

271 of 888
Figure 20-71-52
P-64528
1
Figure 20-71-55
P-64526
Figure 20-71-53

3
4
1
1
P-64529
2 Remove the auxiliary pump section (Item 1) [Figure 20-

P-64527 71-54] & [Figure 20-71-55] from the pump flange
section.
Remove the wear plate (Item 1) and O-ring (Item 2) NOTE: Inspect the auxiliary pump section (Item 1)
[Figure 20-71-52] & [Figure 20-71-53] from the auxiliary [Figure 20-71-55]. If excessive wear or
center section. Inspect for damage and replace as damage is visible, the pump must be
needed. replaced.

toward gears.


272 of 888
Figure 20-71-56
1
1
P-64532

P-64530 the end of the drive gear.

the pump flange section. Figure 20-71-59

Figure 20-71-57
1
1
P-64534
P-64531
Remove the idler gear (Item 1) [Figure 20-71-59] from
57]. If excessive wear or damage is visible, the NOTE: Inspect the idler gear (Item 1) [Figure 20-71-
pump must be replaced. 59]. If excessive wear or damage is visible, the

273 of 888
Figure 20-71-60
P-64537
Figure 20-71-63
P-64535
Figure 20-71-61

2
1 P-64538

2
needed.
Remove the wear plate (Item 1) and section seal (Item 2) Remove the pre-load seal (Item 2) [Figure 20-71-63].
needed.

toward gears.

274 of 888
Figure 20-71-64
3
2
1
P-64540


Figure 20-71-65
2
P-30188A
P-64541
Remove the shaft seal (Item 1) [Figure 20-71-65] from


pump.

275 of 888

276 of 888
HYDRAULIC/HYDROSTATIC FILTERS Disconnect the tubeline (Item 3) [Figure 20-80-1] from
the filter housing.
Description
Figure 20-80-2
The hydraulic/hydrostatic filters help to remove
contaminants from the hydraulic fluid when the hydraulic/
hydrostatic systems are operating.
The hydraulic/hydrostatic filter system consists of one

gear pump filter and one charge pressure filter.
The gear pump hydraulic/hydrostatic filter removes 1

contaminants after the oil cooler.
2
The charge pressure filter removes contaminants after
the hydraulic cooling fan before the oil enters the
hydrostatic pump.
P-68220
IMPORTANT Disconnect the temperature sender connector (Item 1)

[Figure 20-80-2] from the filter housing.

Disconnect the wire connector (Item 2) [Figure 20-80-2]
from the differential pressure switch on the filter housing.
damage the system.
I-2003-0888
Housing Removal And Installation
Figure 20-80-1
2
P-68234
Stop the engine and open the rear door.
Drain the hydraulic fluid. (See Removing And Replacing

Hydraulic Fluid on Page 10-120-2.) and (See Removing
And Replacing Case Drain Filters on Page 10-120-4.)
Remove the mounting bolt (Item 1) and remove the

hydraulic filter drip pan (Item 2) [Figure 20-80-1].

277 of 888
HYDRAULIC/HYDROSTATIC FILTERS (CONT’D) Figure 20-80-4
Housing Removal And Installation (Cont’d)
Figure 20-80-3 1
P-48258
Remove the two mounting screws (Item 1) [Figure 20-

P-48257 80-4] from the filter housing mounting bracket.
Installation: Tighten the mounting screws to 15 - 20 ft.-

Using MEL 1558 tool disconnect the oil cooler tubeline lb. (20 - 27 N•m) torque.
(Item 1) [Figure 20-80-3] from the filter housing.

Remove the hydraulic filter housing and filter.
Reverse the removal procedure to install the filter

housing and filter.
Drain the hydraulic fluid. (See Removing And Replacing

Hydraulic Fluid on Page 10-120-2.) and (See Removing
And Replacing Case Drain Filters on Page 10-120-4.)

278 of 888
HYDRAULIC/HYDROSTATIC FILTERS (CONT’D) Figure 20-80-7
Charge Filter Housing Removal And Installation
Figure 20-80-5 2
2 1
2
1 P-68127
Remove filter inlet hose (Item 1) [Figure 20-80-7].

P-66884
Remove the four mounting screws (Item 2) [Figure 20-
80-7].
Remove filter outlet hose (Item 1) [Figure 20-80-5].
Installation: Tighten the mount screws to 15 - 20 ft.-lb.

Disconnect the electrical connector (Item 2) [Figure 20- (20 - 27 N•m) torque.
80-5] from the charge pressure sender.
Remove filter assembly from the loader.
Figure 20-80-6
Figure 20-80-8
2
1
P-66884
P-66609
Disconnect the charge pressure tubeline (Item 1) [Figure

20-80-6] that connects to the control valve. Remove the four mounting bolts (Item 1) [Figure 20-80-
8].
Disconnect the electrical connector from the filter sensor
(Item 2) [Figure 20-80-6]. Installation: Tighten the mount bolts to 25 ft.-lb. (34
N•m) torque.

279 of 888

280 of 888
HYDRAULIC FLUID RESERVOIR Remove the crossbar linkage. (See Linkage Removal
And Installation on Page 50-90-2.)
Description
Drain the hydraulic fluid reservoir. (See Removing And
The hydraulic fluid reservoir is a storage container for the Replacing Hydraulic Fluid on Page 10-120-2.)
loaders hydraulic/hydrostatic fluid. The reservoir contains
a vented fill cap with a fluid screen to prevent Remove bucket position valve if equipped. (See Removal
contaminants from entering the reservoir while adding And Installation on Page 20-110-3.)
fluid.
Figure 20-90-1
The hydraulic fluid reservoir is located below the
operators cab on the left side of the loader.
1 2
DANGER

P-48379
P-90328 Remove the two bolts (Item 1) and the reservoir bracket
(Item 2) [Figure 20-90-1].
AVOID DEATH
• Disconnecting or loosening any hydraulic Figure 20-90-2
D-1009-0409
WARNING 1

support device. Failure to use an approved lift arm P-48380
W-2059-0598 Disconnect the reservoir vent hose (Item 1) [Figure 20-
90-2] from the hydraulic reservoir.
Raise the lift arms and install an approved lift arm support Disconnect the hydraulic fill hose (Item 2) [Figure 20-90-
device. (See Installing on Page 10-20-1.) 2] from the hydraulic fluid reservoir.

on Page 50-100-2.)

281 of 888
HYDRAULIC FLUID RESERVOIR (CONT'D) Figure 20-90-5
Figure 20-90-3
2 P-48465
Remove the front hydraulic reservoir bracket bolt (Item 1)

P-48378 [Figure 20-90-5].
Figure 20-90-6
Mark, disconnect and cap the two hoses (Item 1) [Figure
20-90-3] from the hydraulic fluid reservoir tee fitting.

Mark, disconnect and cap the hoses (Item 2) [Figure 20-
2
90-3] to the case drain filter.
Figure 20-90-4
1 P-24827 P-24768
Remove the three bolts (Item 1) from the side access

plate (Item 2) [Figure 20-90-6].
Remove side access plate.

P-48377
Remove the bolt from the wire harness clamp (Item 1)

[Figure 20-90-4].

282 of 888
HYDRAULIC FLUID RESERVOIR (CONT'D) Hydraulic Fluid Screen
Removal And Installation (Cont'd) Figure 20-90-9
Figure 20-90-7
2
P-24749
1
1
P-68128
P-24748
Disconnect and cap the hose (Item 1) from the fitting Remove the hose clamp (Item 1) and remove the
(Item 2) [Figure 20-90-7] at the bottom of the reservoir. hydraulic fill hose (Item 2) [Figure 20-90-9] from the

hydraulic reservoir.
Figure 20-90-8
Figure 20-90-10
1
P-48381
P-68129
Tilt the front of the hydraulic reservoir bracket down, by

pushing down on the hydraulic reservoir. Remove the hydraulic fluid screen (Item 1) [Figure 20-
90-10] from the reservoir.
Roll the hydraulic reservoir (Item 1) [Figure 20-90-8] out
from under the fender and remove from the front of the Wash the screen in clean solvent and air dry, before
loader. replacing.

283 of 888

284 of 888
OIL COOLER Figure 20-100-2
Description
The oil cooler is used to cool the loaders hydraulic and

hydrostatic oil. Oil passages are coiled into a heat
exchanger. Air is forced, with the cooling fan, around the
passages cooling the oil.
The oil cooler is located underneath the rear grill between

the A/C condenser (if so equipped) and the radiator.
N-19346
IMPORTANT Figure 20-100-3

damage the system.

I-2003-0888
Remove the rear grill from the loader. (See Removal And
Installation on Page 50-60-1.)
Figure 20-100-1
P-45242
1
2
Slide the rubber sleeve in toward the radiator. The
connector will release [Figure 20-100-2] & [Figure 20-
100-3].
N-19345
Install tool MEL 1558 (Item 1) to outside of rubber sleeve

(Item 2) [Figure 20-100-1].

285 of 888
OIL COOLER (CONT’D)
Figure 20-100-4
1
2
1
P-45101
Disconnect the inlet and outlet hoses (Item 1) from the oil
cooler (Item 2) [Figure 20-100-4].

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.
Reverse the removal procedure to install the oil cooler.

286 of 888
BUCKET POSITION VALVE Figure 20-110-2
Description
The Bucket Position Valve is an option that allows the

loader to meter the lift and tilt circuits. The metering of the
lift and tilt circuits allows the operator to hold the
attachment at the same angle from the ground to 2
maximum lift height without using the tilt function.
The bucket position valve is located below the operators

cab on the right side of the hydraulic fluid reservoir.
See Hydraulic Schematic for more circuit information. 1
Solenoid Removal And Installation P-26311A
Figure 20-110-1
Remove the solenoid nut (Item 1) [Figure 20-110-2].
Installation: Tighten the solenoid nut to 4 - 6 ft.-lb. max.

(5 - 8 N•m max.) torque. Overtightening may cause valve
failure.

Remove the solenoid coil (Item 2) [Figure 20-110-2].
2
1
Figure 20-110-3
P-68162
Disconnect the wire harness connector (Item 1) [Figure

20-110-1] from the bucket position shut-off solenoid.
NOTE: Loosening the two mounting bolts (Item 2)

[Figure 20-110-1] on the Bucket Positioning
Valve Bracket may aid in the solenoid 1
removal. P-26312A
Remove the solenoid stem (Item 1) [Figure 20-110-3]

from the bucket position valve.
Installation: Put oil on O-rings and back-up washers and

tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6
N•m) torque.

287 of 888
BUCKET POSITION VALVE (CONT'D) Solenoid Testing
Solenoid Removal And Installation (Cont’d) Figure 20-110-5
Figure 20-110-4
1
2
P9175
N-18191
Use a test meter to measure coil resistance [Figure 20-
110-5]. Coil wires do not have polarity. Correct resistance
Inspect the solenoid stem and replace the O-rings (Item for the coil is 9.8 ohm.
1) and the back-up washer (Item 2) [Figure 20-110-4].

Replace the test meter with 12 volt power. You can see
and hear the spool shift.

288 of 888
BUCKET POSITION VALVE (CONT'D) Start the engine. Raise the lift arms and install an
approved lift arm support device. (See Installing on Page
Removal And Installation 10-20-1.)
Stop the engine.
DANGER Raise the operator cab. (See Raising on Page 10-30-2.)
Disconnect the electric solenoid connector (Item 1)

[Figure 20-110-6].
Figure 20-110-7
P-90328
AVOID DEATH
2

1
D-1009-0409
P-26311A

W-2059-0598
1
Figure 20-110-6
P-26312A

1
Installation: Tighten the nut to 4 - 6 ft.-lb. max. (5-8 N•m
max.) torque. Overtightening may cause valve failure.
Remove the solenoid (Item 2) [Figure 20-110-7] and the

solenoid stem (Item 1) [Figure 20-110-8].
P-68162
Installation: Put oil on the O-rings and back-up washers
and tighten the solenoid stem to 30 - 35 ft.-lb. (40,8 - 47,6
N•m) torque.

289 of 888
BUCKET POSITION VALVE (CONT'D) Disassembly And Assembly

Figure 20-110-9
N-19069
P-68158

Disconnect the two tubelines (Item 1) [Figure 20-110-9]
from the tee fitting. Assembly: Tighten the nut to 6 ft.-lb. max. (8 N•m max.)
torque. Overtighten may cause valve failure.

Figure 20-110-10
Figure 20-110-12
1 4
2
3 P-68157
N-19070
Remove the tubeline (Item 1) [Figure 20-110-10] from

the B port to the control valve. Remove the solenoid (Item 1) and the solenoid stem
(Item 2) [Figure 20-110-12].
Disconnect the tubeline (Item 2) [Figure 20-110-10] from
the C port (tilt rod end) on the BPV. Assembly: Put oil on O-rings and back-up washers and
tighten the solenoid stem to 30 - 40 ft.-lb. (40,7 - 50,2
Disconnect the tubeline (Item 3) [Figure 20-110-10] from N•m) torque.
the D port (tilt base end) on the BPV.
Remove the mounting screws (Item 4) [Figure 20-110-

10].
Installation: Tighten the mounting screws to 15 ft.-lb. (20

N•m) torque.
Remove the bucket position valve and bracket from the

loader.

290 of 888
BUCKET POSITION VALVE (CONT'D) Figure 20-110-15
Figure 20-110-13
N-18339
1 Remove the plug (Item 1), and flow control spool (Item 2)
N-19072 [Figure 20-110-15].
Assembly: Tighten the plug to 56 - 64 ft.-lb. (75,9 - 86,8

Remove the flow adjustment valve and O-ring (Item 1) N•m) torque.
[Figure 20-110-13].

Check the flow control spool for wear, check the O-ring
Installation: Tighten the flow adjustment valve to 15 - 30 on the plug and replace as needed.
ft.-lb. (20,3 - 40,7 N•m) torque.
Figure 20-110-16
NOTE: Always install new O-rings before any parts
are installed into the valve. Check the parts
for wear or damage and replace as needed.
Figure 20-110-14
3
N-19042
Remove the tilt cylinder check valve (item 1) spring (Item

1 2) and plug (Item 3) [Figure 20-110-16]. Check for wear,
N-19041 check the O-ring and replace as needed.

Remove the plug (Item 1) [Figure 20-110-14]. N•m) torque.

N•m) torque.

291 of 888
BUCKET POSITION VALVE (CONT'D)
Figure 20-110-17
N-19045
Remove the plug [Figure 20-110-17].

N•m) torque.
Figure 20-110-18
N-19046
Remove the plug (Item 1), spring (Item 2) and unloading

spool (Item 3) [Figure 20-110-18].
Check all parts and replace as needed. Install a new O-

ring on the plug before installing.

N•m) torque.

292 of 888
REAR AUXILIARY DIVERTER VALVE Solenoid Testing
Description Figure 20-120-19
The rear auxiliary diverter valve is an optional valve that

diverts oil from the front auxiliary circuit to two sets of rear
auxiliary couplers or the right side auxiliaries. 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.
The right side auxiliaries are located on the inside of the

right side lift arm at the front of the machine.
The rear auxiliary valve is located on the right side of the

machine behind the blower housing. The valve is P9137
accessed by remove a panel on the right side of the
machine.
See Hydraulic Schematic for more circuit information. 120-19]. Coil wires do not have polarity. Correct
resistance is 8.6-9.5 ohms @ 68 degrees Fahrenheit.


293 of 888
REAR AUXILIARY DIVERTER VALVE (CONT'D) Disconnect the negative battery cable. (See Removal
Remove the speed control lever. (See Removal And
DANGER Remove the control panel. (See Removal And Installation

on Page 50-100-2.)
Figure 20-120-1
P-90328
AVOID DEATH
• Disconnecting or loosening any hydraulic 1

P-48301
D-1009-0409
The rear auxiliary valve (Item 1) [Figure 20-120-1] is

located between the control valve and the gear pump on
WARNING the right side of the loader.

IMPORTANT
W-2059-0598 When repairing hydrostatic and hydraulic systems,
damage the system.
WARNING I-2003-0888

explosion or fire.
W-2103-0508

1.)

294 of 888
REAR AUXILIARY DIVERTER VALVE (CONT'D) Figure 20-120-4
Figure 20-120-2
P-48304
2 Disconnect the drain tubeline (Item 1) [Figure 20-120-4]

P-48302 from the lift arm by pass valve.
Disconnect the base and rod end tubelines (Item 1)

[Figure 20-120-2].

Remove the fittings (Item 2) [Figure 20-120-2] from the
valve.
Figure 20-120-3
P-48300
Disconnect the four solenoid connectors (Item 1) [Figure

20-120-3] from the rear auxiliary valve.

295 of 888
Figure 20-120-5
1
1
1
P-48306
Loosen and remove the two bolts and nuts (Item 1)

P-48303 [Figure 20-120-7] that hold the rear auxiliary valve.
Figure 20-120-8
Disconnect and remove the drain tubeline (Item 1)
[Figure 20-120-5] from the rear auxiliary valve.

Figure 20-120-6
2
P-48361
1
Remove the rear auxiliary valve (Item 1) [Figure 20-120-
P-48305 8] by lowering the valve to the drivecase which allows the
valve to be brought forward and removed from the loader.
Disconnect the pump outlet hose (Item 1) [Figure 20-

120-6] from the rear auxiliary valve.
Disconnect the tubeline (Item 2) [Figure 20-120-6] from

the bottom of the control valve and the rear auxiliary
valve.

296 of 888
IMPORTANT
clean the work area before disassembly and keep all 1
damage the system. 1
I-2003-0888
P-76791
Clean the diverter valve to remove dirt before

disassembly. Valve ports are labeled for correct There are 11 #4 SAE hex head plugs (Item 1) [Figure 20-
assembly. 120-10] located on all sides of the diverter valve and can
be removed for clean out purposes.
Figure 20-120-9
Assembly: Put oil on O-rings. Tighten to 10 ft.-lb. (13,6
N•m) torque.

2 Figure 20-120-11
1
P-76747
Remove the two mount bolts (Item 1) from the diverter

valve mount plate (Item 2) [Figure 20-120-9] and remove
P-48752
the mount plate.
Inspect O-ring (Item 1) [Figure 20-120-11].
Assembly: Put oil on O-ring.

297 of 888
Figure 20-120-12
1
1
P-76789A
Remove the differential sensing valve (Item 1) [Figure

P-76789A 20-120-14].
Assembly: Put oil on O-rings and back-up washers.

Remove the shuttle valve (Item 1) [Figure 20-120-12]. Tighten to 85 ft.-lb. (115,25 N•m) torque.

Assembly: Put oil on the O-rings and back-up washers. Figure 20-120-15
Tighten to 8 ft.-lb. (10,8 N•m) torque.
Figure 20-120-13
1
1 1
2 P-48757
P-48756 Inspect the O-rings (Item 1) and back-up washers (Item

2) [Figure 20-120-15] for damage.
Inspect the O-rings (Item 1) and back-up washers (Item


298 of 888

1
Figure 20-120-16
1 P-76794
NOTE: Before removing the solenoid coils, mark the

P-48753 coils for proper alignment.
Remove the nut (Item 1) [Figure 20-120-18] from the

Remove the relief valve (Item 1) [Figure 20-120-16]. solenoid valve stem.

Assembly: Put oil on O-rings and back-up washers. Assembly: Tighten the nut to 4 - 6 ft.-lb. (5 - 8 N•m)
Tighten to 25 ft.-lb. (34 N•m) torque. torque.
Figure 20-120-17 Figure 20-120-19
2
2
1
P-48754 P-76796
Inspect the O-rings (Item 1) and back-up washer (Item 2) Remove the metal shields (Item 1) and solenoid valve
[Figure 20-120-17] for damage. coils (Item 2) [Figure 20-120-19].

299 of 888
Figure 20-120-20
1
P-48761
NOTE: Before removing the solenoid coils, mark the

P-48763A coils for proper alignment.
Remove the nuts (Item 1) [Figure 20-120-22] from the

Remove the solenoid valve stem (Item 1) [Figure 20- solenoid valve stems.
120-20]

Assembly: Tighten the nut to 4 - 6 ft.-lb. (5 - 8 N•m)
Assembly: Put oil on the O-rings and back-up washers. torque.
Tighten to 25 ft.-lb. (34 N•m) torque.
Figure 20-120-23
Figure 20-120-21
1
1
P-48762
2 P-48764
Remove the solenoid valve stems (Item 1) [Figure 20-

Inspect the O-rings (Item 1) and back-up washers (Item 120-23].
Assembly: Put oil on the O-rings and back-up washers.
Tighten to 25 ft.-lb. (34 N•m) torque.

300 of 888
Figure 20-120-24
1 1
P-48752
2

P-76833
Assembly: Put oil on O-ring.
Inspect the O-rings (Item 1) and back-up washer (Item 2) Figure 20-120-27
[Figure 20-120-24].

Figure 20-120-25
1
P-48766
P-48765 Remove and inspect the orifice (Item 1) [Figure 20-120-

27] for dirt and debris.
Remove the #8 SAE hex head plug (Item 1) [Figure 20- Assembly: Tighten the orifice to 22 ft.-lb. (29,8 N•m)
120-25]. torque.
Assembly: Tighten the plug to 38 ft.-lb. (51,5 N•m)

torque.

301 of 888

1
Figure 20-120-28
1
2
P-76798
Remove the #4 SAE hex head plug (Item 1) and the #6

P-48765 SAE hex head plugs (Item 2) [Figure 20-120-30].
Assembly: Tighten the #4 SAE hex head plug to 10 ft.-

Remove the #4 SAE hex head plug (Item 1) [Figure 20- lb. (13,6 N•m) torque.
120-28].

Assembly: Tighten the #6 SAE hex head plugs to 14 ft.-
Assembly: Tighten the plug to 10 ft.-lb. (13,6 N•m) lb. (19 N•m) torque.
torque.
Figure 20-120-31
Figure 20-120-29
P-48752
P-48786

Remove the orifice (Item 1) [Figure 20-120-29] and
inspect for dirt and debris. Assembly: Put oil on O-ring.
Assembly: Tighten the orifice to 3.3 ft.-lb. (4,5 N•m)

torque.

302 of 888
BOB-TACH (POWER) BLOCK
Description
The power Bob-Tach block is an option that allows the

IMPORTANT
operator to hydraulically control the Bob-Tach levers for
mounting and dismounting the attachments. When repairing hydrostatic and hydraulic systems,
The power Bob-Tach is operated by a switch on the front parts clean. Always use caps and plugs on hoses,
console. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
The power Bob-Tach block is mounted on the right side
of the machine in front of the engine on the backside of
the hydraulic gear pump. Figure 20-130-1

3
WARNING 1


support device can allow the lift arms or attachment 3
W-2059-0598 2
P-66869
DANGER Lift and block the loader. (See Procedure Page 10-10-1.)
device. (See Installing Page 10-20-1.)
Raise the operator cab. (See Raising Page 10-30-2.)
Open the rear door.

P-90328 Replacing Hydraulic Fluid Page 10-120-2.) and (See
Removing And Replacing Case Drain Filters Page 10-
AVOID DEATH 120-4.)
tubeline, hose, fitting, component or a part failure Remove the nut from the speed control linkage (Item 1)
can cause lift arms to drop. and unplug the rear lights electrical connector (Item 2)
• Keep out of this area when lift arms are raised [Figure 20-130-1].
support. Replace if damaged. Remove the fuel fill bracket mounting bolts (Item 3)
D-1009-0409 [Figure 20-130-1].

303 of 888
BOB-TACH (POWER) BLOCK (CONT'D) Figure 20-130-4
Figure 20-130-2
P-48227
Remove the four mounting bolts (Item 1) [Figure 20-130-

P-48230 4].

Installation: The harness connectors are marked with (34 - 38 N•m) torque.
Red or Black tie straps. Be sure the connectors with the

same color are connected. Remove the power Bob-Tach block.
Disconnect the power Bob-Tach harness from the NOTE: There is an O-ring in-between the power Bob-
solenoid connectors (Item 1) [Figure 20-130-2] by the Tach block and the hydraulic pump. Inspect
hydraulic pump. and replace as needed.
Figure 20-130-3
P-48226

“DR” port fitting on the block.

power Bob-Tach cylinder rod end fitting on the block.

power Bob-Tach cylinder base end fitting on the block.
Disconnect the outlet hose (Item 4) [Figure 20-130-3]

from the fitting on top of the block.

304 of 888
Figure 20-130-5
1 3
2
2
1
P-48120
Remove the spring guide (Item 1), spring (Item 2) and the
P-48115 spool (Item 3) [Figure 20-130-6].
Check the O-ring (Item 4) [Figure 20-130-6] on the plug

Clean the block (Item 1) [Figure 20-130-5] to remove dirt and replace as needed.
before disassembly. Block ports are labeled for correct

assembly. Figure 20-130-7
Remove the plug (Item 2) [Figure 20-130-5].
Assembly: Tighten the plug to 25 - 30 ft.-lb. (34 - 40,6

N•m) torque.
IMPORTANT 1

tubelines and ports to keep dirt out. Dirt can quickly 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 20-130-7].
Assembly: Tighten the plug to 12 - 14 ft.-lb. (16,3 - 19

N•m) torque.

305 of 888
Figure 20-130-8
1
1
P-48122
Do not remove the plugs (Item 1) [Figure 20-130-10].

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 20-130-8]. will be altered.

Assembly: Oil the check valve and O-rings and tighten Figure 20-130-11
the check valve to 20 - 25 ft.-lb. (27,1 - 34 N•m) torque.
Figure 20-130-9
1
2
1
P-48384
3
P-48119 Remove the plug (Item 1) [Figure 20-130-11], inspect

the O-ring and replace as needed.
Inspect the check valve (Item 1) and piston assembly Assembly: Tighten the plug (Item 1) [Figure 20-130-11]
(Item 2) [Figure 20-130-9]. to 12 - 14 ft.-lb. (16,3 - 19 N•m) torque.
Check the O-rings and back up washers (Item 3) [Figure

20-130-9] on the check valve and piston assembly and
replace as needed.

306 of 888
Figure 20-130-12 2
2
1
P-48106A
Remove the first solenoid coil (Item 1) and the second

P-48664 solenoid coil (Item 2) [Figure 20-130-14].
NOTE: Remember the solenoid coil orientation for

Remove the orifice screw (Item 2) located behind the ease of installation.
plug (Item 1) [Figure 20-130-11] & [Figure 20-130-12].

Figure 20-130-15
Assembly: Tighten the orifice screw (Item 2) [Figure 20-
130-12] to 6 - 8 ft.-lb. (8,1 - 10,8 N•m) torque.
Figure 20-130-13
1
1
2
P-48386

P-48127
Assembly: Tighten the solenoid stem to 20 - 25 ft.-lb.
(27,1 - 34 N•m) torque.
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 20-130-13].
Assembly: Tighten the solenoid valve stem nut to 15 -

45 in.-lb. (1,7 - 5,1 N•m) torque.

307 of 888
Figure 20-130-16
1
P-48174
1
Remove the screened orifice plug (Item 1) [Figure 20-

P-48175 130-18].
Assembly: Tighten the screened orifice plug to 11 - 12

Remove the armature rod assembly (Item 1) [Figure 20- ft.-lb. (14,9 - 16,3 N•m) torque.
130-16].

Figure 20-130-19
Figure 20-130-17
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 130-19] 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.
130-17].
Check the O-ring (Item 2) [Figure 20-130-19] and
NOTE: If the solenoid stem is damaged (Item 1) check replace as needed.
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 20-130-
17].

308 of 888
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Disassembly And Assembly
The front auxiliary hydraulic coupler block is the

connection block that houses the two main auxiliary
couplers along with a case drain coupler. These couplers 1
are for suppling hydraulic flow for various attachments.
The front auxiliary coupler block is located at the front of

the left side lift arm. 2
Removal And Installation 4

3
IMPORTANT P-34661
When repairing hydrostatic and hydraulic systems, Figure 20-140-3

damage the system. 1

I-2003-0888
Figure 20-140-1
6 2
4
5 3
2
1
P-34760
3
Remove the male coupler (Item 1) [Figure 20-140-2] &

[Figure 20-140-3].
Assembly: Tighten the male coupler (Item 1) [Figure 20-

140-2] & [Figure 20-140-3] to 59 ft.-lb. (80 N•m)
P-48464
Remove the drain coupler (Item 2) [Figure 20-140-2] &
[Figure 20-140-3].
Disconnect the auxiliary tubelines (Item 1) and drain
tubeline (Item 2) from the coupler block [Figure 20-140- Assembly: Tighten the drain coupler (Item 2) [Figure
1]. 20-140-2] & [Figure 20-140-3] to 37 ft.-lb. (50 N•m)
Remove the two mounting bolts (Item 3) [Figure 20-140- Remove the female coupler (Item 3) [Figure 20-140-2] &
1]. [Figure 20-140-3].
Assembly: Tighten the female coupler (Item 3) [Figure

20-140-2] & [Figure 20-140-3] to 59 ft.-lb. (80 N•m)
Remove the fittings (Item 4) [Figure 20-140-2] & [Figure

20-140-3] check the O-rings (Item 5) [Figure 20-140-3]
and replace as needed.
Remove the springs (Item 6) [Figure 20-140-3].

309 of 888
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK Figure 20-140-6
(CONT’D)

1
Figure 20-140-4
1
2
P-34665
Check the O-rings (Item 1) backup O-rings (Item 2) for

damage and replace as needed [Figure 20-140-6].
P-34663
Figure 20-140-7
Check the O-ring (Item 1) [Figure 20-140-4] for damage


1
Figure 20-140-5
P-34664
Check the O-rings (Item 1) backup O-rings (Item 2) for

damage and replace as needed [Figure 20-140-7].
P-34701
Press center of male couplers down and check the O-ring

(Item 1) [Figure 20-140-5] for damage and replace as
needed.

310 of 888
HIGH FLOW VALVE
Description
WARNING
The high flow valve is an optional valve with a 12 volt
solenoid that diverts flow from a dedicated high flow
section on the gear pump.
The valve is in plumbed in series with the female coupler
side on the front auxiliary circuit. W-2017-0286
High Flow Relief Valve Testing

Figure 20-150-2
Figure 20-150-1
1
2

2
1 P-76460C
P-34480
Start the engine and run at low idle RPM.
Press the HIGH FLOW button (Item 1) [Figure 20-150-

The tools listed will be needed to do the following 2].
procedure:
The light (Item 2) [Figure 20-150-2] will be ON.

1.)
NOTE: Check the Main Relief Valve See MAIN RELIEF

VALVE on Page 20-30-1 for proper flow and
pressure before checking the High Flow Relief
Valve.
Connect the IN port of the hydraulic tester to the female

quick coupler (Item 1) [Figure 20-150-1] on the loader.
Connect the OUT port of the hydraulic tester to the male

quick coupler (Item 2) [Figure 20-150-1] on the loader.
IMPORTANT
I-2024-0284

311 of 888
HIGH FLOW VALVE (CONT'D)
High Flow Relief Valve Testing (Cont’d)
Figure 20-150-3
Right
Steering
Lever
Control
1
P-31833
• Push the front switch (Item 1) [Figure 20-150-3] to

give the front quick couplers a constant flow of fluid.

• To release from continuous operation, press the front
switch (Item 1) [Figure 20-150-3] a second time.
Watch the flow meter on the hydraulic tester to make

sure the flow is correct. Increase the engine speed to full
RPM.

control on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure.
Turn the restrictor control on the tester counter clockwise,

to obtain free flow, the flow should be at 27 GPM. Start
turning the restrictor clockwise, causing more restriction
on the flow. The GPM should drop off slightly until the
pressure reaches approximately 3100 PSI. At
approximately 3100 PSI the flow should start decreasing
rapidly until the pressure reaches 3250 - 3350 PSI. At
3250 - 3350 PSI the flow should be at 0 GPM. Turn the
restrictor control counter clockwise to free flow. Shut the
If the specs from above are reached, the high flow relief
valve is OK.
If the high flow relief pressure is not correct, stop the

engine and adjust the high flow relief valve. (See High
Flow Relief Valve Adjustment on Page 20-150-3.)

312 of 888
HIGH FLOW VALVE (CONT'D) Figure 20-150-5
High Flow Relief Valve Adjustment
NOTE: The high flow relief valve is located between

the control valve and the hydraulic reservoir.
Figure 20-150-4
1 P-45469
To increase the high flow relief valve PSI turn the screw
(Item 1) [Figure 20-150-5] clockwise a 1/4 turn and
recheck the high flow relief valve. (1/4 turn equals
approximately 200 PSI.)
P-48231
To decrease the high flow relief valve PSI turn the screw

(Item 1) [Figure 20-150-5] counterclockwise a 1/4 turn
If the relief pressure is not correct, stop the engine and and recheck the high flow relief valve. (1/4 turn equals
raise the operator cab. (See Raising on Page 10-30-2.) approximately 200 PSI.)
Remove the high flow relief valve adjustment plug (Item NOTE: If the relief screw (Item 1) [Figure 20-150-5]
1) [Figure 20-150-4]. has been turned in 1/4 turn and the pressure
remains the same, remove and inspect the
high flow relief valve, replace as needed.
Install the plug into the high flow relief valve.

313 of 888
Solenoid Testing
Figure 20-150-6
P9175

150-6]. Coil terminals do not have polarity. Correct

resistance for the pressure relief coil is 7.5 ohms.

314 of 888
Figure 20-150-7
2 2
1
1
P-48236
1
Disconnect the electrical connector (Item 1) [Figure 20-
P-48235 150-8] from the solenoid.
Figure 20-150-9
Scribe a mark across the top of the steering linkage bars
(Item 1) [Figure 20-150-7] which are connected to the

steering shaft on the control panel.
Remove the four steering linkage mounting bolts (Item 2)

[Figure 20-150-7].
2
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 25 -
28 ft.-lb. (34 - 38 N•m) torque.
The high flow valve is located between the control valve

1
and the hydraulic reservoir.
P-48238
IMPORTANT Mark all tubelines and hoses for correct installation.

from the pump outlet to the high flow valve.
from the high flow valve to the pump inlet.
damage the system.
I-2003-0888

315 of 888
HIGH FLOW VALVE (CONT'D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-150-11
Figure 20-150-10
2 1
1
2
P-48108
P-48232
Remove the solenoid nut (Item 1) and solenoid (Item 2)
[Figure 20-150-11] from the solenoid valve.
Disconnect and cap the tubelines (Item 1) [Figure 20-
150-10] to the tilt cylinders. Assembly: Tighten to 4 - 6 ft.-lb. (5 - 8 N•m) torque.

Remove the two mounting bolts (Item 2) [Figure 20-150- Figure 20-150-12
10].

(34 - 38 N•m) torque.
P-48109
Remove the solenoid valve (Item 1) [Figure 20-150-12]

from the valve.
Assembly: Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.

316 of 888
Figure 20-150-13
2 2
P-48112
1 Inspect the relief valve and replace the two O-rings (Item
P-48110 1) and washer (Item 2) [Figure 20-150-15].
Figure 20-150-16
Inspect O-rings (Item 1) and back-up washer (Item 2) on
the solenoid stem [Figure 20-150-13].

Assembly: Put oil on O-rings and back-up washer.
Install and tighten to 25 ft.-lb. (39,9 N•m) torque.
Figure 20-150-14
1
P-45469
Inspect the O-ring (Item 1) [Figure 20-150-16] on the

relief valve adjustment plug for damage and replace as
needed.
P-48111 Assembly: Tighten to 20 ft.-lb. (27,1 N•m) torque.
Remove the relief valve (Item 1) [Figure 20-150-14].
Assembly: Apply to oil to the O-rings and back-up

washers. Tighten to 30 - 35 ft.-lb. (41 - 47 N•m) torque.

317 of 888
Figure 20-150-17
P-48113
Remove the check valve (Item 1) [Figure 20-150-17]

from the high flow valve.

Figure 20-150-18
P-48114
Inspect the check valve, O-rings & back-up washers for

wear and replace as needed [Figure 20-150-18].
Assembly: Apply oil to the O-rings (Item 1) and back-up

washers (Item 2) [Figure 20-150-18]. Tighten to 30 - 35

318 of 888
HYDROSTATIC SYSTEM
CASE DRAIN FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 30-60-1 SAFETY &
MAINTENANCE
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1 HYDROSTATIC
Sender Removal And Installation. . . . . . . . . . . . . . . . . . . . 30-30-3 SYSTEM
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1 DRIVE

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-2 SYSTEM
Belt Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 30-50-3
Tensioner Pulley Assembly . . . . . . . . . . . . . . . . . . . . . . . . 30-50-7
Tensioner Pulley Disassembly . . . . . . . . . . . . . . . . . . . . . . 30-50-6
Tensioner Pulley Parts Identification . . . . . . . . . . . . . . . . . 30-50-5
Tensioner Pulley Removal And Installation . . . . . . . . . . . . 30-50-4
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-50-1

ELECTRICAL
SYSTEM &
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 ANALYSIS
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 30-20-8
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-6 ENGINE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-4 SERVICE
Removing And Replacing Oil . . . . . . . . . . . . . . . . . . . . . . . 30-20-2
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-14 SPECIFICATIONS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5
Parts Identification (Left Half). . . . . . . . . . . . . . . . . . . . . . . 30-40-6
Parts Identification (Right Half) . . . . . . . . . . . . . . . . . . . . . 30-40-7
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3
Replenishing / High Pressure Relief Valve Removal And
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-2

319 of 888
HYDROSTATIC SYSTEM (CONT’D)
HYDROSTATIC PUMP (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1

Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-10
High Pressure Relief And Bypass Valve . . . . . . . . . . . . . . . . . . 30-41-8
Hydraulic Controller Neutral Adjustment . . . . . . . . . . . . . . . . . 30-41-29
Hydraulic Controller Removal And Installation. . . . . . . . . . . . . . 30-41-2
Hydrostatic Pump Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-6
Mechanical Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 30-41-26
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-41-7
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . 30-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE

SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS

MAY VARY.

320 of 888
HYDROSTATIC SYSTEM INFORMATION
Description
The hydrostatic system consists of tandem hydrostatic

pump and two hydrostatic motors. The hydrostatic
system allows forward and reverse motion in 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 do to internal leakage in the components
of the hydrostatic system.

321 of 888
HYDROSTATIC SYSTEM INFORMATION (CONT’D)
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
PROBLEM CAUSE
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4
The loader does not move in a straight line. 2, 3, 4, 5, 9
The hydrostatic system is overheating. 6,7,8
KEY TO CORRECT THE CAUSE

1. The hydrostatic pump replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The hydrostatic motor has damage.

5. Track tension is to tight, on one side.
6. The hydrostatic fluid is not at the correct level.
7. The oil cooler has a restriction.
8. The loader is not being operated at the correct RPM.
9. The hydrostatic pump is not properly calibrated, and/or incorrect steering drift compensation setting.

322 of 888
HYDROSTATIC MOTOR
Description
The hydrostatic motors are driven by the hydrostatic

pumps. Machines equipped with SJC are monitored by a
sensor mounted onto the motor housing. The sensor is
used for detection of motion and for rate of speed for the
SJC option. Standard machines use the same motor but
have a plate and o-ring that covers the sensor hole.
The hydrostatic motors contain a spring applied pressure

release braking system to stop the loader. In addition
there is a separate oil chamber in the motor that is filled
with high performance synthetic oil for maximum
durability, this oil has a recommended service interval.
(See SERVICE SCHEDULE on Page 10-70-1.)
In this system there is a case drain filter for each motor to

filter the excess oil before the hydraulic reservoir.
There are two hydrostatic motors and they are located on

the track carriage.

Charge pressure from the hydraulic gear pump keeps the
motors cool.

323 of 888
HYDROSTATIC MOTOR (CONT’D) Figure 30-20-1
Removing And Replacing Oil
DANGER 1 1
1
A
D F
1
1
B C
1
E
P-28206
P-90328
AVOID DEATH Loosen the six mounting bolts (Item 1) [Figure 30-20-1]
• Disconnecting or loosening any hydraulic and remove the drive sprocket from the motor.
can cause lift arms to drop. Installation: Tighten the mount bolts to 300 - 330 ft.-lb.
• Keep out of this area when lift arms are raised (410 - 450 N•m) torque. Use a cross pattern sequence
unless supported by an approved lift arm (A-B-C, D-E-F) [Figure 30-20-1] to tighten bolts.

D-1009-0409 Figure 30-20-2
WARNING 1

W-2059-0598

1.) 1 P-28207
Raise the lift arms and install an approved lift arm support Remove the plug (Item 1) [Figure 30-20-2] from the
device. (See Installing on Page 10-20-1.) bottom of the motor and drain the oil.
Remove the track. (See Track Removal And Installation
on Page 40-20-4.)
NOTE: Hydrostatic motor oil should be changed with

any track removal.

324 of 888
HYDROSTATIC MOTOR (CONT’D)
Removing And Replacing Oil (Cont’d)
Figure 30-20-3
1 1
P-28207
Install the bottom plug into the motor.

Remove the top plug (Item 1) [Figure 30-20-3] from the
motor.
Fill the motor with 1.5 oz. (45 ml) of high performance
synthetic oil, Bobcat p/n 6682546. The motor will be
approximately 1/2 to 2/3 full.

325 of 888
DANGER 1 1
1
A
D F
1
1
B C
1
E
P-28206
P-90328
• Keep out of this area when lift arms are raised (410 - 450 N•m) torque. Use a cross pattern sequence
unless supported by an approved lift arm (A-B-C, D-E-F) [Figure 30-20-4] to tighten bolts.

D-1009-0409 Figure 30-20-5
1 1
WARNING 1

W-2059-0598

1.) P-28207
device. (See Installing on Page 10-20-1.) Remove the three mounting bolts (Item 1) [Figure 30-20-
5] from the access cover and remove the cover from the
Remove the track. (See Track Removal And Installation loader.
on Page 40-20-4.)
Installation: Tighten the mounting bolts to 190 - 240 in.-
lb. (22 - 27 N•m) torque.
(SJC equipped machines only) Disconnect and remove

the speed sensor (SJC). (See Removal And Installation
on Page 60-80-3.)
NOTE: Speed sensor removal is recommended to

prevent damage while removing the
hydrostatic motor from the track carriage.

326 of 888
HYDROSTATIC MOTOR (CONT'D) Figure 30-20-7
Figure 30-20-6
2
1
1
3 4
4 1
P-28210
1
With an arm hoist support the hydraulic motor.
P-28208
Remove the eight hydraulic motor mounting bolts (Item
1) [Figure 30-20-7].
Mark and remove the main drive hoses (Item 1) [Figure
30-20-6] from the motor. Installation: Tighten the motor mounting bolts to 175 -

190 ft.-lb. (240 - 260 N•m) torque. Apply thread locker
Mark and remove the brake release hose (Item 2) equivalent to (Loctite® #242).
[Figure 30-20-6] from the motor.
Remove the hydrostatic motor from the loader.
Mark and remove the case drain hose (Item 3) [Figure
30-20-6].
Cap and plug all hydraulic lines and hoses.
NOTE: The hydraulic fittings (Item 4) [Figure 30-20-6]

on the hydrostatic motor must be tightened to
115 - 125 ft.-lb. (156 - 170 N•m) torque.

327 of 888
HYDROSTATIC MOTOR (CONT'D)
10
9
7 8
54
5
6
53
4
3
2
1 16
15
54
10 14

13
11
12 38 43
37 42 40
41
24 40
36
25 35 39
28
29
26
27
18
17 34
33
36 51
50
32 49
19 31 48
47 52
23 30
45 46
22
21 44
20
B-16112D

328 of 888
HYDROSTATIC MOTOR (CONT'D)
Parts Identification (Cont’d)
Ref. Description Ref. Description

1. Shaft 29. Spring
2. Bushing 30. Case, rear
3. Seal 31. Bolt
4. Bearing 32. Bolt
5. Case, front 33. Quad Ring
6. Seal 34. Washer
7. Bearing 35. Housing
8. Washer 36. Pin
9. Rings 37. Washer
10. Quad Ring 38. Bolt
11. Cam 39. Shaft
12. Rotor 40. Disc
13. Piston 41. Shim
14. Spring 42. Shim
15. Seal 43. Disc
16. Seal 44. Bushing
17. Seal 45. Seal
18. Seal 46. Snap Ring

19. Pin 47. Piston
20. Plug 48. O-Ring
21. O-ring 49. Washer
22. Spring 50. O-ring
23. Poppet 51. Cover
24. Plug 52. Bolt
25. O-ring 53. O-ring
26. Spring 54. Plug
27. Washer
28. Spool

329 of 888
Figure 30-20-8
1
2
1
P-28348
Remove the twenty four mounting bolts (Item 1) and

P-73279 cover plate (Item 2) [Figure 30-20-10].
NOTE: The bolts should be removed and/or

NOTE: Motors that do not have the SJC sensor will be tightened, one turn at a time to maintain equal
covered by a plate and gasket (Item 1) [Figure preload on the end cap.

30-20-8].
Assembly: Replace the O-ring on the end cap and
Figure 30-20-9 slightly coat with oil.
Assembly: Tighten the bolts to 26 - 29 ft.-lb. (35 - 39

1 N•m) torque.
Figure 30-20-11
P-28347
NOTE: Mark the motor, brake and motor carrier

housings for proper alignment for ease of
assembly [Figure 30-20-9].
P-28350
Drain the oil from the motor casing.

Remove the disc spring (Item 1) [Figure 30-20-11] from
Check for vendor motor serial numbers at (Item 1) the brake housing.
[Figure 30-20-9], these serial numbers will be needed
when ordering replacement parts. NOTE: Mark the top side of the disk spring for proper
installation.
NOTE: Remove any grease on or around the disc

spring. The disc spring does not need to be
greased.

330 of 888

1
Figure 30-20-12
2 3
1
1 P-64411
Remove the six mounting bolts (Item 1) [Figure 30-20-

P-28351 14] from the brake housing.
Remove the brake housing (Item 2) [Figure 30-20-14]

Remove the piston from the brake housing [Figure 30- from the rear housing.
20-12].

Remove snap ring (Item 3) [Figure 30-20-14].
NOTE: The use of air pressure through the brake line
connection (Item 1) [Figure 30-20-12] will aid Remove inner piston seal (Item 4) [Figure 30-20-14].
in piston removal.
NOTE: Install seal with metal case end towards the
Figure 30-20-13 brake pack.
Assembly: Use the alignment pins and reference marks

1 to install the brake housing on the rear housing.
Assembly: Install new washers on the brake housing

mount bolts (Item 1) [Figure 30-20-14].
Assembly: Apply Loctite® #243 or equivalent

threadlocker to the bolts and install bolts and washers
into the rear housing. Start each bolt by hand, tighten
opposite bolts to maintain squareness.
2 Assembly: Tighten bolts to 52 - 57 ft.-lb. (70 - 77 N•m)

torque.
N-18298
Check the brake piston (Item 1) [Figure 30-20-13] for

damage including the surface that contacts the brake
shaft.
Replace the seal (Item 2) [Figure 30-20-13].
Assembly: Apply oil to the seal (Item 2) [Figure 30-20-

13] for added protection when installing the brake piston.

331 of 888
Figure 30-20-15
1
3 2
1 N-18348
Assembly: Assemble the brake discs into a pack making

P-28519A sure the inner discs, alternate with the outer disc and an
outer disc is placed at each end of the disc pack (Item 1)
[Figure 30-20-17].
Assembly: Install the needed amount of shims (Item 1)
[Figure 30-20-15]. Outer discs can also be used as Figure 30-20-18

shims.
Figure 30-20-16
1 1
P-28407
1 P-64413
P-28464 Disassembly: Remove the brake disks (Item 1) [Figure

30-20-18] and shims from the brake shaft.
Assembly: Lightly clamp the disc pack in a vice and

check the disc pack height, make sure to include brake
Assembly: The correct disc pack specifications is 1.44 ±

0.002 in. (36,50 ± 0,05 mm).
Assembly: Extra outer discs (Item 2) are used to reduce

the number of required shims (Item 3) [Figure 30-20-17]
to make up the required thickness for the brake pack.

332 of 888
Figure 30-20-19
4
3
5 1
5
2
1
2
P-28412 P-28411
Remove the flushing valve plug (Item 1) [Figure 30-20-

P-64414 20] from the rear housing assembly.
Check O-ring (Item 2) [Figure 30-20-20] and replace.

Remove the brake washer (Item 1) [Figure 30-20-19].
Figure 30-20-21

Remove and replace the O-ring (Item 2) [Figure 30-20-
19].
Assembly: Slightly coat the O-ring (Item 2) [Figure 30-

20-19] with a layer of oil. 1 2 3
4
Remove the brake shaft (Item 3) [Figure 30-20-19] from
the rear housing.
NOTE: The bushing (Item 4) [Figure 30-20-19] can be

replaced in the brake shaft. When bushing is
replaced, install flush with the top of the brake
shaft.
Check the alignment pins (Item 5) [Figure 30-20-19] for P-28414

Remove spring (Item 1), washer (Item 2), spool (Item 3)

and rear spring (Item 4) [Figure 30-20-21].
Inspect all parts and replace as needed.

333 of 888
Disassembly And Assembly (Cont'd) 1 1

Figure 30-20-22
2
1
1
P-28434
1 1
1 1
1
P-64415
Remove the twelve mounting bolts (Item 1) and (Item 2)

P-28433 [Figure 30-20-24] from the rear housing.
NOTE: The bolts (Item 2) [Figure 30-20-24] are shorter

Figure 30-20-23 bolts and must be returned to their original
holes.

Assembly: Use Loctite® #243 or equivalent thread
1 locker on the bolt threads and install the twelve mounting
2 3 bolts (Item 1) and (Item 2) [Figure 30-20-24].
Assembly: Tighten the bolts to 111 - 114 ft.-lb. (150 - 155

N•m) torque.
P-28436
Remove the flushing relief valve plug (Item 1) [Figure 30-

20-22] & [Figure 30-20-23] and replace O-ring.

30-20-23].
Inspect all parts and replace as needed.

334 of 888

1
Figure 30-20-25
P-28489
Remove and replace the two seals (Item 1) [Figure 30-

P-64416 20-27] and the back-up O-rings under the seals on the
distributor.
Remove and replace the O-ring (Item 1) [Figure 30-20- Assembly: Apply a slight amount of oil to the O-rings
25]. and seals (Item 1) [Figure 30-20-27]

Remove the distributor (Item 2) [Figure 30-20-25] from Check the distributor surfaces for scratches.
the rear housing.
Figure 30-20-28
Assembly: Install the distributor (Item 2) [Figure 30-20-
25] by using the alignment pin (Item 2) [Figure 30-20-
26]. 1
Figure 30-20-26
2 1
1
P-28488
Remove and inspect the nine springs (Item 1) [Figure

30-20-28] from the distributor. Replace as necessary.
P-28487
Remove and replace the two seals and back-up O-rings

(Item 1) [Figure 30-20-26] on the rear housing.
Assembly: Apply a slight amount of oil to the O-rings

and seals (Item 1) [Figure 30-20-26]
Remove and inspect the alignment pin (Item 2) [Figure

30-20-26].

335 of 888
Figure 30-20-29
1
P-48690
2
Remove the snap ring (Item 1) [Figure 30-20-31] from
P-64418 the bottom side of the rotating group.
Figure 30-20-32
Remove the cam ring (Item 1) [Figure 30-20-29] from the
front housing assembly.

Check the cam ring inside surface for wear and
scratches.
Assembly: Align the marks (Item 2) [Figure 30-20-30]

on the cam ring to the front housing.
Figure 30-20-30
2
1
P-48691
Remove the retainer ring (Item 1) [Figure 30-20-32] from

the bottom side of the rotating group.
1
P-64419

30] from the front housing assembly.
Assembly: Slightly smear the O-ring (Item 1) [Figure

30-20-30] with grease to hold in place.
Remove the rotating group (Item 2) [Figure 30-20-30]

from the front housing assembly.

336 of 888
Figure 30-20-33
P-48695
1 Lift the retaining ring (Item 1) [Figure 30-20-35].

P-48689
Use low air pressure and remove the roller/piston
assembly (Item 2) [Figure 30-20-35] from the cylinder
Remove the snap ring (Item 1) [Figure 30-20-33] from block.
the top side of the rotating group.

Check the roller/piston assembly (Item 2) [Figure 30-20-
Figure 30-20-34 35] for wear and replace as needed.
NOTE: Soak the roller/piston assembly (Item 2)

[Figure 30-20-35] in oil and put all roller/piston
assembles back in the original bore.
NOTE: The roller/piston assembly (Item 2) [Figure 30-

20-35] is not a serviceable part.
1
Figure 30-20-36
P-48694
1
The retainer ring (Item 1) [Figure 30-20-34] cannot be

removed from the top side of the rotating group, because
the RPM target disk is attached directly to the rotating
group.
P-28443
Disassembly: With a hammer and punch remove the

split ring (Item 1) [Figure 30-20-36].

337 of 888
Figure 30-20-37
1
3
P-28444
Disassembly: Remove the washer (Item 1) [Figure 30-

P-30728
20-38] from under the split ring.
Figure 30-20-39
Assembly: Place the shaft on a hydraulic press table.
2

Assembly: Install the front housing (Item 1) [Figure 30-
20-37] and bearing over the shaft.
Assembly: Install the special tool (MEL 1612) (Item 2)

[Figure 30-20-37] over the bearing and press the
bearing onto the shaft. Apply 4400 lb. of pressure to set 1
the bearing. Rotate the housing to check for free travel.
NOTE: The 4400 lb. of force, is NOT the amount of

pressure required by the press. It is the
amount of downward force applied by the
press.
Assembly: Install the split ring (Item 3) [Figure 30-20- P-28445
37] and measure the distance between the split ring and
the top of the bearing inner race with a feeler gauge. Add Disassembly: Install the bearing puller (Item 1) [Figure
0.002 - 0.004 in. (0,05 - 0,1 mm) to get the correct 30-20-39] under the front housing and support the puller
washer thickness for the preload. and housing with blocks.
Assembly: Add one pre-load washer (Item 1) below the Disassembly: Press the shaft (Item 2) [Figure 30-20-39]
split ring (Item 3) that is closest to the measurement from the housing.
between the bearing race and split ring with the
additional 0.002 - 0.004 in. (0,05 - 0,1 mm) [Figure 30-
20-38].
Assembly: Release the pressure from the bearing.

Remove the tool from the bearing.

338 of 888
Figure 30-20-40 1
2 2
3
P-28450
4
Remove the shaft seal (Item 1) [Figure 30-20-42].
P-48471
Remove and replace the bearing cup (Item 2) [Figure
30-20-42].
Use a bearing puller to remove the bearing from the shaft
[Figure 30-20-40]. Figure 30-20-43

NOTE: The bearing will be destroyed during the
removal procedure. Be sure to have a new 1
bearing on hand before removing the old
bearing. 2
Replace the O-ring (Item 1), bearing (Item 2), face seal
(Item 3) and the bushing (Item 4) [Figure 30-20-40].
Figure 30-20-41
P-28451
Remove and replace the bearing cup (Item 1) [Figure

30-20-43].

43].
Reverse procedure for assembly.

P-28448
Remove and inspect the bearing (Item 1) [Figure 30-20-

41].
Replace the bearing if worn or damaged.

339 of 888

340 of 888
CHARGE PRESSURE support device can allow the lift arms or attachment
Description W-2059-0598
Charge pressure is a supply of oil to the hydrostatic

Figure 30-30-2
pumps. Charge pressure is regulated by a charge relief
valve located inside the hydrostatic pump. Charge
pressure is used to replenish hydrostatic fluid removed 1
from the drive circuit, pump and motor “internal leakage”
and from the hydrostatic motors shuttle (flushing) valve.
Charge pressure is obtained from the standard section

on the hydraulic gear pump.
Charge pressure is also used to operate other hydraulic 3

functions, such as shifting the auxiliary spool in the main 2
hydraulic control valve.
The charge pressure sender is located on the charge

filter housing mounted next to the blower housing.
P-43197
Charge pressure alarm settings are pre-programmed into
the main controller and are based on loader type and
options installed. Connect the gauge (Item 1), to the adapter fitting (P/N
93F5) (Item 2) [Figure 30-30-2].

Testing
Connect the hydraulic hose (Item 3) [Figure 30-30-2] to
Figure 30-30-1 the adapter fitting. Tighten all connections.
Raise the loader lift arms and install an approved lift arm
support device. (See Installing on Page 10-20-1.)
Place the loader on jackstands. (See Procedure on Page

10-10-1.)
2 4
1 3
P-43196
The tools needed to check charge pressure, hydraulic

hose (Item 1), T fitting (P/N 13K-5) (Item 2), Hydraulic
gauge (1000 PSI) (Item 3) and adapter fitting (P/N 93F-5)
(Item 4) [Figure 30-30-1].
WARNING

341 of 888
CHARGE PRESSURE (CONT’D) Figure 30-30-4
Testing (Cont’d)
Figure 30-30-3
3 2
1
P-68256
Install the T fitting (P/N 13K-5) (Item 1) [Figure 30-30-4].

P-66884
Install a hose (Item 2) [Figure 30-30-4], to replace the
tubeline that was there.
Remove the hydraulic tubeline (Item 1) [Figure 30-30-3]
from the charge pressure sender adapter fitting and the Install the hose (Item 3) [Figure 30-30-4], that is

hydraulic control valve. attached to the pressure gauge, to the T fitting.
Tighten the hydraulic fittings.
Start the loader and warm the hydraulic fluid to 140° F

(60° C).
The charge pressure at high idle, with the fluid

temperature of 140° F (60° C) is 335 - 385 PSI (23,1 -
26,5 bar) with the pump in neutral.

342 of 888
CHARGE PRESSURE (CONT’D)
Sender Removal And Installation
Figure 30-30-5
P-66884
Disconnect the charge pressure sender connector (Item

1) [Figure 30-30-5] from the sender.

Remove the sender (Item 2) [Figure 30-30-5] from the
adapter fitting.
Installation: Tighten the charge pressure sender to 7.4 -

8.1 ft.-lb. (10 - 11 N•m) torque.

343 of 888
CHARGE PRESSURE (CONT'D) Figure 30-30-7
Adjusting
Non SJC Machines
IMPORTANT
damage the system. N-17231
I-2003-0888
Remove the plug, spring and poppet [Figure 30-30-7].

Figure 30-30-6
Check the poppet and spring for wear or damage.
1
Inspect the seat inside the hydrostatic pump case for
wear or damage.

Figure 30-30-8
N-19567
If the charge pressure is not correct loosen the charge 1

relief valve plug (Item 1) [Figure 30-30-6].
Assembly: Always use a new O-ring. Tighten the plug to

N-19568
30 - 50 ft.-lb. (41 - 68 N•m) torque.
There are several different thickness of the shims (Item

1) [Figure 30-30-8] and are used to adjust the charge
pressure.
NOTE: 0.010 in. (0,254 mm) is 8 PSI (0,55 bar)

increase in pressure.
The charge pressure should be set at 335 - 385 PSI (23,1

- 26,5 bar).

344 of 888
CHARGE PRESSURE (CONT'D) Figure 30-30-10
Adjusting (Cont’d)
SJC Machines
IMPORTANT
1
damage the system. P-64435
I-2003-0888
Check the poppet and spring for wear or damage.

Figure 30-30-9
Inspect the seat inside the hydrostatic pump case for
wear or damage.
There are several different thickness of shims (Item 1)

[Figure 30-30-10] used to adjust the charge pressure.
NOTE: 1.0 mm shim (Item 1) [Figure 30-30-10] = 43.5

1 PSI (3 bar) in pressure change. Adding shims
increases charge pressure. Removing shims
decreases charge pressure.
The charge pressure should be set at 335 - 385 PSI (23,1

- 26,5 bar).
P-64431
If the charge pressure is not correct remove the charge

relief valve (Item 1) [Figure 30-30-9].
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

30 - 50 ft.-lb. (41 - 68 N•m) torque.

345 of 888

346 of 888
HYDROSTATIC PUMP
Description
The hydrostatic pump is composed of two hydrostatic

piston pumps connected together. The pumps provide bi-
directional flow to two separate hydrostatic 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 contains the charge pressure

relief. The charge pressure relief is adjustable with
shims.
The hydrostatic pump is located in the center of the

mainframe mounted to the engine flywheel housing.

347 of 888
HYDROSTATIC PUMP (CONT'D) Figure 30-40-2
Replenishing / High Pressure Relief Valve Removal

And Installation 1
Figure 30-40-1
P-66670
Remove the replenishing/high pressure relief valve (Item

1) [Figure 30-40-1] from the pump.
N-19565
Assembly: Tighten the plug to 30 - 50 ft.-lb. (41 - 68
N•m) torque.
There are four replenishing/high pressure relief valves

(Item 1) [Figure 30-40-1] 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. Check the O-ring (Item 2) [Figure 30-40-2] for damage
NOTE: The two top valves are for the reverse drive
loop and the two bottom valves are for the If the replenishing/high pressure relief valve must be
forward drive loop. replaced, it must be replaced as a complete unit.
The pressure setting for a new replenishing/high

pressure relief valve is 5000 PSI (345 bar).

348 of 888
HYDROSTATIC PUMP (CONT’D) Figure 30-40-4

1
IMPORTANT
clean the work area before disassembly and keep all 2
damage the system.
I-2003-0888
P-34567B
Remove the engine/hydrostatic pump assembly from the

loader. (See Removal And Installation on Page 70-10-8.) Loosen the drive belt tensioner (Item 1) [Figure 30-40-4]
and remove the drive belt.
Remove the control handle linkage from the hydrostatic
pump. (See Linkage Removal And Installation on Page Remove the hydrostatic pump drive pulley mounting nut
50-100-7.) (Item 2) [Figure 30-40-4] and washer.

Remove the hydraulic pump from the hydrostatic pump. Installation: Tighten the pump pulley mounting nut to
(See HYDRAULIC PUMP (STANDARD) on Page 20-60- 175 - 200 ft.-lb. (237 - 271 N•m) torque.
1.)
Figure 30-40-5
Figure 30-40-3
1 P-34567A
P-34568
Install a puller on the hydrostatic pump drive pulley and

Remove the hydrostatic pump mounting bolt (Item 1) remove the pulley from the pump shaft [Figure 30-40-5].
[Figure 30-40-3] and washer(s).
Installation: Tighten the mounting bolt to 90 - 100 ft.-lb.

(125 - 135 N•m) torque.
NOTE: Mounting bolt (Item 1) [Figure 30-40-3] is a

special purpose bolt, replace with genuine
Bobcat parts only.

349 of 888
HYDROSTATIC PUMP (CONT’D)
Figure 30-40-6
P-48650
Installation: Install the key in the hydrostatic pump shaft

(Item 1) [Figure 30-40-6] before installing the pump drive

pulley.
Figure 30-40-7
P-28850
Hold the nut (Item 1) [Figure 30-40-7] on the two

hydrostatic pump mounting bolts (Item 2) [Figure 30-40-
6].
Remove the two hydrostatic pump mounting bolts from

the pump and drive belt housing.
Installation: Tighten the pump mounting bolts to 65 - 70

Reverse the removal procedure to install the hydrostatic

pump assembly.

350 of 888
HYDROSTATIC PUMP (CONT'D)
Hydrostatic Pump Startup
Follow the hydraulic pump start up procedure. (See

Hydraulic Pump Startup on Page 20-60-8.)
WARNING
explosion or fire.
W-2103-0508

351 of 888
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

352 of 888
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

353 of 888
Disassembly
1
Figure 30-40-8
1 1
N-17193
Remove the valve plate (Item 1) [Figure 30-40-10].

N-19550
Check the valve plate for wear. (Both Sides.)
Remove the four bolts (Item 1) [Figure 30-40-8] from the

pump housing end cap.

Figure 30-40-9
N-19551
Remove the pump housing end cap (Item 1) [Figure 30-

40-9].
Remove the gasket (Item 2) [Figure 30-40-9].

354 of 888
Disassembly (Cont'd)
1
Figure 30-40-11
2
1
N-17198
Remove the slipper guide and pistons (Item 1) [Figure

N-17194 30-40-13] from the cylinder block.
Check all the pistons (Item 2) [Figure 30-40-13] for wear

Check the valve plate locating pin (Item 1) [Figure 30-40- and replace the rotating group as needed.
11] for wear and replace if needed.

Figure 30-40-14
Check the needle bearing (Item 2) [Figure 30-40-11] for
wear and replace if needed. 1
Figure 30-40-12
N-17199
Remove the ball guide retainer (Item 1) [Figure 30-40-

N-17197 14] from the cylinder block.
Remove the rotating group (Item 1) [Figure 30-40-12]

from the pump.

355 of 888
Figure 30-40-15
1
3 3
2
3 3 2 1
3
N-17481
Remove the driveshaft key (Item 1) the snap ring (Item 2)

N-17200 and the support washer (Item 3) from the drive shaft end
of the pump [Figure 30-40-17].
Check the ball guide retainer (Item 1) and washer (Item Figure 30-40-18
2) for wear and replace as needed [Figure 30-40-15].

Remove the four pins (Item 3) [Figure 30-40-15] from the
cylinder block. 1
Check the cylinder block for wear and replace as needed.
Check pins (Item 3) [Figure 30-40-15] to see if they are

all the same length.
Figure 30-40-16
N-17239
Use a seal puller and remove the seal (Item 1) [Figure

30-40-18] from the pump housing.
1
N-17201
Remove the thrust plate (Item 1) [Figure 30-40-16] from

the pump housing.

356 of 888
Figure 30-40-19 1
1
N-17242
Check the pump shaft (Item 1) [Figure 30-40-21] for

N-17240 wear and replace if needed.
Figure 30-40-22
the pump housing and remove the driveshaft and bearing

from the housing.
Figure 30-40-20
1 1
N-17243
1
Remove the four mount bolts (Item 1) [Figure 30-40-22]
from the lower trunnion cover. Remove the cover.
N-17241

the driveshaft and remove the bearing.
Check the bearing for wear and replace if worn.

357 of 888
Figure 30-40-23
2
2
1 1
1 N-17246
Remove the four mount bolts (Item 1) from the pump

N-17244 housing and remove the linkage bracket (Item 2) [Figure
30-40-25].
Remove the O-ring (Item 1) and bearing race (Item 2) Figure 30-40-26
from the pump housing [Figure 30-40-23].

Figure 30-40-24
1
2
N-17247
N-17245 Remove the upper trunnion cover (Item 1) [Figure 30-40-

26].
Check the bearing race (Item 1) and O-ring (Item 2)

[Figure 30-40-24] for wear and replace as needed.

358 of 888
Figure 30-40-27
1 N-17249
Inspect the bearing race (Item 1) and O-ring (Item 2)

N-17250 [Figure 30-40-29] and replace as needed.
Figure 30-40-30
Inspect the seal (Item 1) [Figure 30-40-27] in the upper
trunnion cover and replace if needed.

Figure 30-40-28
1 N-17251
2
Slide the swash plate from side to side and remove the
N-17248 tapered roller bearing (Item 1) [Figure 30-40-30] from
the swash plate shaft.
Remove the O-ring (Item 1) and bearing race (Item 2)

[Figure 30-40-28] from the pump housing.

359 of 888
Assembly
Figure 30-40-31
N-17252
Install the swash plate and bearing into the pump

N-17252 housing [Figure 30-40-33].
Tilt the swash plate (Item 1) [Figure 30-40-31] and

remove the swash plate and lower bearing from the

pump housing.
Figure 30-40-32
N-17253
Install the lower bearing (Item 1) [Figure 30-40-32] on

the swash plate.

360 of 888
Assembly (Cont'd)
Figure 30-40-34
1 1
2
N-17247
3
Install the upper trunnion seal (Item 1) [Figure 30-40-36]
N-17249 and cover.
Figure 30-40-37
Install the tapered bearing (Item 1) [Figure 30-40-34] on
the swash plate shaft.

Figure 30-40-35
2
N-17246
3
Install the linkage bracket (Item 1) [Figure 30-40-37] and
N-17248 the four mounting bolts and tighten to 18 - 22 ft.-lb. (24 -
30 N•m) torque.
Install the bearing race (Item 2) and O-ring (Item 3) as

shown in [Figure 30-40-34] & [Figure 30-40-35].

361 of 888
Assembly (Cont'd)
Figure 30-40-38
2
N-17243
Align the marks on the lower trunnion cover and pump

N-17245 housing as shown in [Figure 30-40-40].
Install the four mounting bolts and tighten to 18 - 22 ft.-lb.

Figure 30-40-39 (24 - 30 N•m) torque.

Figure 30-40-41
N-17244
N-17242
Install the bearing race (Item 1) [Figure 30-40-38] and O-
ring (Item 2) [Figure 30-40-38] at the lower trunnion as
shown in [Figure 30-40-39]. Install the snap ring (Item 1) [Figure 30-40-41] on the
pump shaft.

362 of 888
Assembly (Cont'd) 1 1
Figure 30-40-42
3
2
1 1
1 N-17200
Install the four slipper pins (Item 1) [Figure 30-40-44]

N-17241 into the cylinder block.
Apply a small amount of grease to the washer (Item 2)

Install the bearing and snap ring (Item 1) [Figure 30-40- and install into the ball guide retainer (Item 3) [Figure 30-
42] on the pump shaft. 40-44].

Figure 30-40-43 Figure 30-40-45
N-17240 N-17199
Install the pump shaft into the pump housing [Figure 30- Install the ball guide retainer and washer (Item 1) [Figure
40-43]. 30-40-45] onto the slipper holddown pins.
Install the snap ring (Item 1) [Figure 30-40-43].

363 of 888
Assembly (Cont'd)
1
2
Figure 30-40-46
N-17194
Replace the needle bearing (Item 1) and valve plate

N-17198 locating pin (Item 2) [Figure 30-40-48] in the charge
pump.
Assemble the piston assemblies into the slipper guide. Figure 30-40-49
Lubricate the pistons and cylinder block bores and insert

the piston assemblies into the cylinder bores [Figure 30-
40-46].
Figure 30-40-47
2 1
N-17196
The bearing cage (Item 1) [Figure 30-40-49] will

protrude from 0.08 - 0.10 in. (2,0 - 2,5 mm) from the
N-17197 surface of the charge pump.
The valve plate locating spring pin (Item 2) [Figure 30-

Lay the pump housing on its side and install the cylinder 40-49] will protrude from 1.65 - 0.185 in. (4,19 - 4,70 mm)
block, piston assembly into the housing. from the surface of the charge pump.
Place the pump on a work surface with the end cap

opening up [Figure 30-40-47].

364 of 888
Assembly (Cont'd)
1 1
Figure 30-40-50
N-19550
Install the valve plate and end cap on the pump housing.
N-17193 Tighten the bolts (Item 1) [Figure 30-40-52] to 35 - 45 ft.-
Coat the backside of the valve plate with petroleum jelly Figure 30-40-53
to hold it in position and install the valve plate onto the

charge pump, bronze face up [Figure 30-40-50].
The notch (Item 1) [Figure 30-40-50] on the valve plate

must engage the locating pin.
Figure 30-40-51 1
2
1
N-19571
1 Install the two small O-rings (Item 1) [Figure 30-40-53].
Install the large new O-ring (Item 2) [Figure 30-40-53].
N-19551 Install the pump coupler (Item 3) [Figure 30-40-53].
Coat a new end cap gasket (Item 1) [Figure 30-40-51]

with petroleum jelly and install onto the end cap.

365 of 888
Assembly (Cont'd)
Figure 30-40-54
N-19570
Install the two pumps together [Figure 30-40-54].

Figure 30-40-55
1
N-19569
Tighten the four bolts (Item 1) [Figure 30-40-55] to 35 -

45 ft.-lb. (47 - 61 N•m) torque.

366 of 888
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 Ports are labeled on the hydrostatic pump casting.
a spool in the hydraulic controller that directs flow to a
servo piston.
Figure 30-41-1

P-64943
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

367 of 888
HYDROSTATIC PUMP (SJC) (CONT'D) Figure 30-41-3
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
removed when the hydrostatic pump is separated from
the engine/hydrostatic pump cast mount.
Controller solenoids can be bled of trapped air in the 1

controller. This should be performed when hydraulic
controllers are replaced, removed or uncommanded
oscillations in the controls are present.
Raise the lift arms and install and approved lift arm P-64460
Place the loader on jack stands. (See Procedure on Page Disconnect all of the electrical harness connectors (Item
10-10-1.) 1) [Figure 30-41-3] from the loader harness.
Removal:
WARNING

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
damage the system.
I-2003-0888
Figure 30-41-2
1 Figure 30-41-4
P-64425
P-64426
Locate the two hydraulic controllers (Item 1) [Figure 30-
41-2] on the hydrostatic pumps.
Remove the four mount bolts (Item 1) [Figure 30-41-4]
from the hydraulic controller.

368 of 888
Hydraulic Controller Removal And Installation 1

(Cont'd)
Figure 30-41-5
1
2
2 P-64427
3
Alternately tighten bolts (Item 1) [Figure 30-41-7] to 7.7
ft.-lb. (10,4 N•m) torque. Ensure bolts are tight to
P-64427 specifications.
NOTE: When a hydraulic controller is replaced, the

Remove the controller (Item 1) [Figure 30-41-5] from the hydrostatic pumps must be calibrated. (See

pump. Hydraulic Controller Neutral Adjustment on
Page 30-41-29.)
Remove the controller gaskets (Item 2) [Figure 30-41-5]
from the pump. Figure 30-41-8
Installation:
Figure 30-41-6
P-64978
With the engine running and the loader on jack stands:

P-64444 Bleed the trapped air in the controller by loosening the
small set screw (Item 1) [Figure 30-41-8] a maximum of
2 turns. Leave the screw loose until oil comes dripping
Be sure the feedback lever (Item 3) [Figure 30-41-5] is in out of the set screw. Tighten set screw to 18 in.-lb. (2
the center of the servo piston groove (Item 1) [Figure 30- N•m) torque.
41-6].
Repeat the bleeding procedure for all of the solenoids.
Use a small amount of grease on a new gasket and
install the gasket on the hydraulic controller (Item 1)
[Figure 30-41-5].
Be sure the pump surface is clean.

369 of 888
Remove the hydrostatic pump/engine assembly from the

loader. (See Removal And Installation on Page 70-10-8.)
IMPORTANT 1

tubelines and ports to keep dirt out. Dirt can quickly P-64345
damage the system.

I-2003-0888
Loosen the washer and nut (Item 1) [Figure 30-41-10] on
the hydrostatic pump drive shaft.
Figure 30-41-9
Installation: Tighten the nut to 175 - 200 ft.-lb. (237 - 271
N•m) torque

1 Figure 30-41-11
P-64344 1
Loosen the tensioner mount bolt (Item 1) [Figure 30-41-

9].
P-64346
Remove the drive belt (Item 2) [Figure 30-41-9].

Use a puller (Item 1) [Figure 30-41-11] to loosen the
Installation: (See Belt Removal And Installation on Page pulley from the pump drive shaft.
30-50-3.)
NOTE: DO NOT strike puller or pump shaft with a
hammer. Internal pump damage may result.
Remove the nut and washer from the pump drive shaft.
Remove the pump pulley from the pump drive shaft.

370 of 888
Figure 30-41-12
1 1 1 P-64343
Remove the mounting bolt (Item 1) [Figure 30-41-14] at

P-64348 the hydraulic pump mounting bracket.
Installation: Tighten mounting bolt to 90 - 100 ft.-lb. (125

Figure 30-41-13 - 135 N•m)

NOTE: The mounting bolt is a special purpose bolt.
Only replace with original Bobcat Parts.
1 1 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 30-41-6.)
P-64337 P-64338

12] and nuts (Item 1) [Figure 30-41-13].
Installation: Tighten the mounting bolts and nuts to 65 -

70 ft.-lb. (88 - 95 N•m) torque.
Make sure the key (Item 2) [Figure 30-41-12] is installed.

371 of 888
HYDROSTATIC PUMP (SJC) (CONT'D)
Hydrostatic Pump Startup
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 30-41-15

1
P-64458
Remove the air bleed plugs (Item 1) [Figure 30-41-15].
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 18 ft.-lb. (25 N•m) torque.

372 of 888
3 1
1. O-ring 5 4
2. Bolt
3. End Housing
4. O-ring 7 6
5. Right Rotating Assembly 8
6. Timing Pin
7. Bearing
8. Spacer/Coupler
9. Pin
10. Positioning Pin
11. O-ring 10
12. Snap Ring 11 9
13. Position Sensor 2
14. Washer 12 13
15. Bolt 14
15
16
19 17
21
24 23 22 26

20
25
18
26
18
27
32 19 29
28
31 16. Steel Cover
17. Bolt
18. Hydraulic Controller
19. High Pressure Relief
20. Case Housing
21. Bolt
6 22. Plug
2
7 23. Screen
24. Plug
25. Orifice
30 26. Dowel Pin
27. Charge Pressure Relief
4 28. Left Servo
29. Right Servo
30. Left Rotating Assembly
31. Key
32. End Housing
B25010

373 of 888
High Pressure Relief And Bypass Valve
Figure 30-41-16
1
1
P-64437
Check the valve seat surface (Item 1) [Figure 30-41-18]

P-64431 for scratches and replace as needed.
Inspect the spring (Item 2) [Figure 30-41-18] for

There are four system check relief valves (Item 1) breakage.
[Figure 30-41-16] in the back of the hydrostatic pump.

Inspect seats inside case housing.
Remove the relief valve cap (Item 1) [Figure 30-41-16].
Do not disassemble the relief valve assembly. If
Assembly: Tighten cap to 111 - 125 ft.-lb. (150 - 170 replacement is required, replace as an assembly.
N•m) torque.
Factory setting on the relief valve is 5075 PSI (350 bar).
Figure 30-41-17
4
3
2 1
P-64436
Check the valve cap O-ring (Item 1) and back-up ring

(Item 2) [Figure 30-41-17], replace as needed.
Remove relief valve assembly (Item 3) [Figure 30-41-17]

from the valve cap.
Check the conical spring (Item 4) [Figure 30-41-17] to

ensure it is not broken or flattened.

374 of 888
Charge Relief Valve
Figure 30-41-19 3 4
2 5
1
1 P-64435
Inspect the poppet (Item 1) and the mating seat (Item 2)

P-64431 [Figure 30-41-21] for damage or foreign material. Ensure
the poppet moves freely in it’s bore.
The charge relief valve (Item 1) [Figure 30-41-19] is Inspect the sealing ring (Item 3) [Figure 30-41-21] 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 52 ft.-lb. (70 shims (Item 5) [Figure 30-41-21].
N•m) torque.
NOTE: 1.0 mm shim (Item 5) [Figure 30-41-21] = 43.5
Figure 30-41-20 PSI (3 bar) 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 30-41-20].

375 of 888
Remove the hydrostatic pump/engine assembly from the

2
Figure 30-41-22
1
1
P-64439
Remove the bolts (Item 1) mounting the steel covers

(Item 2) [Figure 30-41-24].
Assembly: Tighten bolts to 38 ft.-lb. (51 N•m) torque.

P-64458
Figure 30-41-25

Remove the hydraulic controllers (Item 1) [Figure 30-41-
22]. (See Hydraulic Controller Removal And Installation
on Page 30-41-2.) 1
Figure 30-41-23
2 2
1 1 1
P-64440
Remove the mounting bolts and washers for the swash

plate angle sensor (Item 1) [Figure 30-41-25].
P-64438 Assembly: Tighten bolts to 27.4 in.-lb. (3,1 N•m) torque.
Swash plate angle sensors (Item 1) are mounted on the

bottom of the hydrostatic pump. They are protected by
steel covers (Item 2) [Figure 30-41-23].
Note the connectors facing each other.
Note the steel covers facing direction.

376 of 888
Figure 30-41-26
P-64442
Both swash plate angle sensors and associated

P-64441 hardware removed from the hydrostatic pump. [Figure
30-41-28].
Assembly: Note the slotted portion (Item 1) of the

positioning pin tightly fits the machined section on the

swash plate angle sensor shaft (Item 2) [Figure 30-41-
26].
Note the machined section of the swash plate angle

sensor shaft faces the center of the hydrostatic pump.
Figure 30-41-27
P-64453
NOTE: Improperly installing the swash plate angle

sensor, with the shaft facing toward the
outside of the hydrostatic pump, will make it
hard to install the sensor mounting bolts and
also destroy the seal (Item 1) [Figure 30-41-
27].

377 of 888
Right End Housing
Figure 30-41-29
3
1
2
P-64464
Pull the end housings from the case housing [Figure 30-
41-31].
1
P-64445

Left End Housing
Figure 30-41-30
3 1
P-64447
Remove the four mount bolts (Item 1) securing the end

housing (Item 2) to the main case housing (Item 3)
[Figure 30-41-29] and [Figure 30-41-30].
Assembly: Alternately, tighten mount bolts to 96 ft.-lb.

(130 N•m) torque.

378 of 888
Figure 30-41-32
1 2
1
2
P-64463
Assembly: Ensure dowel pin (Item 1) is aligned with hole

P-64465 in case housing (Item 2) [Figure 30-41-34] before
tightening screws.
Replace O-ring (Item 1) [Figure 30-41-32].

Figure 30-41-33
P-64466
Ensure servo follower (Item 2) [Figure 30-41-32] is

swung out for proper engagement with the notch in the
servo piston (Item 1) [Figure 30-41-33].

379 of 888
Figure 30-41-35
RIGHT SIDE
P-64454
Figure 30-41-36

LEFT SIDE
P-64501
Remove valve plate (Item 1) [Figure 30-41-35] and

[Figure 30-41-36] 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

30-41-35] and [Figure 30-41-36] in the valve
plate for assembly reasons. There are
different valve plates for the left and right
side. The valve plates are NOT
interchangeable.

380 of 888

RIGHT SIDE
Figure 30-41-37
1
2
RIGHT SIDE
1 P-64456
2
Figure 30-41-40
P-64455
LEFT SIDE
Figure 30-41-38 1
2

LEFT SIDE
P-64503
1
2
Assembly: Align the timing pin (Item 1) [Figure 30-41-
P-64502 37] and [Figure 30-41-38] in the case housing with the
notch (Item 1) [Figure 30-41-39] and [Figure 30-41-40]
that does not go through the valve plate.
Align the shoulder of the roller bearing (Item 2) [Figure

30-41-37] and [Figure 30-41-38] with the beveled edge
on the valve plate (Item 2) [Figure 30-41-39] and [Figure
30-41-40].
NOTE: Valve plate should sit FLUSH with the case

housing when properly installed.

381 of 888
Figure 30-41-41
1
P-64469
Remove the piston assembly (Item 1) [Figure 30-41-43].

B25012
Figure 30-41-44
Right Side Rotating Group [Figure 30-41-41].

Figure 30-41-42
1
P-64475
Remove the pistons (Item 1) [Figure 30-41-44] from the

B25011 rotating block.
Left Side Rotating Group [Figure 30-41-42].

382 of 888

1
Figure 30-41-45
P-64471
Remove the spherical washer (Item 1) [Figure 30-41-

P-64476 47].
Figure 30-41-48
Inspect the pistons, look for scoring and scratches.
Ensure the holes (Item 1) [Figure 30-41-45] in the
1

slippers, are not plugged.
Figure 30-41-46
1
P-64472
Inspect the pins (Item 1) [Figure 30-41-48]. 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 30-41-46].

383 of 888

3
Figure 30-41-49
1
1
P-64479
Inspect mating surface for the slippers on the swash

P-64474 plate (Item 1) [Figure 30-41-51].
Remove the swash plate from the endcap housing (Item

Inspect the spherical washer for scoring and wear (Item 2) [Figure 30-41-51].
1) [Figure 30-41-49].

Remove the slide ring (Item 3) [Figure 30-41-51], ensure
Figure 30-41-50 it pivots freely.
Figure 30-41-52
1
3 1
P-64478
P-64480
Inspect the back surface of the rotating block (Item 1)
[Figure 30-41-50] 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 30-41-52].
Visually ensure spring (Item 2) and c-clip (Item 3) [Figure
30-41-50] are not bent or damaged.

384 of 888
Disassembly And Assembly (Cont'd) 2

1 1
Figure 30-41-53
1 P-64483
Remove the shell bearing races (Item 1) [Figure 30-41-

P-64481 55].
Assembly: Note shell bearing races have an edge (Item

Assembly: Ensure bearing pins are in the holes of the 2) [Figure 30-41-55] on them. The edges face towards
swash plate (Item 1) [Figure 30-41-53]. the outside of the endcap housing

Figure 30-41-54 Inspect bearing surfaces for scratches or scoring.
P-64482
Remove the shell bearing (Item 1) [Figure 30-41-54].
Inspect individual roller bearings and machined surfaces

(Item 2) [Figure 30-41-54] on swash plate.

385 of 888
Disassembly And Assembly (Cont'd) LEFT SIDE

Figure 30-41-56
1
2
1
P-64486
Figure 30-41-59
P-64484
RIGHT SIDE
Remove the snap ring (Item 1) from the positioning pin 1
(Item 2) [Figure 30-41-56].

Figure 30-41-57
2 1
P-64523
Remove the snap ring (Item 1) [Figure 30-41-58] and

[Figure 30-41-59] from the end housing.
Figure 30-41-60
P-64485
Pull the positioning pin from the end housing.
Replace O-ring (Item 1) [Figure 30-41-57].
Inspect wear surfaces (Item 2) [Figure 30-41-57] for

scratches or scoring. Ensure positioning pin can rotate
smoothly in the end housing without excessive play.
1
P-64524
The pump seal (Item 1) [Figure 30-41-60] is removed by

inserting a screw into the seal and prying out.

386 of 888
Figure 30-41-61
P-64488
The drive shaft can be tapped out of the end housing with
B25013
a rubber mallet.

Inspect wear surfaces for scratches, and inspect splines
Servo Piston Assembly [Figure 30-41-62].
for excessive wear.
The Servo Piston Assembly [Figure 30-41-62] cannot be
Inspect bearing (Item 1); if bearing needs replacement,
removed unless the hydraulic controller and rotating
remove snap ring (Item 2) [Figure 30-41-61] and remove
group is removed first.
bearing.
Figure 30-41-63
1 1
P-64489
Remove servo piston mounting bolts (Item 1) [Figure 30-

41-63].
Installation: Tighten bolts to 7.7 ft.-lb. (10,4 N•m) torque.

387 of 888
Figure 30-41-64
P-64492
Slide the servo piston assembly out of the bore. [Figure

P-64490 30-41-66].
Measure and record servo piston depth at the adjustment

screw [Figure 30-41-64].

Figure 30-41-65
P-64491
Use a rubber mallet to rotate servo piston cover (Item 1)

[Figure 30-41-65].

388 of 888
Figure 30-41-67 1
2
1
P-64493
Remove the bushings (Item 1), seals and O-rings (Item

P-64467 2) [Figure 30-41-69] from the pump housing.
Figure 30-41-70
Figure 30-41-68

1
3
P-64494
P-64466
Assembly: Align the servo piston so the guide slot Each servo has a pair of bushings (Item 1), O-rings (Item
(Item 1) [Figure 30-41-68] is parallel to the driveshaft 2) and square-cut seals (Item 3) [Figure 30-41-70].
centerline. Measure with a straight-edge [Figure 30-41-
67].

389 of 888
Figure 30-41-71
P-64497
1
Remove snap ring (Item 1) [Figure 30-41-73] from the
P-64495 servo piston.
Figure 30-41-74
Remove the lock nut (Item 1) [Figure 30-41-71] from the
servo piston.
1

Assembly: Tighten lock nut to 22 ft.-lb. (30 N•m) torque. 2
Figure 30-41-72
P-64498
Remove the piston stop adjustment mechanism (Item 1)

[Figure 30-41-74] from the servo piston.
P-64496 Inspect mechanism for broken parts.
Replace O-ring (Item 2) [Figure 30-41-74]

Remove the servo cover (Item 1) [Figure 30-41-72] from
the servo piston.

390 of 888
Figure 30-41-75
1
1
2 1
3
P-64499
Remove the four control pressure plugs (Item 1) [Figure

P-64461 30-41-77] at the top of the case housing to gain access to
the four orifices (Item 1) [Figure 30-41-78].
Remove the plug (Item 1) from the top center of the case Replace O-rings on plugs.
housing. Replace O-ring (Item 2) [Figure 30-41-75].

Assembly: Tighten plugs to 18 ft.-lb. (25 N•m) torque.
Assembly: Tighten plug to 45 ft.-lb. (10 N•m) torque.
Figure 30-41-78
Remove internal screen (Item 3) [Figure 30-41-75].
Assembly: Tighten internal screen to 7.4 ft.-lb. (62 N•m)

1
torque.
Figure 30-41-76
P-64500
Ensure the four orifices (Item 1) [Figure 30-41-78] in

case housing are clean and not plugged.
P-64462
Ensure screen is clean [Figure 30-41-76].

391 of 888
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 30-41-79 relative to the hydraulic controller. This procedure should
be followed if the hydrostatic pump has been
disassembled for servicing the servo piston and the
setting has been disrupted.

10-10-1.)
2
1
WARNING
P-64502
W-2017-0286
Bearings (Item 1) [Figure 30-41-79] in case housing are
replaced by using a press and bearing driver. Raise the lift arms, and install an approved lift arm

Inspect center coupler (Item 2) [Figure 30-41-79].

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
find an accessible connector to disconnect.
Disconnect the speed sensors located on the top of the

motor carriers. This prevents uncommanded wheel
movement error codes from occurring during
adjustments.
WARNING
immediately.
W-2145-0290

392 of 888
Mechanical Neutral Adjustment (Cont’d)
Figure 30-41-80
1
P-64438
Remove the plugs (Item 1) [Figure 30-41-82] from the

P-64973 MA ports on the bottom of the pump, and install 7500 PSI
pressure gauges.
Connect a hydraulic hose (Item 1) [Figure 30-41-80] Figure 30-41-83

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 30-41-81
1
1
1 1
P-64977
Remove drive hoses from the A and B ports (Item 1)

[Figure 30-41-83]. Plug the ports with metal caps. The
P-64425 caps must be able to handle at least 7500 PSI. Plugging
the A and B ports eliminates leakage at the drive motors
from causing errors in the pump mechanical neutral
Remove the plugs (Item 1) [Figure 30-41-81] from the setting.
MB ports on the front side of the pump, and install 7500
PSI (241 bar) pressure gauges.

393 of 888
Mechanical Neutral Adjustment (Cont’d)
Figure 30-41-84
1
P-64457
Turn the adjustment screw (Item 1) [Figure 30-41-86]

P-64457 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 30-41-84]. Figure 30-41-87

Start the loader using the remote start tool and run at an
idle.
WARNING
Stay clear of the loader wheels. They will turn
whenever the pump is not centered.
W-2276-1297
1
Figure 30-41-85
P-64457

clockwise, to a position halfway between the recorded
positions. The pressure gauges should read equal
pressures.
P-64457

clockwise, until one of the gauges registers an increase
in system pressure. Mark the position of the adjustment
screw.

394 of 888
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 30-41-88 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
right side hydraulic controller and connect
1 pressure gauges in the X1 and X2 ports on the
right side of the pump.
P-64457
Place the loader on jack stands. (See Procedure on Page
10-10-1.)
While holding the adjustment screw (Item 1) in position,
tighten the lock nut (Item 2) [Figure 30-41-88] to 22 ft.-lb.

(30 N•m) torque.
Shut loader OFF. WARNING
Remove the hydraulic hose from the X1 and X2 ports on
the pump. Install the plugs and tighten to 18 ft.-lb. (25 Put jackstands under the front axles and rear corners
N•m) torque. of the frame before running the engine for service.
Remove the pressure gauges from the MA and MB ports
on the pump. Install the plugs and tighten to 18 ft.-lb. (25 W-2017-0286
N•m) torque.
NOTE: The Hydraulic Controller Neutral Adjustment Raise the lift arms, and install an approved lift arm
must be performed whenever the Mechanical support device. (See Installing on Page 10-20-1.)
Neutral Adjustment is done. (See Hydraulic
Controller Neutral Adjustment on Page 30-41- Raise the operator cab. (See Raising on Page 10-30-2.)
29.)
WARNING
immediately.
W-2145-0290

395 of 888
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-41-89
2
1
P-64975
1
Install 500 PSI pressure gauges in the X1 and X2 ports

P-64460 pertaining to the side of the hydrostatic pump you are
adjusting.
Disconnect the hydraulic controller connectors (Item 1) Figure 30-41-92

[Figure 30-41-89] from the loader wiring harness for the

hydraulic controller you are adjusting.
Figure 30-41-90
1 1
P-64459
Loosen the locking screw (Item 1) [Figure 30-41-92].

P-64458
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 30-41-90] 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

396 of 888
Hydraulic Controller Neutral Adjustment (Cont’d)
Figure 30-41-93
P-64459

P-64459 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 30-41-96

in system pressure. Mark the position of the adjustment
screw.
2
Figure 30-41-94
P-64459
While holding the adjustment screw (Item 1) in position,

P-64459 tighten the locking screw (Item 2) [Figure 30-41-96] to
4.5 ft.-lb. (6,1 N•m) torque.
Turn the adjustment screw (Item 1) [Figure 30-41-94] 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 18 ft.-lb. (25
N•m) torque.
Connect the hydraulic controller wire connectors to the

loader wiring harness.
Perform a controller calibration procedure. (See

CALIBRATION on Page 60-160-1.)

397 of 888

398 of 888
DRIVE BELT Shield Removal And Installation
The drive belt makes the mechanical connection from the

engine flywheel to the hydrostatic pump pulley.
The belt is a cord-reinforced rubber design.
Constant tension is applied to the drive belt by the use of

a spring-loaded belt tensioner.
The drive belt is protected by a plastic shield fastened to

1
the flywheel housing by metal clips. The shield is also in
place to protect the operator.
P-66811
Remove the three drive belt shield mounting clips

(Item 1) [Figure 30-50-1].
Figure 30-50-2

1
P-66812
Remove the belt shield (Item 1) [Figure 30-50-2].

399 of 888
DRIVE BELT (CONT’D) Figure 30-50-4
Adjusting
Stop the engine.
Open the rear door and disconnect the negative (-) cable
from the battery.
1
Remove three belt shield fasteners and remove the belt
shield.
Figure 30-50-3
1
N-18454
2 Push the idler pulley against the belt, using a pry bar
[Figure 30-50-4]. The pointer will be at the 3 o'clock
position (Item 1) [Figure 30-50-4] when the idler pulley is
against the stop (maximum movement)
Raise the idler assembly slightly so that the pulley is

operating on spring tension and not against the stop.

NOTE: Do not set the idler against the travel stop in
the 3 o'clock position.
N-18436
Tighten the mounting bolt (Item 1) [Figure 30-50-3] to 25

Loosen the bolt (Item 1) [Figure 30-50-3] on the spring - 28 ft.-lb. (34 - 38 N•m) torque.
loaded drive idler.
Run the engine for a few minutes. Stop the engine and
NOTE: The pointer will be at the 1 o'clock position recheck the pointer position.
(Item 2) [Figure 30-50-3] when the belt
tensioner is not under spring tension. Readjust if necessary.
After the idler has been in service, readjust when the

pointer reaches the 1 o'clock position.
Install the belt shield and fasteners.
Connect the negative (-) battery cable.

400 of 888
Belt Removal And Installation
Figure 30-50-5
P-66813
Remove the air conditioner belt if so equipped.
P-48000
The belt tensioner is located between the flywheel and
pump pulley. Loosen and remove the bolt (Item 1)
Stop the engine. Open the rear door. [Figure 30-50-6] from the belt tensioner.
Raise the operator cab. (See Raising Page 10-30-2.) Remove the belt tensioner assembly.

Remove the negative (-) cable from the battery. The Figure 30-50-7
battery may be removed for additional working clearance.
(See Removal And Installation Page 60-20-1.)
Remove the belt shield [Figure 30-50-5]. (See Shield

P-48481
Remove the drive belt from the pump pulley and flywheel.
Remove the drive belt from the loader [Figure 30-50-7].
Install the new drive belt. Install the belt tensioner

assembly.
Adjust the drive belt. (See Adjusting Page 30-50-2.)
Reinstall belt shield and connect the negative (-) cable to

the battery.

401 of 888
Tensioner Pulley Removal And Installation
Figure 30-50-8
P-66813
Loosen and remove the belt tensioner mounting bolt

(Item 1) [Figure 30-50-9].
P-48000
Installation: Apply Loctite® 242 to the mounting bolt and

Stop the engine. Open rear door. tighten to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Remove the negative (-) cable from the battery. the Remove the belt tensioner from the flywheel housing.

battery may be removed for additional working clearance.
(See Removal And Installation Page 60-20-1.) Reverse the removal procedure to install the belt
tensioner.
Remove the belt shield [Figure 30-50-8]. (See Shield

402 of 888
DRIVE BELT (CONT’D)
Tensioner Pulley Parts Identification
1. Cover
2. Bolt 1
3. Washer
4. Pins
5. Washer
6. Spring
2
7. Snap Ring
8. Snap Ring
9. Bearing
10. Dust Shield 11
11. Pulley 3
12. Bushing
13. Hub 12
4
14. Washer
15. Seal
16. Arrow Indicator Plate 5
17. Locating Pin
18. Spring

19. Shaft 6 13
20. Bracket
NOTE: Tensioner Pulley parts are not all 5 14

available individually. Consult
parts catalog for available 15
sub-assemblies. 7
8 16
17
9
18
10
19
20
E-2296

403 of 888
Tensioner Pulley Disassembly
Figure 30-50-10
3
1
1
4
P-8861
Remove the two pins (Item 1) from the hub assembly

(Item 2) [Figure 30-50-12] only if they have been
P-8858
damaged.
Remove the grease cover (Item 1) [Figure 30-50-10]. Remove the bracket assembly (Item 3) by tapping on the
shaft (Item 4) [Figure 30-50-12] with a plastic hammer.
Figure 30-50-11

Figure 30-50-13
2
3 2
1 4
P-8859
P-8862
Remove the bolt (Item 1), the flat washer (Item 2), the
retainer washer (Item 3), the spring washer (Item 4) and Remove the spring (Item 1) from the bracket (Item 2)
the second retainer washer (Item 3) from the pulley [Figure 30-50-13].
assembly (Item 5) [Figure 30-50-11].

404 of 888
Tensioner Pulley Assembly
Figure 30-50-14
1
1
P-8873
2
Turn the pulley assembly over and install the two pins
(Item 1) [Figure 30-50-16] into the hub.
P-8871
Figure 30-50-17
Install the spring (Item 1) on the pulley (Item 2) [Figure
30-50-14] as shown.

Figure 30-50-15
2
3
P-8874
Install a punch as shown and turn clockwise while

applying down pressure on the pulley.
P-8872
Turn until the pulley snaps down into place; this

Install the shaft from the bracket assembly (Item 1) into procedure winds the spring and retains the end of the
the pulley assembly (Item 2) and align the spring (Item 3) spring in proper location [Figure 30-50-17].
[Figure 30-50-15] over the alignment pin on the bracket.

405 of 888
Tensioner Pulley Assembly (Cont'd)
Figure 30-50-18
1
1
P-8877
Press the grease cap (Item 1) onto the pulley assembly

(Item 2) [Figure 30-50-20]. Press on the outer formed
P-8875
edge of the grease cap.
Install the first retainer washer (Item 1) and spring NOTE: When pressing the grease cap onto the pulley
washer (Item 2) [Figure 30-50-18] over the roll pins. assembly, do not press down on the arrow
indicator plate. Support the hub assembly so

Figure 30-50-19 that it contacts only the hub and not the arrow
indicator plate.
2
1
P-8876
Install the second retainer washer (Item 1), the washer

(Item 2) and the bolt (Item 3) [Figure 30-50-19].
Tighten the bolt to 28 - 32 ft.-lb. (38 - 45 N•m) torque.
Fill the grease cap 1/4 full (approximately 1/2 - 3/4 oz.) of
grease.

406 of 888
CASE DRAIN FILTER Figure 30-60-3
Description
The case drain filter is an external filter assembly in the

case drain circuit that filters the case drain hydraulic oil.
The case drain filter can be replaced as a complete 1
assembly or disassembled to replace the element with an
element kit and/or the spring kit purchased from Bobcat
Parts.
Remove the case drain filter(s) from the machine. (See

120-4.)
P-76218
Figure 30-60-1
Remove the filter element and spring assembly (Item 1)
[Figure 30-60-3]
NOTE: Remember the orientation of the filter element

and spring assembly for correct assembly.
Figure 30-60-4

2
1
3
P-76212
1
Remove the filter housing nut (Item 1) from the filter
housing (Item 2) [Figure 30-60-1].
2
Figure 30-60-2
P-76216
The larger taper spring (Item 1) slides over the end of the
2
filter element (Item 2) and the smaller tapered spring
(Item 3) [Figure 30-60-4] slides into the filter element.
P-76214
Remove the packing (Item 1) and O-ring (Item 2) [Figure

30-60-2] from the filter housing nut.

407 of 888

408 of 888
DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 40-10-5
Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-10-3 SAFETY &
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1 MAINTENANCE
Left Motor Brake Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-2
Right Motor Brake Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
TRACK CARRIAGE COMPONENTS . . . . . . . . . . . . . . . . . . . 40-20-1

Adjusting Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Carriage Removal And Installation . . . . . . . . . . . . . . . . . 40-20-11
Checking Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 DRIVE
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1 SYSTEM
Idler (Front) Removal And Installation . . . . . . . . . . . . . . . . 40-20-7
Idler (Rear) Removal And Installation . . . . . . . . . . . . . . . . 40-20-9
Roller Removal And Installation. . . . . . . . . . . . . . . . . . . . . 40-20-9
Sprocket Removal And Installation . . . . . . . . . . . . . . . . . 40-20-10
Track Damage Identification . . . . . . . . . . . . . . . . . . . . . . 40-20-13
Track Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-20-4

ELECTRICAL
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD SYSTEM &
TORQUE SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS ANALYSIS
ENGINE
ITEMS MAY VARY.
SPECIFICATIONS

409 of 888

410 of 888
BRAKE Right Motor Brake Test
Description
The brake is used to hold the machine in place. The

brake is operated by a switch (Item 1) [Figure 40-10-1] WARNING
located on the front accessory panel.
Figure 40-10-1 Diesel fuel or hydraulic fluid under pressure can
W-2072-0807
1
WARNING
P-21944 Always clean up spilled fuel or oil. Keep heat, flames,

The brake is automatically applied by a spring in the
explosion or fire.
hydrostatic drive motor, if the loader is running, or not. W-2103-0508
The brake block constantly receives hydraulic pressure

from the charge pump while the engine is running. When Figure 40-10-2
the switch (Item 1) [Figure 40-10-1] is pressed to the
“off” position, 12 volts is applied to a solenoid on the
brake block. The hydraulic charge pressure is then
diverted to a piston in the hydrostatic drive motor to
compress the spring and relieves the pressure on the
brakes metal and fiber discs. When the brake discs have 1
enough pressure released, the hydrostatic drive motor is
free to rotate.
When the solenoid is de-activated, the switch (Item 1)

[Figure 40-10-1] is pressed to the “P” position, 12 volts is
not being supplied to the brake block solenoid. The brake
block will not let the hydraulic charge pressure enter the
brake area of the hydrostatic drive motor. The spring will
push back on the brake release piston in the hydrostatic P-68392
motor and push the oil back to the hydraulic reservoir

through the brake block.
Mark and disconnect the right motor brake release hose
(Item 1) [Figure 40-10-2] from the fitting on the #2 port of
the brake block.
Cap the fitting on the #2 port of the brake block where the
hose was removed.

411 of 888
BRAKE (CONT’D) Left Motor Brake Test
Right Motor Brake Test (Cont'd)
Figure 40-10-3
WARNING
1 Use a piece of cardboard or wood to find leaks. Do
W-2072-0807
P-68441
WARNING
Connect the port-a-power and gauge to the right motor
brake release hose (Item 1) [Figure 40-10-3].

Pump the port-a-power up to 400 PSI (Max. 435 PSI).
explosion or fire.
Verify that the hydrostatic motor brake holds pressure. W-2103-0508
If the brake does not hold pressure, the motor needs to

be removed and serviced. Figure 40-10-4
If the hydrostatic motor brake components hold pressure,

the hydrostatic motor brake components are okay. If
brake problems persist, check the solenoid for proper
operation and inspect the brake block cartridge for
contamination.
1
P-68392
Mark and disconnect the left motor brake release hose

(Item 1) [Figure 40-10-4] from the fitting on the #2 port of
the brake block.
Cap the fitting on the #2 port of the brake block where the
hose was removed.

412 of 888
BRAKE (CONT’D) Block Removal And Installation
Left Motor Brake Test (Cont'd)
Figure 40-10-5
DANGER
1 P-90328
AVOID DEATH
P-68440
Connect the port-a-power and gauge to the left motor support. Replace if damaged.
brake release hose (Item 1) [Figure 40-10-5]. D-1009-0409

Pump the port-a-power up to 400 PSI (Max. 435 PSI).
Verify that the hydrostatic motor brake holds pressure.

WARNING
If the brake does not hold pressure, the motor needs to
be removed and serviced. Never work on a machine with the lift arms up unless
If the hydrostatic motor brake components hold pressure, support device. Failure to use an approved lift arm
the hydrostatic motor brake components are okay. If support device can allow the lift arms or attachment
brake problems persist, check the solenoid for proper to fall and cause injury or death.
operation and inspect the brake block cartridge for W-2059-0598
contamination.
WARNING
W-2072-0807

413 of 888
BRAKE (CONT’D) Remove and cap the brake pressure drain hose (Item 5)
[Figure 40-10-6] from the brake block.
Block Removal And Installation (Cont’d)
Figure 40-10-7
WARNING 1

explosion or fire.
W-2103-0508
P-43999

Remove the bolts (Item 1) [Figure 40-10-7] from the
Drain the hydraulic reservoir. (See Removing And bracket and remove the brake block.
Replacing Hydraulic Fluid on Page 10-120-2.) and (See

120-4.)
Figure 40-10-6
1
3
4
5
2
P-68392
Disconnect the electrical wire harness connector (Item 1)

[Figure 40-10-6].
Mark the hydraulic hoses on the brake block for proper

installation.
Remove and cap the charge pressure hose (Item 2)

Remove and cap the right brake release hose (Item 3)

Remove and cap the left brake release hose (Item 4)


414 of 888
BRAKE (CONT’D) Figure 40-10-10
Block Disassembly And Assembly
Figure 40-10-8
P-37796
Inspect the O-rings and back-up washer on the solenoid

P-37797 valve and replace as needed [Figure 40-10-10].
Check the screens (Item 1) [Figure 40-10-10] and clean

Loosen the electrical brake solenoid nut (Item 1) [Figure with solvent.
40-10-8].

Assembly: Tighten the solenoid nut 4 - 5 ft.-lb. (5,4 - 6,8
N•m) torque.
Figure 40-10-9
2
1
P-37795
Remove the solenoid nut (Item 1) and solenoid coil (Item

2) [Figure 40-10-9].
Remove the solenoid valve (Item 3) [Figure 40-10-9]

from the block.
Assembly: Tighten the solenoid valve to 16 - 20 ft.-lb.

(21,7 - 27,1 N•m) torque.

415 of 888

416 of 888
TRACK CARRIAGE COMPONENTS NOTE: The wear of track rollers vary with the working
conditions and different types of soil
Description conditions.
The track carriage components consist of front and rear Park the loader on a level surface.
idlers, rollers, the track, the drive sprocket and the track
carriage. Lift and block the loader. (See Procedure on Page 10-10-
1.) Be sure the jackstands do not touch the tracks.
Checking Tension
NOTE: When the loader is on jackstands be sure the
bottom of the track clears the floor by at least
3 in. (76 mm).
WARNING Measure the track sag at the middle track roller [Figure
40-20-1]. DO NOT put your fingers into the pinch points
AVOID INJURY between the track and the roller. Use a 1/2 to 5/8 in. bolt,
Keep fingers and hands out of pinch points when dowel or block to check the gap (Item 1) [Figure 40-20-
checking the track tension. 1], & [Figure 40-20-2].
W-2142-0903
Adjusting Tension
Figure 40-20-1
Increase Track Tension
1 Figure 40-20-3

P-28176A
P-45250
Figure 40-20-2 N-18491

procedure:
MEL1560- Bleed Tool [Figure 40-20-3].
1/2-5/8 in. Track

(13-16 mm) Roller
Track P-13810A
Track tension is important for good performance and to

prevent the tracks from derailing.

417 of 888
TRACK CARRIAGE COMPONENTS (CONT'D) Figure 40-20-5
Adjusting Tension (Cont'd) Right Side Shown
Increase Track Tension (Cont'd)
Figure 40-20-4
P-28179
1
NOTE: The grease cylinder used on the left side of
the loader is identical to the cylinder on the
right side. When the cylinder is located on the
P-28178 left side, the adjustment fitting is the lower
fitting; on the right side it is the upper fitting.

Loosen the two mount bolts (Item 1) [Figure 40-20-4] Add grease to the adjustment fitting (Item 1) [Figure 40-
from the covers. 20-5] (lower fitting on left side, upper fitting on right
side) until the track adjustment is correct [Figure 40-20-
1] & [Figure 40-20-2].
WARNING NOTE: Do not remove adjustment fitting (Item 1)

[Figure 40-20-5] unless pressure is released.
(See Adjusting Tension on Page 40-20-1.)
• Do not loosen bleed fitting more than 1-1/2 turns. NOTE: If replacement is necessary, always replace
• Do not loosen parts other than bleed fitting. adjustment fitting (Item 1) [Figure 40-20-5]
Grease is under high pressure. with genuine Bobcat Parts. It is a special
W-2474-0104 fitting designed for high pressure.

418 of 888
Adjusting Tension (Cont'd)
Figure 40-20-6
1
Right Side
P-28182
Pivot the track cover (Item 1) [Figure 40-20-8] against

P-26945 the MEL tool and lock the mount bolt (Item 2) [Figure 40-
20-8].
NOTE: There are stop blocks (Item 1) [Figure 40-20-6] Turn the tool 1/4 turn counterclockwise and let the grease
that keep the cylinders from turning. If the flow into a container. Turn the tool one additional turn to

cylinders turn, the fittings will not be continue to release pressure.
accessible. Check the stop block bolts to be
sure they are tight. Raise the loader. Remove the jackstands.
Decrease Track Tension Repeat the procedure for the other track.
Figure 40-20-7 Dispose of the grease in an environmentally safe

manner.
P-28179
Pressure must be released from the spring and

adjustment cylinder to decrease track tension.
Install the bleed tool (MEL1560) on the bleed fitting (Item

1) [Figure 40-20-7] (upper fitting on left side, lower
fitting on right side), adjust and tighten the collar to fit
behind the edge of the access hole and the cover.

419 of 888
Track Removal And Installation
Figure 40-20-9
P-28180
Pivot the covers downward [Figure 40-20-11].

N-18491
Figure 40-20-12

procedure:

MEL1560- Bleed Tool [Figure 40-20-9].
Figure 40-20-10 1
P-28181
1 Install the MEL1560 tool on the bleed fitting [Figure 40-

1 20-12].
Be sure the collar (Item 1) [Figure 40-20-12] is

P-28178 positioned behind the track housing plate.

1.)
NOTE: When the loader is on jackstands be sure the

bottom of the track clears the floor by at least
3 in. (76 mm).
Loosen the four mount bolts (Item 1) [Figure 40-20-10]

from the covers.

420 of 888
Track Removal And Installation (Cont'd)
Figure 40-20-13
P-28183
2
With a bar pry, move the front idler assembly toward the
P-28182 rear of the track assembly until all track tension has been
released [Figure 40-20-14].
Pivot the track cover (Item 1) [Figure 40-20-13] against Figure 40-20-15
the MEL tool and lock the mount bolt (Item 2) [Figure 40-

20-13].
Give the MEL tool/bleed fitting a 1/4 turn,

counterclockwise to release the pressure from the spring
assembly.
Turn the MEL tool/bleed fitting one more complete turn

counterclockwise.
IMPORTANT
P-28184A
Fluid such as engine oil, hydraulic fluid, coolants,
grease, etc. must be disposed of in an
environmentally safe manner. Some regulations With pry bars, pry the track up and over the front idler
require that certain spills and leaks on the ground [Figure 40-20-15].
must be cleaned in a specific manner. See local, state
and federal regulations for the correct disposal. Turn the MEL tool/Bleed fitting clockwise to close fitting.
I-2067-0499
Remove the MEL1560 tool.

421 of 888
Track Removal And Installation (Cont'd)
Figure 40-20-16
P-28188A
With a chain hoist or arm hoist lift the track clear of the
P-28186 drive sprocket and remove the track from the loader
[Figure 40-20-18].
NOTE: To protect your hands from injury always NOTE: Hydrostatic motor oil should be changed with
wear gloves before removal or installation of any track removal.

the track.
To install the rubber track:
Completely remove the track from the front track
assembly [Figure 40-20-16]. Completely retract the front idler/spring assembly.
Put the track over the rear drive sprocket lugs.

Figure 40-20-17
Put the track over the rear idler.
Slide the track under the rollers.
Put the track on the front idler wheel.
Adjust the track to the proper tension. (See Adjusting

Tension on Page 40-20-1.)
NOTE: The grease cylinder must be completely

1 retracted against the spring assembly block
before adding grease, to prevent air from
being trapped in the grease cylinder.
P-28187
With a pry bar slide the track clear of the rear idler (Item
1) [Figure 40-20-17].

422 of 888
Idler (Front) Removal And Installation
Figure 40-20-19
P-28194
1 Remove the track tensioner [Figure 40-20-21] from the

P-28191 track housing.
NOTE: When installing the track tensioner, make

Lift and block the loader. (See Procedure on Page 10-10- sure the grease fittings are pointed to the
1.) outside of the track frame.

on Page 40-20-4.)
Install a chain hoist on the front idler.
Slide the front track idler out of the track frame [Figure
40-20-19].
NOTE: The short side of the block (Item 1) [Figure 40-

20-19] is toward the bottom of the track
housing for installation.
Figure 40-20-20
P-28190
Installation: Make sure the tabs (Item 1) [Figure 40-20-

20] engage the holes (Item 2) [Figure 40-20-20] and
(Item 1) [Figure 40-20-21] on the track tensioner block.

423 of 888
Idler (Front) Removal And Installation (Cont'd)
WARNING 2
3
1
N-18079
P-62574
Remove the wiper seal (Item 1), O-ring (Item 2) and

AVOID INJURY OR DEATH back-up ring (Item 3) from the cylinder [Figure 40-20-
• Spring loaded components under pressure can 23].
cause serious injury or death.
• Do not disassemble the coil spring assembly. Installation: Apply oil to the O-ring, back-up ring and
W-2617-1004 seal before installation.

Figure 40-20-22 Figure 40-20-24
P-28195 P-28196
Remove the cylinder (Item 1) [Figure 40-20-22] from the NOTE: The grease cylinder (Item 1) [Figure 40-20-22]
shaft. must be completely retracted against the
spring assembly block (Item 2) [Figure 40-20-
22] before adding grease, to prevent air from
being trapped in the grease cylinder.
DO NOT DISASSEMBLE OR REPAIR THE COIL

SPRING ASSEMBLY. THE COMPRESSION FORCE OF
THE SPRING EXCEEDS 10,000 lb.
The coil spring assembly (Item 1) [Figure 40-20-24] is

only sold as a complete unit from Bobcat Parts.

424 of 888
TRACK CARRIAGE COMPONENTS (CONT'D) Roller Removal And Installation
Idler (Rear) Removal And Installation Lift and block the loader. (See Procedure on Page 10-10-
1.)
on Page 40-20-4.) Remove the track. (See Track Removal And Installation
on Page 40-20-4.)
Figure 40-20-25
Figure 40-20-26
1
1 1
1
1
2 3
P-37965 P-37964
N-18082

Remove the two mount bolts (Item 1) [Figure 40-20-25].
Remove the nuts (Item 1) [Figure 40-20-26] from the
Remove the rear idler from the loader. roller shaft. (Both ends of the roller shaft.)
Installation: Align the square sides of the idler shaft Installation: Tighten the nuts to 300 - 330 ft.-lb. (406,8 -
(Item 2) [Figure 40-20-25] with the notches in the track 443,5 N•m) torque.
housing (Item 3) [Figure 40-20-25].
Remove the roller from the track assembly.
Align the holes in the frame with the holes in the shaft.
Install the bolts and tighten to 190 ft.-lb. (257,6 N•m)

torque.

425 of 888
Sprocket Removal And Installation
DANGER
1
1
P-28206
P-90328
• Keep out of this area when lift arms are raised (406 - 447 N•m) torque.

D-1009-0409
WARNING
W-2059-0598

1.)

on Page 40-20-4.)

426 of 888
Carriage Removal And Installation
Figure 40-20-28
1
2
1
1
P-28200
2
Remove the four rear mounting bolts (Item 1) [Figure 40-
P-28199 20-29] from the track housing mount plate.
Figure 40-20-30
1.)

NOTE: Position the jackstand (Item 1) [Figure 40-20- 1
28] at the front of the loader to allow for track
housing removal.
Remove the track from the loader. (See Track Removal

Remove the hydrostatic motor from the track housing.

(See Removal And Installation on Page 30-20-4.)
Support the track housing.

P-28211
Remove the four front mounting bolts (Item 2) [Figure
40-20-28] from the track housing mount plate.
At the rear of the loader remove the two mount bolts
(Item 1) [Figure 40-20-30].
Installation: Tighten the two mounting bolts to 300 - 330

ft.-lb. (410 - 450 N•m) torque.

427 of 888
TRACK CARRIAGE COMPONENTS (CONT'D)
Carriage Removal And Installation (Cont’d)
Figure 40-20-31
P-28201
At the front of the loader remove the two mounting bolts

(Item 1) [Figure 40-20-31].

Remove the track housing from the loader.
Installation: Tighten the two mounting bolts to 300 - 330

ft.-lb. (410 - 450 N•m) torque.

428 of 888
TRACK CARRIAGE COMPONENTS (CONT'D) Cutting Of Steel Cords
Track Damage Identification Figure 40-20-33
The following pages show photos and illustrations of

track damage and the probable cause of the damage. It
is intended to be used for identifying the reason for track
damage and how to avoid future track damage.
Track and Sprocket Rotation:
Figure 40-20-32
Move Sprockets to opposite sides of the loader
P-3864
Figure 40-20-34
Remove track
Reinstall 180°

P-51184A
Steel Cords
PI-13034
NOTE: All applications and conditions will cause
wear on the track inbeds and sprocket teeth.
Rotating the tracks and sprockets will extend Damage:
their life. The track can be removed and
reinstalled 180 degrees. The sprocket can be Embedded steel cords are cut off [Figure 40-20-33]
removed and installed on the opposite side of & [Figure 40-20-34].
the loader [Figure 40-20-32].
Prevention:
The following preventions should be taken to minimize

the risk of this damage:
Periodical checking on site of the recommended track

tension. (See Checking Tension on Page 40-20-1.)
Avoiding quick turns on bumpy and rocky fields.
Drive carefully to avoid having stones and other

articles clog the rubber tracks.
Driving over sharp objects should be avoided. If this

is impossible, do not make turns while driving over
sharp objects.

429 of 888
TRACK CARRIAGE COMPONENTS (CONT'D) Causes of the damage:
Track Damage Identification (Cont'd) When the track rollers, sprockets and idler gears roll over
the embedded metals, abrasion of embedded metals is
Abrasion Of Embedded Metals inevitable. The following cases sometimes accelerate
their abrasion:
Figure 40-20-35
Rubber tracks are driven with an extraordinary heavy
load on them.
Rubber tracks are used on sandy fields.
Prevention:
As long as rubber tracks are used under normal

operating conditions, abnormal abrasion is unlikely to
occur. The level of abrasion should be carefully checked
when the machines are used for dozing which generate a
heavy load for rubber tracks, and when they are operated
under a sandy field condition for a long time.
P-3865 Figure 40-20-37

Damage:
Embedded metals will gradually wear away by friction Minimum Wear

[Figure 40-20-35].
Figure 40-20-36
Excessive Wear
PI-13037A
Track Rotation:
Certain applications or conditions can cause wear on the

track inbeds and sprocket teeth. Rotating the tracks 180
degrees will help extend track life [Figure 40-20-37].
PI-13037 (See Track Damage Identification on Page 40-20-13.)
Remove the track and rotate it 180 degrees on the same

Replacement: side of the loader. (See Track Removal And Installation
on Page 40-20-4.)
When track embedded metals are worn
approximately 50% or more, replace the track.
Example of excessive wear is shown in [Figure 40-
20-35] and [Figure 40-20-36].

430 of 888
Track Damage Identification (Cont'd) Embedded metals are adhered between the steel cords
and the rubber body. The following cases generate
external forces greater than the adhesion strength,
Separation Of Embedded Metals causing separation of the embedded metals:
Figure 40-20-38 When the idler continually rides on the projections of

embedded metals, the embedded metals will
eventually peel off [Figure 40-20-39].
Figure 40-20-40
Guide
P-4379

Damage:
Extraordinary outer forces applied to embedded PI-13040
metals cause their separation from the rubber track's

body [Figure 40-20-38].
When a rubber track is detracked, it becomes stuck
between the guide or the undercarriage frame,
Replacement:
causing the separation of embedded metals [Figure
Even a partial separation of embedded metals 40-20-40].
requires replacement of the track.
Figure 40-20-39
Idler
Rubber
track
PI-13039

431 of 888
Track Damage Identification (Cont'd)
Figure 40-20-41
Minimum
wear
Excessive
wear
PI-13041A
Sprocket Rotation:
PI-13041
Certain applications or conditions can cause wear on the
sprockets. Rotating the sprockets to the opposite side of
Excessively worn sprockets, example shown [Figure the loader will help extend sprocket life [Figure 40-20-
40-20-41] will pull embedded metals out of the track. 42]. (See Track Damage Identification on Page 40-20-

13.)
Prevention:
Remove the sprocket. (See Sprocket Removal And
Similar to the prevention against the cutting of the steel Installation on Page 40-20-10.)
cords:
Recommended track tension should be periodically

checked. (See Checking Tension on Page 40-20-1.)
Quick turns on bumpy and rocky fields should be

avoided.

432 of 888
Track Damage Identification (Cont'd) Embedded metals are bonded to the rubber body. The
following operating conditions cause embedded metals
Separation Of Embedded Metals Due To Corrosion to corrode, causing deterioration of the bonding, and
finally resulting in separation of the embedded metals
Figure 40-20-43 from the rubber body [Figure 40-20-44].
Excessively salty fields, like the sea shore
Strong acidic or alkali soil conditions
Compost spread grounds
On tracks that are out of adjustment, the track rollers,

idlers and sprockets will gradually wear the rubber
surface at track roller side, causing exposure of the
embedded metals. Consequently the embedded metals
will corrode resulting in their separation from the rubber
body.
P-4378 Prevention:
If rubber tracks are used under such field conditions as

Damage: described under (Causes of the damage), they should be
washed with plenty of water. After being completely
Due to corrosion of embedded metals, the adhesion dried, they should be stored correctly.
to the rubber body deteriorates, resulting in complete
separation [Figure 40-20-43]. When the bonded rubber cover is separated from the
embedded metal projections and the metals in the rubber
Replacement: body become loose, it is time to consider replacement of
the rubber track.
Even a partial separation of embedded metals
requires a rubber track replacement.
Figure 40-20-44
Embedded metal
Good
Separation of
bonded rubber
cover
PI-13043

433 of 888
Track Damage Identification (Cont'd) When rubber tracks drive over projections or sharp
stones in the fields, the concentrated forces applied
Cuts On The Lug Side Rubber cause cuts on the lug side rubber surface. In case of
making turns on projections, the lug side rubber surface
Figure 40-20-45 will have an even higher chance to be cut. If the cuts run
through the embedded steel cords, it might result in the
steel cords' breakage due to their corrosion. It is highly
recommended to repair the cuts with cold vulcanization
rubber as soon as they are observed [Figure 40-20-46].
Prevention:
Machine operators are requested to drive with great

attention to the ground's surface especially in terrains of
the following type:
Construction sites
Demolition sites
P-4377
Paths covered with rocks and wood

Damage: Concrete ridges
Cuts on the lug side rubber often occurs as one of the Stumpy fields
most typical failure modes [Figure 40-20-45].
When operating on terrains as mentioned above, high
Replacement: speed, quick turns and overloading should be avoided.
When a cut on the lug side rubber reaches the
embedded steel cords, it should be immediately
repaired with cold vulcanization rubber.
Figure 40-20-46
Cuts
PI-13045

434 of 888
Track Damage Identification (Cont'd) Because of wound stress applied to rubber tracks around
the undercarriage parts during operation, the fatigue
Cracks On The Lug Side Rubber Due To Fatigue especially causes cracks on the lug side rubber surface.
Once the cracks occur, they gradually deteriorate with
Figure 40-20-47 even small external cracks. Also when operating near
seashores or under cold temperatures, rubber tracks are
more likely to suffer from ozone cracks.
Prevention:
Rubber tracks are designed with special rubber

compounds to prevent cracks due to fatigue. However,
external injuries on the lug side rubber sometimes cause
more chance of cracking. Machine operators should
observe soil conditions when driving, so as not to cause
external injuries to the lug side rubber. In order to
minimize the occurrence of ozone cracks, attention
should be paid to the following instructions for
maintenance:
P-4382
Avoid exposing stored tracks to direct sun light.

Figure 40-20-48 Avoid exposing stored tracks to direct rain and snow
fall.
Store tracks in well ventilated warehouses.
Use the tracks at least once a month.
P-4380
Damage:
Small cracks around the root of the lug as a result from

operation fatigue [Figure 40-20-47] & [Figure 40-20-48].
Replacement:
When the cracks reach so deep that they expose the

steel cords, track replacement is required.

435 of 888
TRACK CARRIAGE COMPONENTS (CONT'D) Replacement:
Track Damage Identification (Cont'd) No replacement is required.
Lug Abrasion Causes of the damage:
Figure 40-20-49 Lug abrasion is more or less inevitable. Even if lug

abrasion is proceeding, the rubber track can be used.
However, as the traction performance deteriorates
accordingly, it is highly recommended to replace the
abraded tracks with new ones when the lug height
becomes less than 5 MM.
Prevention:
In order to prevent the rubber track from abnormal or

premature abrasion, the following operating conditions
should be avoided:
Making quick and repeated turns on concrete and

asphalt roads
P-4381
Driving up and down hilly paths with slippage

Figure 40-20-50 Making frequent turns on paths covered with rocks
and wood
Lug abrasion
PI-13049
Damage:
As its service time proceeds, the lug side inevitably

undergoes abrasion [Figure 40-20-49] & [Figure 40-
20-50].

436 of 888
Cracks And Cuts On The Lug Side Rubber

Crack at the edge of Cut on lug side
Figure 40-20-51 embedded metal rubber
PI-13051
Causes of the damage:
When rubber tracks drive over sharp projections,

CD-13050 intensive stress is applied to the lug side rubber surface,
especially at the edges of embedded metals, causing
cracks and cuts in the area around the embedded metals

Damage: [Figure 40-20-52].
Sometimes cracks and cuts on the lug side rubber at Prevention:

the edges of the embedded metals can be observed
[Figure 40-20-51]. To avoid extensive stress applied to the lug root where
metals are embedded, machine operators are requested
Replacement: to avoid driving over stumps and ridges.
Basically, no replacement is required unless the cuts on

the lug side rubber are discovered all around the edges
of the embedded metals, as this will result in a complete
cut off.

437 of 888
Abrasion Of The Track Roller Side

Track roller
Figure 40-20-53
Abrasion
PI-13053
The abrasion of the track roller side rubber surface

P-4383 occurs because of sand and gravel being clogged
between the rubber and the outside surface of the track
rollers. The stress pushes the sand and gravel against

Damage: the side of the rubber track to cause the abrasion [Figure
40-20-54].
The rubber surface on which track rollers run is
gradually abraded. It will end in the exposure of the The level of abrasion is highly dependent on terrain
embedded metals [Figure 40-20-53]. conditions. A higher level of abrasion will occur when the
rubber tracks are operated in fields covered with many
Replacement: stones and gravel. Small stones hardened with mud,
stuck to the track rollers increase the abrasion level. After
It is recommended to replace the rubber track when an extended period of abrasion, it will be more likely for
more than half of the embedded metals are exposed embedded metals to catch moisture through the
completely exposed. inside steel cords, which can cause breakage of steel
cords and separation of the metals from the rubber body.
Prevention:
After operation in wet fields containing many small

stones, wash off the mud that is stuck to the track rollers
completely. When operating on gravel paths and stony
grounds, machines should be driven slowly and the
turning radius should be big enough to prevent stones
and gravel from getting stuck to the track roller side
rubber.

438 of 888
Cuts On The Edges Of Track Roller Side
Figure 40-20-55
PI-13056
This damage is caused by objects on the field or by

P-4384 interference with the machine frame.
In case of damage by objects on the operating ground:

Figure 40-20-56
The edges of rubber track are often deformed largely
due to a bumpy ground surface, stones and other
objects, which cause extensive stress on the edges
resulting in the damage. Especially, when a machine
drives over concrete ridges, this type of damage
Edge Edge easily occurs [Figure 40-20-57].
PI-13055
Damage:
Both edges of a rubber track have no special

reinforcements. It sometimes occurs during operation
that they are cut or torn off [Figure 40-20-55] &
[Figure 40-20-56].
Replacement:
In such case, the rubber track does not have to be

replaced.

439 of 888
TRACK CARRIAGE COMPONENTS (CONT'D)
Cuts On The Edges Of Track Roller Side
Figure 40-20-58
Cut
Tear
PI-13057

In case of damage by interference with the machine
frame
If a machine continues operating with rubber tracks

being detracked, the rubber tracks may get caught up
in the machine frame or undercarriage parts resulting
in damage. Furthermore, when a machine travels
along side slopes, the rubber tracks are deformed so
much that they come into contact with the machine
frame and undercarriage parts, which causes cutting,
gouging and rubbing of rubber tracks in the end
[Figure 40-20-58].
Prevention:
When traveling, a machine operator should be careful not

to drive over any projections on the ground. He should
also prevent rubber tracks from coming into contact with
concrete walls, ditches and ridges. If rubber tracks are
detracked, the machine should be stopped immediately
for retracting.

440 of 888
MAIN FRAME
ACCESS PANEL (INSIDE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1

Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . 50-120-1 SAFETY &
MAINTENANCE
ACCESS PANEL (INSIDE) (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Left) . . . . . . . . . . . . . . . . . . . . . . . . 50-121-1
Removal And Installation (Right) . . . . . . . . . . . . . . . . . . . . . . . 50-121-2
BOB-TACH (HAND LEVER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Lever And Wedge Disassembly And Assembly. . . . . . . . . . . . . 50-40-2 DRIVE
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . 50-40-4 SYSTEM
BOB-TACH (POWER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1 MAIN FRAME
Lever And Wedge Disassembly And Assembly. . . . . . . . . . . . . 50-41-3
Pivot Pin Bushing And Seal Removal And Installation . . . . . . . 50-41-4

ELECTRICAL
SYSTEM &
CAB DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
ANALYSIS
Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3
Aligning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-2
Checking Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-3 ENGINE
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1 SERVICE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
CONTROL HANDLE / LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1

Boot Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . 50-110-2 SPECIFICATIONS
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-110-1
CONTROL HANDLE / LEVER (ACS) . . . . . . . . . . . . . . . . . . . . . . .50-111-1

Boot Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . .50-111-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-111-1
Handle Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . .50-111-5
Handle Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . .50-111-4
Handle Sensor Removal And Installation . . . . . . . . . . . . . . . . .50-111-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . .50-111-5
CONTROL HANDLE / LEVER (SJC) . . . . . . . . . . . . . . . . . . . . . . 50-112-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1
Joystick Mount Removal And Installation . . . . . . . . . . . . . . . . 50-112-6
Joystick Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-112-2
Joystick Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-112-1

441 of 888
MAIN FRAME (CONT’D)
CONTROL PANEL (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-101-1
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
Linkage Neutral (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-13
Linkage Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-100-7
Linkage Travel (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-17
Pintle Arm Disassembly And Assembly . . . . . . . . . . . . . . . . . 50-100-11
Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . 50-100-6
Shaft Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 50-100-5
CONTROL PEDALS AND LINKAGES . . . . . . . . . . . . . . . . . . . . . . 50-90-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1
Pedal (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-4
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

CONTROL PEDALS (ACS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-91-1
Foot Pedal Linkage Disassembly And Assembly. . . . . . . . . . . . 50-91-3
Foot Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-91-2
Foot Sensor Removal And Installation. . . . . . . . . . . . . . . . . . . . 50-91-1
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Link Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-2
Stabilizer Bar Removal And Installation . . . . . . . . . . . . . . . . . . . 50-50-1
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Fuel Fill Screen Removal And Installation . . . . . . . . . . . . . . . . . 50-80-2
Fuel Level Sender Removal And Installation . . . . . . . . . . . . . . . 50-80-2
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Cylinder Bracket Disassembly And Assembly . . . . . . . . . . 50-20-3
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . 50-20-1
OPERATOR SEAT (SUSPENSION) . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Back Cushion Removal And Installation . . . . . . . . . . . . . . . . . . 50-30-4
Lower Cushion Removal And Installation . . . . . . . . . . . . . . . . . 50-30-2
Seat Belt Removal and Installation . . . . . . . . . . . . . . . . . . . . . . 50-30-2
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . 50-30-4
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 50-30-2
3-Point Seat Belt Removal And Installation . . . . . . . . . . . . . . . . 50-30-5

442 of 888
MAIN FRAME (CONT’D)
REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Latch Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-70-3
Striker (Adjusting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-2
Striker Disassembly and Assembly . . . . . . . . . . . . . . . . . . 50-70-2
Striker Removal and Installation . . . . . . . . . . . . . . . . . . . . 50-70-2
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1
Compression Spring Disassembly And Assembly . . . . . . . 50-10-4
WINDOW (CAB DOOR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-133-1

Installation (Standard Window) . . . . . . . . . . . . . . . . . . . . 50-133-2
Removal And Installation (Special Applications Window) 50-133-4

Removal (Standard Window) . . . . . . . . . . . . . . . . . . . . . . 50-133-1
WINDOW (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1

Installation (Continuous Molding). . . . . . . . . . . . . . . . . . . 50-130-3
Installation (Split Molding) . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1
WINDOW (SIDE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 50-132-1
WINDOW (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-131-1



ITEMS MAY VARY.

443 of 888

444 of 888
SEAT BAR Figure 50-10-3
Description
The seat bar is the secondary restraint system that has a

sensor that automatically stops the loader functions until
the seat bar is lowered.
The seat bar is located in the operator cab.
Figure 50-10-1
P10564 P10563
Loosen the nut (both sides) at the front corners of the

1 operator cab [Figure 50-10-3].
Remove the nuts and plates (both sides) [Figure 50-10-

3].

Installation: Tighten the nuts to 40 - 50 ft.-lb. (54 - 68
N•m) torque.
N-19225 Figure 50-10-4
Raise the seat bar (Item 1) [Figure 50-10-1].
Figure 50-10-2
1
P-31858
Lift on the grab handle and bottom of the operator cab

slowly until the cab is all the way up and the latching
N-18463 mechanism engages [Figure 50-10-4].
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]

from the cab harness.
Lower the seat bar.

445 of 888
SEAT BAR (CONT’D) Disassembly And Assembly
Figure 50-10-5
4 6
5
7
1
2 9 8
10
1
N-19383
N-18572
Figure 50-10-8
Remove the seat bar mounting nuts (Item 1) [Figure 50-

4
10-5] (both sides).
5

9 8
Installation: Tighten the nuts to 28 ft.-lb. (38 N•m) 3
torque. 6
2 10
3.)
7
1
Figure 50-10-6
N-19219
1 Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
Seat Bar Mount (Item 1)

Mounting Bolt (Item 2)
Keyed Plastic Bushing (Item 3)
Seat Bar (Item 4)
Magnetic Bushing Assembly (Item 5)
N-19224 Pivot Bushing (Item 6)
Sensor Bracket (Item 7)
Sensor Mounting Nut (Item 8)
Remove the seat bar (Item 1) [Figure 50-10-6] from the Sensor Mounting Bolt (Item 9)
operator cab. Mounting Nut (Item 10)
Reverse the above procedure to install the seat bar into Installation: Tighten the mounting bolt (Item 2) [Figure
the operator cab. 50-10-7] & [Figure 50-10-8] to 50 - 70 in.-lb. (5,6 - 7,9
N•m) torque.

446 of 888
SEAT BAR (CONT’D)
Figure 50-10-9
5
4 6
2 7
1
N-19340
Figure 50-10-10

4
5
3 6
2
7
1
N-19220
Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-9] & [Figure 50-10-
10].
Seat Bar Mount (Item 1)

Mounting Nut (Item 2)
Pivot Bushing (Item 3)
Spacer Bushing (Item 4)
Seat Bar (Item 5)
Keyed Plastic Bushing (Item 6)
Mounting Bolt (Item 7)
Installation: Tighten the mounting bolt (Item 7) [Figure

50-10-9] & [Figure 50-10-10] to 50 - 70 in.-lb. (5,6 - 7,9
N•m) torque.

447 of 888
SEAT BAR (CONT’D) Figure 50-10-12
Compression Spring Disassembly And Assembly 1
Figure 50-10-11
6 7
5
4 6
N-19222
3
2
1 Turn the bolt (Item 1) [Figure 50-10-12] & [Figure 50-10-
N-19384 11] out of the clevis.
Assembly: Apply Loctite® #518 adhesive to the bolt

threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.

NOTE: For procedures requiring the use of Loctite®
#518 adhesive, thoroughly clean and dry
affected parts before the application of
Loctite® #518.
Disassemble and assemble the seat bar compression

spring and parts as shown in Fig. [Figure 50-10-11].
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Clevis (Item 4)
Retaining Pin (Item 5)
Pin (Item 6)
Bushing (Item 7)

448 of 888
OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 50-20-1
P-66826 P-66827
1 Remove the cab nut and holddown plate (Item 1) [Figure

50-20-2] (both sides).

N•m) torque.

Figure 50-20-3
P-66825
Remove the operator cab stop (Item 1) (both sides)

[Figure 50-20-1].
WARNING
P-66828
support device. Failure to use an approved lift arm Raise the operator cab (See Raising on Page 10-30-2) to
support device can allow the lift arms or attachment release the tension on the gas cylinder.
W-2059-0598 Install a strap (Item 1) [Figure 50-20-3] to the cab
handles to prevent the cab from falling forward.
Raise the lift arms. (See Installing on Page 10-20-1.)
Install an approved lift arm support device.

449 of 888
OPERATOR CAB (CONT’D) Figure 50-20-6
Gas Cylinder Removal And Installation (Cont’d)
Figure 50-20-4
SINGLE GAS CYLINDER
N-19184
1
P-48262A Rotate the mounting bracket forward to relieve any

remaining tension on the gas cylinder(s) [Figure 50-20-
6].
Figure 50-20-5
Remove the front screw (Item 1) [Figure 50-20-6] from

DUAL GAS CYLINDER the gas cylinder mounting bracket.
Installation: Tighten the screws to 100 - 130 in.-lb. (11,3

- 14,7 N•m) torque.
1 2
P-43354A
Loosen the front screw (Item 1) and remove the rear

screw (Item 2) [Figure 50-20-4] and [Figure 50-20-5]
from the gas cylinder mounting bracket.

450 of 888
OPERATOR CAB (CONT’D) Gas Cylinder Bracket Disassembly And Assembly
Gas Cylinder Removal And Installation (Cont’d) Figure 50-20-9
Figure 50-20-7
SINGLE GAS CYLINDER
2
1
P1008
P-66830
Remove the clevis (Item 1) and washer (Item 2) [Figure
50-20-9] from the end of the gas cylinder.
Figure 50-20-8
Remove the gas cylinder from the outer housing.

DUAL GAS CYLINDER
Assembly: Install a replacement cylinder inside the
cylinder housing.
1 Figure 50-20-10
P-66829
Remove the retaining pin(s) (Item 1) [Figure 50-20-7]

and [Figure 50-20-8] from the top pivot pin(s).
Remove the gas cylinder(s) (Item 2) [Figure 50-20-7]

P1006
and [Figure 50-20-8] from the operator cab.
Reverse the above procedure to install the gas cylinders Apply a small amount of thread-locker on the threads of
onto the operator cab. the cylinder rod [Figure 50-20-10].
Reinstall the washer and clevis on the cylinder rod.

451 of 888
WARNING
Attach a chain hoist to the grab handles of the
operator cab before removing the operator cab gas
2
cylinders. If the operator cab is tilted forward without
the gas cylinders operational, the cab will fall and
could cause injury or death.
W-2245-0796 P-66831
Remove the operator cab gas cylinder(s). (See Gas

Remove screw (Item 1) [Figure 50-20-12] from the cab
Cylinder Removal And Installation on page 50-20-1.)
ground.
Figure 50-20-11
torque.

Remove any tie-straps connected to the harness [Figure
50-20-12].
Disconnect the cab harness connector screw (Item 2)

[Figure 50-20-12].
Installation: Tighten the connector screw to 30 - 35 in.-

lb. (3,39 - 3,96 N•m) torque.
Figure 50-20-13
P-66828
1
P-66829
Use the hoist connected to the operator cab grab handles
to lower or (raise) the operator cab when the gas
cylinders are disconnected [Figure 50-20-11]. Remove the bolt (Item 1) [Figure 50-20-13] from the cab
ground.

452 of 888
Figure 50-20-14
1
1
P-66832
Remove the rear mounting bolt (Item 1) [Figure 50-20-

N-19231 16] (both sides) and nut from the operator cab.
Installation: Tighten the bolt and nut to 25 - 35 ft.-lb. (34

Install lift eye (Item 1) [Figure 50-20-14] (both sides) to - 47 N•m) torque.
the cab.

Lift the operator cab up and forward.
Figure 50-20-15
Remove the operator cab from the loader.
2 Reverse the above procedure to install the operator cab.

1
N-19202
P-31967
Connect the slings (Items 1 & 2) [Figure 50-20-15] to a

chain hoist.

453 of 888

454 of 888
OPERATOR SEAT (SUSPENSION) Figure 50-30-3
Figure 50-30-1
1 2
N-20974
NOTE: Assure seat tethers are securely fastened to

N-20647 seatbelt studs (Item 1) and seat rail studs
(Item 2) [Figure 50-30-3].
Raise the operator cab. (See Raising on Page 10-30-2.) Figure 50-30-4

Remove the four seat mounting nuts (Item 1) [Figure 50-
30-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lb. (27

N•m) torque.
Figure 50-30-2
N-20973
NOTE: Verify the front two seat rail studs have

washers attached (Item 1) [Figure 50-30-4].
P10564 P10563
Lower the cab and install one of the mounting washers

and a nut [Figure 50-30-2].
NOTE: With the seat removed, the cab will raise.
Reverse the removal procedure to install the operator

seat.

455 of 888
OPERATOR SEAT (SUSPENSION) (CONT’D) Seat Belt Removal and Installation
Slide Rail Removal And Installation Figure 50-30-6
Figure 50-30-5
1 1
2 1
2
1
1
N-20974
N-18587
Remove the nut (Item 1) [Figure 50-30-6] from the seat
belt mount.
Remove the seat belt.

Remove the operator seat. (See Removal And
Installation on Page 50-30-1.) Installation: Tighten the mounting nuts to 58 - 62 ft.-lb.
(78,6 - 84 N•m) torque.
Remove the two slide rail mounting bolts (Item 1) [Figure
50-30-5]. Lower Cushion Removal And Installation
Remove the slide rail (Item 2) [Figure 50-30-5] from the Figure 50-30-7
bottom of the seat frame.

seat slide rail. 1
N-18579
Press the two buttons (Item 1) [Figure 50-30-7] &

[Figure 50-30-8] and lift the seat cushion.

456 of 888
OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-30-10
Lower Cushion Removal And Installation (Cont’d)
Figure 50-30-8
1 1
N-18580
Inspect the seat ride adjustment [Figure 50-30-10].

N-18582
seat back.
Figure 50-30-9

1
N-18581
Remove the cushion (Item 2) [Figure 50-30-8] from the

seat frame (Item 1) [Figure 50-30-9].

457 of 888
OPERATOR SEAT (SUSPENSION) (CONT’D) Shock Removal And Installation
Back Cushion Removal And Installation Figure 50-30-13
Figure 50-30-11
2
1
P-43118
N-18583
Pull the seat back adjustment lever (Item 1) [Figure 50- Remove the operator seat. (See Removal And
30-11] and tilt the seat back all the way forward. Installation on Page 50-30-1.)

Figure 50-30-12 Remove the seat shock mounting bolts (Item 1) [Figure
50-30-13] (Both ends.)
Remove the seat shock (Item 2) [Figure 50-30-13].

seat shock.
1 1
N-18578

30-12] from the seat back and remove the back.

seat back.

458 of 888
OPERATOR SEAT (SUSPENSION) (CONT’D) Figure 50-30-15
3-Point Seat Belt Removal And Installation
Remove the operator seat. (See Removal And

Installation on Page 50-30-1.) 2
Figure 50-30-14
1
2 3
P16284
Remove the mounting nut (Item 1) [Figure 50-30-15]
1 Remove the seat belt retractor (Item 2) [Figure 50-30-

15]
3
Installation: Be sure tether strap (Item 3) [Figure 50-30-

P16285 15] is on the seat belt stud behind the seat belt retractor.
Remove the end release buckle (Item 2) [Figure 50-30-

14]
Installation: Be sure tether strap (Item 3) [Figure 50-30-

14] is on the seat belt stud behind the end release
buckle.

459 of 888
OPERATOR SEAT (SUSPENSION) (CONT’D)
3-Point Seat Belt Removal And Installation (Cont’d)
Figure 50-30-16
OUTSIDE OF CAB
P16131
Remove the mounting bolt (Item 1) [Figure 50-30-16]

Figure 50-30-17
1 2
P16126
INSIDE OF CAB
P16128
Remove the shoulder harness retractor (Item 1) [Figure

50-30-17]
Installation: Line up the bolt (Item 1) [Figure 50-30-16]

with the mounting bracket (Item 2) [Figure 50-30-17] on
the inside of the cab.

460 of 888
BOB-TACH (HAND LEVER) Figure 50-40-2
Description
The Bob-tach is the section of the loader lift arm that

attachments mount to. The Power Bob-tach uses two
manually operated, spring assisted, locking wedge and
lever assemblies to secure the attachment the Bob-tach. 1
2
The Bob-tach is located on the front of the loader
connected to the loader lift arms.
Figure 50-40-1
N-18545
Remove the pivot pin (Item 1) [Figure 50-40-2] from the

tilt cylinder rod end (both sides).
Remove the tilt cylinder rod end from the Bob-Tach (both
sides).
1

Loosen the bolt (Item 2) [Figure 50-40-2] at the Bob-
Tach pivot pin.
Installation: Tighten the bolt to 175 - 190 ft.-lb. (240 -

260 N•m) torque.
N-18544
Figure 50-40-3
Tilt the Bob-Tach forward, so it is parallel to the floor. Put
blocks (approximately 3 in.) under each side of the Bob-
Tach [Figure 50-40-1].
Lower the Bob-Tach onto the blocks.

nut from the tilt cylinder rod end pin (both sides). 1
Installation: Tighten the retainer bolt and nut to 25 - 30

P-48132
Remove the grease fitting (Item 1) (both sides)

[Figure 50-40-3] out of the Bob-Tach frame. This allows
grease to escape when driving the pivot pins into the
Bob-Tach frame.

461 of 888
BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-6
Figure 50-40-4
1
N-18559
Use a punch and hammer, remove the roll pin (Item 1)

N-18547 [Figure 50-40-6] from the Bob-Tach Wedge and spring
clevis.
Strike the head of the bolt (Item 1) [Figure 50-40-4] to Figure 50-40-7
push the pivot pin into the Bob-Tach frame.

Remove the bolt.
Use a long punch to push the pivot pin all the way into the
1
Bob-Tach.
Remove the Bob-Tach from the lift arms.
Remove the Bob-Tach pivot pin (both sides).
Lever And Wedge Disassembly And Assembly
Figure 50-40-5
N-18560
Remove the Wedge (Item 1) [Figure 50-40-7].
Always replace bent or broken wedges.
N-18558
Use the following procedure to remove and install the

Bob-Tach lever (Item 1) [Figure 50-40-5], spring and
wedge.

462 of 888
BOB-TACH (HAND LEVER) (CONT’D) Figure 50-40-10

(Cont’d)
Figure 50-40-8
3 N-18563
2 Use a punch and hammer to drive the roll pin (Item 1)

1 [Figure 50-40-10] flush with the face of the Bob-Tach.
N-18561
Reverse the removal procedure to install the Bob-Tach
lever and wedge [Figure 50-40-10].
Remove the lever mounting nut (Item 1), washer (Item 2),

spring (Item 3) and lever (Item 4) [Figure 50-40-8].

N•m) torque.
Figure 50-40-9
2 4
3
N-20625
If the bolt (Item 1), handle pivot (Item 2), spring (Item 3),
or clevis (Item 4) [Figure 50-40-9] are damaged, put the
assembly in a vise.
Remove the bolt and replace the damaged parts as

needed.

463 of 888
BOB-TACH (HAND LEVER) (CONT’D)
Pivot Pin Bushing And Seal Removal And Installation
Figure 50-40-11
2 1
N-18557
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-
11] on the Bob-Tach.
Remove and replace bushing (Item 2) [Figure 50-40-11]

with a driver tool and hammer.

464 of 888
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
2 3
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
lever assemblies by pressing a switch on the front
accessory 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. 1
The Power Bob-tach block is located on the rear of the

P-48131
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. blocks (approximately 3 in.) under each side of the Bob-
Tach [Figure 50-41-1].

Lower the Bob-Tach onto the blocks.
Remove the hoses to the cylinder fittings

[Figure 50-41-1].
NOTE: The hose with the 45 degree end (Item 1)

[Figure 50-41-1] is connected to the base end
fitting on the cylinder.
Remove the hose clamp on the hoses and use the bolt
(Item 2) [Figure 50-41-1] on the tilt cylinder pivot pin to
secure the clamp.

nut from the tilt cylinder rod end pin (both sides).
Installation: Tighten the retainer bolt and nut to 25 - 28


465 of 888
BOB-TACH (POWER) (CONT’D) Figure 50-41-4
Figure 50-41-2
N-18547
2
Strike the head of the bolt (Item 1) [Figure 50-41-4] to

P-48185 push the pivot pin into the Bob-Tach frame.
Remove the bolt.

Remove the pivot pin (Item 1) [Figure 50-41-2] from the
tilt cylinder rod end (both sides). Use a long punch to push the pivot pins all the way into

the Bob-Tach frame.
Remove the tilt cylinder rod end from the Bob-Tach (both
sides). Remove the Bob-Tach from the lift arms.
Loosen the bolt (Item 2) [Figure 50-41-2] at the Bob- Remove the Bob-Tach pivot pin (both sides).
Tach pivot pin.
Installation: Tighten the bolt to 175 - 190 ft.-lb. (240 -

260 N•m) torque.
Figure 50-41-3
P-48132
Remove the grease fitting (Item 1) (both sides)

[Figure 50-41-3] out of the Bob-Tach frame. This allows
the grease to escape when driving the pivot pins in to the
Bob-Tach frame.

466 of 888
BOB-TACH (POWER) (CONT’D) Figure 50-41-7
Figure 50-41-5
N-18560
1
Remove the Wedge (Item 1) [Figure 50-41-7].

P-48135
Always replace bent or broken wedges.
Use the following procedure to remove and install the Figure 50-41-8
Bob-Tach lever (Item 1) [Figure 50-41-5], spring and

wedge.
Figure 50-41-6
1
2
1
3
5
4
P-48135
Remove the washers and bolts (Item 1) [Figure 50-41-

N-18559 8].

Use a punch and hammer, remove the roll pin (Item 1) N•m) torque.
[Figure 50-41-6] from the Bob-Tach Wedge and spring
clevis. Remove the cylinder off the lever pivots. Position the rod
end to the left with the grease fitting holes to the top
[Figure 50-41-8].
Remove the lever mounting nut (Item 2), washer (Item 3),
spring (Item 4) and lever (Item 5) [Figure 50-41-8].

N•m) torque.

467 of 888
BOB-TACH (POWER) (CONT’D) Pivot Pin Bushing And Seal Removal And Installation
Lever And Wedge Disassembly And Assembly Figure 50-41-11

(Cont’d)
Figure 50-41-9
2 1
4
N-18557
3 2
N-20625 Remove the Power Bob-Tach. (See Removal And

If the bolt (Item 1), handle pivot (Item 2), spring (Item 3), Use a seal pick to remove seal (Item 1) [Figure 50-41-

or clevis (Item 4) [Figure 50-41-9] are damaged, put the 11] on the Bob-Tach.
assembly in a vise.
Remove and replace bushing (Item 2) [Figure 50-41-11]
Remove the bolt and replace the damaged parts as with a driver tool and hammer.
needed.
Figure 50-41-10
N-18563
Use a punch and hammer to drive the roll pin (Item 1)

[Figure 50-41-10] flush with the face of the Bob-Tach.
Reverse the removal procedure to install the Power Bob-

Tach lever and wedge [Figure 50-41-10].

468 of 888
LIFT ARMS Figure 50-50-3
Stabilizer Bar Removal And Installation
Figure 50-50-1
1
P-31969
Remove the retainer bolt (Item 1) from the stabilizer link

P-45007 pivot pin (Item 2) [Figure 50-50-3].
Figure 50-50-4
Lower the lift arms.
Remove the tracks.

Connect a chain to the front of the lift arm and around the
track carriage [Figure 50-50-1].
NOTE: Bob-Tach is removed in photo for clarification

3
of procedure only.
Figure 50-50-2 2
1
P-43989A
Use a slide hammer (Item 1), remove the stabilizer link

pivot pin (Item 2) [Figure 50-50-4].
1
Remove the stabilizer link (Item 3) [Figure 50-50-4] from
the lift arm.
2 Reverse the above procedure to install the stabilizer link.
N-18813
Remove the retainer bolt (Item 1) [Figure 50-50-2] from

the stabilizer link pivot pin.
Remove the stabilizer link pivot pin (Item 2) [Figure 50-

50-2].

469 of 888
LIFT ARMS (CONT’D) Figure 50-50-6
Link Removal And Installation
Figure 50-50-5
1
2
P-31974
Connect a chain and chain hoist on the lift arm link

N-18806 [Figure 50-50-6].

Lower the lift arms. Stop the engine. nut from the lift arm link pivot pin.

Remove the retainer bolt (Item 1) [Figure 50-50-5] and Figure 50-50-7
nut from the lift arm pivot pin.
Use a drift pin and hammer, remove the lift arm pivot pin
WARNING
Wear safety glasses to prevent eye injury when any 1
P-31975
W-2019-0907
Open the rear door.
Raise the radiator cover part way to gain access to the

pivot pin.
Use a drift pin and hammer, remove the lift arm pivot pin
Lower the rear grill. Close the rear door.
Raise the lift arm link with the chain hoist and remove it
from the loader frame.
Reverse the removal procedure to install the lift arm link

on the loader.

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Figure 50-50-8
N-18850
Mark the tubelines for correct installation (both sides).

P-43990 Pull the tubelines down, disconnect the hoses (Item 1)
[Figure 50-50-10] (both sides).
Roll the Bob-Tach fully forward. Stop the engine. Install plugs into the hose and tubeline ends.

Remove the Bob-Tach frame from the lift arms. (See Figure 50-50-11
Install jackstands under the rear of the loader [Figure 50-

50-8].
Figure 50-50-9
1
P-31832
1
Remove the front auxiliary mount mounting bolts (Item 1)
[Figure 50-50-11].
N-18805 Remove the front auxiliary tubelines from the lift arms.
Remove the tubeline clamps (Item 1) [Figure 50-50-9]

under the lift arms (both sides).

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Figure 50-50-12
1
P-34136
Remove the tilt cylinder mounting bolt base end (Item 1)

N-18792 [Figure 50-50-14].

Remove the three front step mounting bolts (Item 1)
[Figure 50-50-12]. Remove the tilt cylinders and tilt tubelines from the

loader.
Figure 50-50-13
Figure 50-50-15
N-18793
P-45007
Remove the tilt port block mounting bolt (Item 1) [Figure

50-50-13] under the step. Connect a chain to the front of the lift arm and around the
track carriage [Figure 50-50-15].

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Figure 50-50-16
1 1
P-31973
Use a slide hammer remove the lift cylinder rod end pivot
N-18806 pin (Item 1) [Figure 50-50-18] (both sides).
Strap the lift cylinders to rear of the uprights.

nut from the lift arm pin (both sides).

Use a drift pin and hammer remove the lift arm pivot pin
Figure 50-50-17
P-31972

nut from the lift cylinder rod end pivot pin (both sides).

473 of 888
Figure 50-50-19
3
P-43989A

P-43988
Connect a nylon lift strap, chain and chain hoist to the lift
arms (Item 1) [Figure 50-50-19] & [Figure 50-50-20].
Remove the retainer bolt (Item 2) [Figure 50-50-19] from

the stabilizer pivot pin (both sides).
Use a slide hammer, remove the stabilizer pivot pin (Item

3) [Figure 50-50-19] (both sides).
Remove the chain from the lift arms and track carriage.
Remove the lift arms from the loader.
Reverse the removal procedure to install the lift arm.

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REAR GRILL Figure 50-60-3
Figure 50-60-1
2
P-48130
Installation: Line up the tab (Item 1) on the grill with the

P-48251 slot (Item 2) [Figure 50-60-3] on the loader mainframe.
Insert the tab fully and then push down.
Open the rear door. Reverse the removal procedure to install the grill.

Figure 50-60-2
P-48252
Lift up on the rear grill (Item 1) [Figure 50-60-1] and

[Figure 50-60-2].
Lift the grill away from the loader.

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476 of 888
REAR DOOR Figure 50-70-3

1
Figure 50-70-1
2
3
2
P-34606
1
Remove the top and bottom door hinge mounting bolts
P-68264 (Item 1) [Figure 50-70-3] and nuts.
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 engine harness.
[Figure 50-70-3].

Remove both rear lights (Item 2) [Figure 50-70-1] from
Installation: Tighten the mounting bolts and nuts to 25 -
the door. (See Rear Removal And Installation on Page
28 ft.-lb. (34 - 38 N•m) torque.
60-60-2.)
Lift the door away from the loader frame and put the door
Figure 50-70-2
flat on the floor.
P-34588
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.

477 of 888
REAR DOOR (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-31126
Remove the two striker mount bolts (Item 1) [Figure 50-

70-4].

Remove the striker assembly from the loader. 1
Striker Disassembly and Assembly

P-31126
Figure 50-70-5
Loosen the striker assembly mount bolts (Item 1) [Figure
50-70-6].
2 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-31320
Tighten both striker mount bolts (Item 1) [Figure 50-70-6]
to 90 - 100 ft.-lb. (125 - 135 N•m) 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.

478 of 888
REAR DOOR (CONT’D) Figure 50-70-9
Latch Removal And Installation
Figure 50-70-7
1
P-31128
1 Remove the door handle (Item 1) [Figure 50-70-9] from

P-31125 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
1
P-31127
Remove the spring (Item 1) [Figure 50-70-8] from the

door handle.

door latch.
Remove the door latch (Item 3) [Figure 50-70-8] from the

door handle.

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FUEL TANK Figure 50-80-3

2
Figure 50-80-1
1 P-28143

P-28152 3] from the battery holder.
Remove the battery holder (Item 2) [Figure 50-80-3]

Remove left access cover (Item 1) [Figure 50-80-1] from the loader.
which is located from the rear of the machine below the

undercarriage. Figure 50-80-4
Figure 50-80-2
1
1 1
P-28144
P-28153
Remove the mounting bolts (Item 1) [Figure 50-80-4]
from the fuel tank retainer bracket.
Drain the fuel from the tank through the fuel drain (Item 1)
[Figure 50-80-2].


481 of 888
FUEL TANK (CONT'D) Fuel Fill Screen Removal And Installation
Figure 50-80-5
1 2
1
P13874A
P-28145
Remove the clamp (Item 1) and remove the fuel fill hose
(Item 2) [Figure 50-80-7] from the tank.
Disconnect fuel sender (Item 1) [Figure 50-80-5].
Figure 50-80-8
Disconnect fuel vent hose (Item 2) [Figure 50-80-5].

Disconnect fuel fill hose (Item 2) [Figure 50-80-7].
Remove tank from loader.
Fuel Level Sender Removal And Installation 1
Figure 50-80-6
P13875A
2
Remove the fuel fill screen (Item 1) [Figure 50-80-8]
from the tank. Check the screen for damage and replace
if necessary.
P-28145
Disconnect fuel level sender (Item 1) [Figure 50-80-6].
Loosen the fuel level sender (Item 2) [Figure 50-80-6]

with a wrench.
Turn the fuel level sender out and remove it from the fuel
tank. Check the fuel level sender for damage and replace
if necessary.
Installation: Tighten the fuel level sender to 50 - 60 in.-

lb. (5,7 - 6,8 N•m) torque.

482 of 888
CONTROL PEDALS AND LINKAGES Figure 50-90-1
Description
The control pedals and linkages are connected to the 1

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-26008
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 rubber bushing in the pedal for wear and
to fall and cause injury or death. replace as 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.) 1
DANGER
P-34375
P-90328 Remove the two mounting bolts (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

483 of 888
CONTROL PEDALS AND LINKAGES (CONT’D) Figure 50-90-5
Linkage Removal And Installation
Figure 50-90-3
2
1
P-34376
Remove the crossbar from the pivot [Figure 50-90-5].

P-66969A
Installation: Check the nylon bushing (Item 1) [Figure
50-90-5] for wear and replace as needed.
Remove the bolt and nut (Item 1) [Figure 50-90-3] to
disconnect the lift pedal linkage from the crossbar.

Remove the crossbar pivot bolt (Item 2) [Figure 50-90-
3].
Figure 50-90-4
P-34260
Remove the hairpin clip and cross-pin (Item 1) [Figure

50-90-4] from the control valve lift spool.
Disconnect the crossbar from the control valve.

484 of 888
Linkage Removal And Installation (Cont’d)
Figure 50-90-6
P-34258
Remove the hairpin clip and cross-pin (Item 1) [Figure

P-66969 50-90-8] from the control valve tilt spool.
Figure 50-90-9
disconnect the lift foot pedal linkage from the crossbar

linkage.
Figure 50-90-7
1
P-26008

disconnect the lift foot pedal.
P-24759

disconnect the lift foot pedal.

485 of 888
Pedal (Adjusting)
After installing the pedal, adjust the pedal angle so that 2

there is clearance under the rear of the pedal. The valve 1
spool must travel full stroke without the pedal hitting the
floor panel.
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.
Figure 50-90-10
P-26008
1
Loosen the bolt (Item 2) [Figure 50-90-11] and nut on the
pedal linkage.
Check the rubber 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 mounting bolts (Item 1) and pivot bolt

P-34375 (Item 2) [Figure 50-90-11] on the pedal assembly to
standard torque.
Loosen the two mounting bolts (Item 1) [Figure 50-90-

10] from the pedal mounting bracket.

486 of 888
CONTROL PEDALS (ACS) Figure 50-91-2
Description
The control pedals 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. 1
The control pedals are located on the lower mainframe at

the operators feet.
Foot Sensor Removal And Installation
Figure 50-91-1
P-21935
2
Tilt the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-2].
P-21936
Remove the foot pedal and sensor assembly from the

loader.

Figure 50-91-3
1
P-21938
Pull the pin (Item 1) [Figure 50-91-1] holding the foot

pedal linkage to the sensor. 1
Disconnect the two connectors (Item 2) [Figure 50-91-1]

from the sensor and lock solenoid.
P-21927
Remove the two bolts (Item 1) [Figure 50-91-3] from the

foot sensor shield.
Installation: Tighten the bolts to 80 - 90 in.-lb. (9,0 - 10,2

N•m) torque.

487 of 888
CONTROL PEDALS (ACS) (CONT'D) Foot Pedal Removal And Installation
Foot Sensor Removal And Installation (Cont’d) Figure 50-91-5
Figure 50-91-4
1
P-21940
P-21924
Remove the pin (Item 1) [Figure 50-91-5] holding the
linkage to the sensor.
Remove foot lock solenoid (Item 1) [Figure 50-91-4].
Figure 50-91-6

Installation: Apply a drop of oil to the solenoid threads
and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 N•m)
lubed torque. 1
Remove the two bolts (Item 2) [Figure 50-91-4] from the
bracket and sensor assembly.
P-21935A
N•m) torque.
Remove the sensor assembly.
P-21934
Tip the foot pedal up and remove the two nuts (Item 1)
[Figure 50-91-6].
Remove the foot pedal assembly.

488 of 888
CONTROL PEDALS (ACS) (CONT'D)
Foot Pedal Linkage Disassembly And Assembly
Figure 50-91-7
P-21931
Remove the bolt (Item 1) holding the linkage (Item 2) to

the side of the foot pedal [Figure 50-91-7].

Figure 50-91-8
2
3
1
P-21932
Remove the spacer (Item 1), linkage (Item 2), and nut
(Item 3) from the foot pedal [Figure 50-91-8].

489 of 888

490 of 888
CONTROL PANEL
Description
Figure 50-100-1

P-54658
The steering system [Figure 50-100-1] consists of Pintle arms are of a two-piece design that allow easy
independent steering levers the operator uses to provide adjustment of the neutral or “creep”.
steering input to the 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. The returning force of the torsion bushings.
bellcranks have grease fittings.
NOTE: Torsion bushings need to be replaced if torn
The forward travel is adjusted by drift adjustment bolts. or rotating in the housing. Loosen torsion
bushing bolts slightly before adjustments are
The bellcranks are attached to steering linkage bars with made. Do not fully tighten torsion bushing
rubber torsion bushings pressed into the bellcranks. bolts again until all steering adjustments have
Bellcranks mount to the control panel. been made first.
Steering linkage bars are a two-piece design. Steering Sequence of steering adjustments:
linkage bars are adjustable in length for “full travel
adjustment”. 1. Set neutral of pintle arms, “creep”
2. Set linkage travel at steering linkage bars
Steering linkage bars attach to the pintle arms where a 3. Set drift at drift adjustment bolts
rubber torsion bushing is pressed into the pintle arms.

491 of 888
CONTROL PANEL (CONT'D) Figure 50-100-2
2 1
DANGER 3
P-48462
P-90328
AVOID DEATH Raise the lift arms and install an approved lift arm support
• Disconnecting or loosening any hydraulic device. (See Installing on Page 10-20-1.)
can cause lift arms to drop. Raise the operator cab. (See Raising on Page 10-30-2.)
unless supported by an approved lift arm Remove the engine speed control. (See Removal And

D-1009-0409
Loosen the jam nut (Item 1) from the bypass control knob
(Item 2) [Figure 50-100-2].
WARNING Remove the control knob (Item 2), jam nut (Item 1) and
rubber washer (Item 3) [Figure 50-100-2].
Never work on a machine with the lift arms up unless Figure 50-100-3
W-2059-0598
WARNING
P-48277
W-2017-0286
Disconnect the control harness connectors (Item 4)

[Figure 50-100-2] & [Figure 50-100-3] from the control
levers.

492 of 888
Figure 50-100-4 2
1 1
2 2
3
P-26323
1 1
Remove the fuse cover mount screws (Item 1) [Figure

P-54609 50-100-5].
Installation: Tighten screws to 8 - 11 ft.-lb. (11 - 15 N•m)

Scribe a mark across the top of the steering linkage bars torque.

steering shaft on the control panel. Remove the fuse/relay cover (Item 2) [Figure 50-100-5].
Remove the four steering linkage mounting bolts (Item 2) Remove the fuse/relay shield mounting screws (Item 3)
[Figure 50-100-4]. [Figure 50-100-5].
Installation: Align the marks on the steering linkage Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
bars. Tighten the steering linkage mounting bolts to 35 - N•m) torque.
40 ft.-lb. (47,5 - 54,2 N•m) torque.
Remove the fuse/relay shield (Item 4) [Figure 50-100-5]
Figure 50-100-6
P-26325
Remove the fuse/relay block [Figure 50-100-6].

493 of 888

1
Figure 50-100-7
11
P-26329
P-26328 P-26329
1
Remove the control panel mounting bolts (Item 1)

P-26326 [Figure 50-100-7], [Figure 50-100-8] & [Figure 50-100-
9] from both sides of the control panel.
Figure 50-100-8 Installation: Tighten the control panel mounting bolts to

15 - 20 ft.-lb. (20 - 27 N•m) torque.

Remove the control panel from the loader.
Reverse the removal procedure to install the control

panel.
1
1
P-26327

494 of 888
CONTROL PANEL (CONT’D) Shaft Removal And Installation
Shock Removal And Installation NOTE: The steering shaft can be removed without
removing the control panel from the loader.
Figure 50-100-10 Photo [Figure 50-100-11] shows the control
panel removed for clarity purpose only.
Remove the steering linkage mounting bolts (Item 3)

[Figure 50-100-10].
1
Remove the steering shock mounting nuts (Item 2)
3 [Figure 50-100-10].
Figure 50-100-11
P-48275

from the end of the shock connected to the steering

linkage. 3

from the other end of the shock connected to the bracket 1 2
on the control panel.
P-48278

(34 - 38 N•m) torque. Remove Control Handle Lever (Item 1) [Figure 50-100-
11]. (See Lever Removal And Installation on Page 50-
110-1.)
Remove the steering shaft pivot bolt (Item 2) [Figure 50-

100-11] from both sides of the control panel.
Installation: Tighten the pivot bolts to 25 - 28 ft.-lb. (34 -

38 N•m) torque.
Remove the steering shaft from the control panel.

495 of 888
CONTROL PANEL (CONT’D) Figure 50-100-13
Shaft Disassembly And Assembly

1
Figure 50-100-12
2
2
1 1
P-26331
2
To remove the steering shaft mounting bracket (Item 3)

P-4154 [Figure 50-100-11], remove the three mounting bolts
(Item 1) [Figure 50-100-13] from the front of the control
panel.
Disassemble the right and left steering bellcranks
(Item 1) from the cross shaft assembly [Figure 50-100- Remove the steering shaft mounting bracket.

12].
(20 - 27 N•m) torque.
Assembly: Install new nylon bushings (Item 2) [Figure
50-100-12] as needed when assembling the steering
shaft. Be sure to apply grease on the cross shaft before
installing the right and left bellcranks.
NOTE: The bellcranks should pivot freely on the

cross shaft when assembled correctly.

496 of 888
Linkage Removal And Installation
WARNING 2 2
support device can allow the lift arms or attachment 1 1
W-2059-0598
P-54609
WARNING Scribe a mark across the top of the steering linkage bars
steering shaft on the control panel.
Remove the four steering linkage mounting bolts (Item 2)
[Figure 50-100-14].

W-2017-0286
Installation: Align the marks on the steering linkage
bars. Tighten the steering linkage mounting bolts to 35 -
Raise the lift arms and install an approved lift arm support 40 ft.-lb. (47,5 - 54,2 N•m) torque.
NOTE: After removal and installation of the linkage,
Lift and block the loader. (See Procedure on Page 10-10- the linkage neutral adjustment procedure
1.) must be performed. See Page 50-100-13 for
Linkage Neutral (Adjusting) procedure.

497 of 888

7
Figure 50-100-15 6 8
3 1 4
1
2
5
2
P-48630
The centering plate/centering spring assembly consists

2 of the following parts:
P-48631
ITEM DESCRIPTION
Remove the nut (Item 1) from the end of the centering
spring shoulder bolt (Item 2) [Figure 50-100-15]. 1 Bolt

2 Bushings
Remove the bolt/spring assembly.
3 Washer
Installation: Tighten the centering spring bolt and a
4 Bushing Spacer
NEW lock nut to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
5 Spring
Figure 50-100-16 6 Lock Nut
7 Centering Plate
8 Guide Bushings
1
P-48632
Slide the centering plate (Item 1) [Figure 50-100-16] to

the right to remove it from the hydrostatic pumps.
NOTE: Directions are shown and stated as if you

were sitting in the operators seat.

498 of 888
Linkage Removal And Installation (Cont’d) SOLID CAMS
Figure 50-100-18
2
1
3
2 3
6
5
1
1 4
2
1
P-48627
2
If the surface of any of the four solid pintle cams (Item 1)

P-48629 are worn, loosen the bolt (Item 2) and rotate the cams 1/4
turn [Figure 50-100-19].
Check the wear on the centering blocks (Item 1) [Figure Remove the bolts and washers (Item 3) [Figure 50-100-
50-100-18]. 19] from the pintle.

If the centering blocks need replacement, remove the Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 -
bolts (Item 2) [Figure 50-100-18]. Remove the centering 54,2 N•m) torque.
blocks.
Loosen the creep adjustment bolt (Item 4) [Figure 50-
Installation: Tighten the centering block bolts to 35 - 40 100-19].
ft.-lb. (47,5 - 54,2 N•m) torque.
Remove the pintle arm (Item 5) from the pintle base (Item
NOTE: The washers go between the bolts and the 6) [Figure 50-100-19].
centering plate.
NOTE: If the centering blocks are worn, they can be

removed and rotated 180 degrees and
reinstalled. If the solid cams are worn, they
can be loosened and rotated 90 degrees and
reinstalled.

499 of 888
Figure 50-100-20
ROLLER CAMS 2
2
1
P-54615
3
Loosen the bolt (Item 1) and remove the pintle base (Item
P-54617 2) [Figure 50-100-22].
Remove the bolts and washers (Item 1) [Figure 50-100-

20] from the pintle.

Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 -
54,2 N•m) torque.
Remove the pintle arm (Item 2) from the pintle base (Item
3) [Figure 50-100-20].
Figure 50-100-21
4
3
1
P-48624
Remove the bolt and nut (Item 1) [Figure 50-100-21].
Inspect the washers (Item 2), pintle arm (Item 3) and the
steering linkage bar (Item 4) for damage and replace as
needed [Figure 50-100-21].
NOTE: The washers (Item 2) [Figure 50-100-21] are

hardened, and should only be replaced
through Bobcat Parts.

500 of 888
CONTROL PANEL (CONT’D) Pintle Arm Disassembly And Assembly
Linkage Removal And Installation (Cont’d) Figure 50-100-24
Figure 50-100-23 2
1
3
1
P-54625
P-48659
Remove the bolt (Item 1) from the pintle solid cams (Item
2) [Figure 50-100-24] and inspect the pintle solid cams
NOTE: When installing the pintle base (Item 1) onto for damage or excessive wear.
the pump shaft, the cutouts on the pump shaft

will not line up with the bolt (Item 3) [Figure Installation: Tighten the bolts to 35 - 40 ft.-lb. (47,5 -
50-100-23]. 54,2 N•m) torque.
Installation: Install the pintle base (Item 1) onto the Figure 50-100-25
pump shaft (Item 2) [Figure 50-100-23]. The top of the
pintle base should be level with the top of the pump shaft. 2
Tighten the bolt to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque. 3
NOTE: After installing the linkage onto the
hydrostatic pumps the linkage neutral
adjustment procedure must be performed.
See Page 50-100-13 for Linkage Neutral
(Adjusting) procedure. 2
1
P-54624
NOTE: The pintle roller cams (Item 2) [Figure 50-100-

25] are used on ACS loaders only.
Remove the nut (Item 1) from the pintle roller cams (Item
2) and inspect the pintle roller cams and washers (Item 3)
for damage [Figure 50-100-25].
Inspect the torsion bushing (Item 3) [Figure 50-100-25]

for damage and replace as needed.
Installation: Tighten the nuts to 35 - 40 ft.-lb. (47,5 - 54,2

N•m) torque.

501 of 888
Pintle Arm Disassembly And Assembly (Cont’d)
Figure 50-100-26
4 1 3
2 2
3 P-48619
Using a bushing driver (Item 1) remove the torsion

P-54626 bushing (Item 2) by pressing the bushing through the
pintle arm into an oversized socket (Item 3) to catch the
torsion bushing [Figure 50-100-27].
Remove the base pintle (Item 1) [Figure 50-100-26] from
the pump shaft. Installation: Install the torsion bushing (Item 2) [Figure

50-100-27] into the pintle arm using the same procedure
Remove the retaining bolt (Item 2), adjusting screw (Item as the removal.
3) and neoprene dampener (Item 4) [Figure 50-100-26]
from the base pintle. NOTE: When the torsion bushing is installed, the
amount of bushing on each side of the pintle
Inspect parts for wear and damage, replace as needed arm should be the same.
[Figure 50-100-26].
NOTE: Anti-seize should be used on the adjusting

screw to prevent corrosion and allow free
movement while adjusting.

502 of 888
Linkage Neutral (Adjusting)
The following tool listed will be needed to do the following 1

procedure:
MEL1563 or 6689779 - Remote Start Tool Kit
Connect the remote start tool to the engine harness. (See

REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.)

1.)
P-48448
Figure 50-100-28
Loosen the bolt/nut (Item 1) [Figure 50-100-29] only until

3
the tension is released from the torsion bushing.
Figure 50-100-30

1
P-48450
2
Tool that may assist in the neutral adjustment [Figure 50-

100-28].
P-54612
To make this tool use a locking grip C-Clamp and grind
one edge flat (Item 1) and grind the other edge (Item 2)
[Figure 50-100-28] to a small rounded edge. Loosen the nut (Item 1) only until the tension is released
from the torsion bushing (Item 2) [Figure 50-100-30].
A steering centering block (Item 3) [Figure 50-100-28] is
also needed. The centering block can be placed as NOTE: The bolt must be loose enough to allow the
shown and welded to the C-clamp if desired. torsion bushing (Item 2) [Figure 50-100-30] to
turn freely between the torsion bushing and
the steering linkage bar.
WARNING
W-2017-0286

503 of 888
Linkage Neutral (Adjusting) (Cont’d)
Figure 50-100-31
2
P16121
2 Using the remote start tool, turn the key (Item 1) [Figure
P-54614 50-100-33] to the run position.
Move the traction lock override switch (Item 2) [Figure

Loosen the two bolts (Item 1) holding the right centering 50-100-33] so the traction function is unlocked. (The
block. Move the right hand centering block (Item 2) traction lock override switch light will be ON.) On a

[Figure 50-100-31] until both pintle cams contact the standard loader the wedge brake will unlock.
centering block.
NOTE: When the engine is started, the wheels/tracks
NOTE: The left centering block is not adjustable. By may begin to move.
adjusting the right centering block the left
centering block will also become aligned NOTE: In loaders equipped with manual steering and
properly. hydraulic brake, the steering levers may have
to be moved during engine start-up to reduce
Figure 50-100-32 the amount of creep. This reduction in creep
will allow time for the engine to run and build
up hydraulic charge pressure, which will
3 release the hydraulic brake.
Using the remote start tool, turn the key (Item 1) [Figure
50-100-33] and start the engine and run at low idle.
1
Tighten bolts (Item 3) [Figure 50-100-32] to 35 - 40 ft.-lb.
(47,5 - 54,2 N•m).
2
NOTE: Check for slack between centering blocks and
pintle cams. If there is excessive slack repeat
above steps [Figure 50-100-31] & [Figure 50-
100-32].
P-48451
A modified locking grip C-Clamp and steering block

shown in [Figure 50-100-28] 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-
32] around both centering blocks.
Lock the C-Clamp in place.

504 of 888
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 50-100-34
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.
NOTE: This procedure is shown for neutral

P-48632 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 50-100-34].) Loosen the bolts enough to Turn the adjustment screw (Item 1) [Figure 50-100-35]
allow free movement between the pintle arm and the counterclockwise until forward creep is seen.
pintle base.
NOTE: If the bolts are too loose or too tight, the counterclockwise to a point between forward and reverse
neutral adjustment may be affected. where there is zero 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.

505 of 888
CONTROL PANEL (CONT’D)
Figure 50-100-36
1
2 2 1
P-48632
Torque the left pump pintle adjustment lock bolts (Item 1)

[Figure 50-100-36] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m).

Repeat the adjustment procedure for the right pump.
Torque the right pump pintle adjustment lock bolts (Item

2) [Figure 50-100-36] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m).
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-

100-36] at a time and apply Loctite® 242 or equivalent
thread locker to the bolt and re-install the bolt. Torque the
bolt to 35 - 40 ft.-lb. (47,5 - 54,2 N•m). 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 loader remote start tool.
NOTE: After the neutral adjustment is completed on

both pumps, the linkage travel adjustment
MUST be completed. (See Page 50-100-17.)

506 of 888
Linkage Travel (Adjusting)
NOTE: When the linkage travel adjustment procedure 2

is being done as part of the loader neutral
adjustment 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.
2
1
WARNING
P-48448
support device. Failure to use an approved lift arm Loosen the nut (Item 1) 3 to 4 turns, then loosen the bolt
support device can allow the lift arms or attachment (Item 2). The bolt (Item 2) [Figure 50-100-37] must be
to fall and cause injury or death. loosened enough to allow the torsion bushing to turn
W-2059-0598
freely between the steering bellcrank and the linkage bar.
Raise the lift arms and install an approved lift arm support Figure 50-100-38

1
WARNING
Put jackstands under the front axles and rear corners 2
W-2017-0286

1.) P-54613

Loosen the nut (Item 1) only until the tension is released
Pre-load tension in the torsion bushings must be from the torsion bushing (Item 2) [Figure 50-100-38].
removed before adjusting the steering linkage.
The bolt must be loose enough to allow the torsion
bushing (Item 2) [Figure 50-100-38] to turn freely
between the torsion bushing and the linkage bar.

507 of 888
Linkage Travel (Adjusting) (Cont’d)

2
Figure 50-100-39
1 3 4
P-51174
Move the right side steering lever forward and install a

P-37574 15/16 in. (24 mm) thick spacer (Item 1) between the
center plate (Item 2) and the mounting plate (Item 3)
[Figure 50-100-41].
Remove access plug from the top of the control panel.
This will allow the pintle arms to move freely while

Turn the control lever drift adjustment bolts (Item 1) adjusting the steering linkage for full forward travel
[Figure 50-100-39] (one on each control lever) out until it speed.
is flush with the bottom of the nut.
Remove the 3/8 in. (10 mm) thick spacer (Item 4) [Figure
Figure 50-100-40 50-100-41].
Figure 50-100-42
3 2
4
1
P-51173
1
P-51133
Move the right side steering lever to the rear and install a
3/8 in. (10 mm) thick spacer (Item 1) between the pintle
arm cam (Item 2) and the centering block (Item 3) Before adjusting the linkage, check that the base pintle
[Figure 50-100-40]. arm mounting bolt (Item 1) and both of the upper pintle
mount bolts (Item 2) [Figure 50-100-42] and tighten to 35
- 40 ft.-lb. (48 - 54 N•m) torque. There should be no play
between the pintle arm and the square pump shaft.
Also check that the cam mounting nuts or bolts (Item 4)

[Figure 50-100-40] are tight, 35 - 40 ft.-lb. (48 - 54 N•m)
torque.

508 of 888
Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-43
1 1 1
P-51175
Remove the spacer (Item 1) [Figure 50-100-45].

P-54609
Disconnect the remote start tool. (See REMOTE START
Loosen the two bolts and nuts (Item 1) [Figure 50-100-
43] on each steering linkage bar.
Figure 50-100-46

Figure 50-100-44
2
P-54613
P-51134
Tighten the two bolts (Item 1) and nuts (Item 2) to 35 - 40

ft.-lb. (47,5 - 54,2 N•m) [Figure 50-100-46].
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 50-100-44]. Use a locking plier, clamp the two
linkage bars together.
Installation: Tighten the nuts and bolts to 35 - 40 ft.-lb.

(47,5 - 54,2 N•m) torque.
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.

509 of 888
Linkage Travel (Adjusting) (Cont'd)
Figure 50-100-47 1
1
P-37574
Push the control lever to full stroke and turn drift

P-48448 adjustment bolt (Item 1) [Figure 50-100-48] in until it
touches the U-bolt holding the control lever.
Tighten the two bolts and nuts (Items 1 & 2) [Figure 50- Repeat steps on the other control lever.
100-47] to 35 - 40 ft.-lb. (47,5 - 54,2 N•m) torque at the

steering bell cranks. Drive the loader forward and check for drift.
The traditional benchmark for drift is less than 10 ft. of

“drift” in 100 ft. of travel distance.
If the drift is excessive to the left, turn the right

adjustment bolt (Item 1) [Figure 50-100-48] in.
If the drift is excessive to the right, turn the left

adjustment bolt in.
NOTE: When using the drift adjustment bolts, only

adjust one bolt for each test drive.
In addition, only move each bolt a maximum

of one turn for each test drive. This will help
prevent over-correction and excessive
reduction in travel speed.
Drift adjustment is for forward travel only.
Adjust the drift to an acceptable level.
Re-install the plug in the drift bolt access hole after

adjustment.

510 of 888
CONTROL PANEL (SJC)
Description
WARNING
The SJC control panel has two electronic handles that
control the steering, lift, and tilt functions. There is no
mechanical linkages connecting to the hydrostatic pumps
or the control valve.
The control panel is connected to the lower main frame
and wraps around and underneath the operator seat. W-2059-0598

WARNING Raise the operator cab. (See Raising on Page 10-30-2.)
Remove the engine speed control. (See Removal And

Put jackstands under the front axles and rear corners Installation on Page 70-20-1.)
Failure to use jackstands can allow the machine to Figure 50-101-1
W-2017-0286

DANGER
1
P-73451
P-90328
AVOID DEATH Remove the lift arm bypass control knob and rubber
• Disconnecting or loosening any hydraulic washer (Item 1) [Figure 50-101-1].
D-1009-0409

511 of 888
CONTROL PANEL (SJC) (CONT’D) Installation: Tighten the control panel mounting screws
to 15 - 20 ft.-lb. (20 - 27 N•m) torque.
Figure 50-101-4
Figure 50-101-2
2
1
1
1
1
4
3 3
P-73293
P-64319
Disconnect the right and left joystick wire harness

Remove the fuse cover mount screws (Item 1) [Figure connectors (Item 1) [Figure 50-101-4].
50-101-2].

Remove the control panel from the loader.
Installation: Tighten screws to 8 - 11 ft.-lb. (11 - 15 N•m)
torque.
Remove the fuse/relay cover (Item 2) [Figure 50-101-2].
Remove the fuse/relay shield mounting screws (Item 3)

[Figure 50-101-2].
Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27

N•m) torque.
Remove the fuse/relay shield (Item 4) [Figure 50-101-2]
Figure 50-101-3
1 1
P-64309
Remove the control panel mount screws (Item 1) [Figure

50-101-3] from the both sides of the control panel.

512 of 888
CONTROL HANDLE / LEVER Figure 50-110-2
Description
The control handles/levers are used to control the

forward and reverse travel.
The control handles/levers are mounted to the control

panel.
Lever Removal And Installation

1 1
Figure 50-110-1 2
N-22658
Remove the nuts from the two U-bolts (Item 1) [Figure

50-110-2] used to mount the control lever.
Remove the U-bolts from the control lever mount.
Remove the control lever (Item 2) [Figure 50-110-2] by

sliding the lever through the rubber boot (Item 1) [Figure
50-110-3] on the front of the control panel.
1
P-48462 Installation: Tighten the U-bolts so the lever can not be
moved either right or left when seated in the operator
seat. Be sure the control lever does not interfere with the
Disconnect the electrical connectors from the control operator cab when lowering or raising the cab.
lever [Figure 50-110-1].

513 of 888
CONTROL HANDLE / LEVER (CONT’D)
Boot Removal And Installation
Figure 50-110-3
N-18884
To replace the rubber boot (Item 1) [Figure 50-110-3] on

the control panel, remove the control lever (See above

procedure).
Drill out the four rivets (Item 2) [Figure 50-110-3] located

on the flange of the rubber boot and remove the old boot.
Install the new boot and reinstall the control lever.

514 of 888
CONTROL HANDLE / LEVER (ACS) Handle Sensor Removal And Installation

forward and reverse travel and the lift and tilt
functions.The lift and tilt functions can be controlled by
handle sensors (Item 1) [Figure 50-111-1] that are
located in the base of the control handle/levers.

panel.
1
Figure 50-111-1
P-21864
1 Loosen the nuts (Item 1) [Figure 50-111-2].
Installation: Tighten the u-bolts so the lever can not be


seat. Be sure the control lever does not interfere with the
operator cab when lowering or raising the cab.
Figure 50-111-3
P-21879
Handle Sensor (Item 1) [Figure 50-111-1]. 2
P-21837
Tilt the control handle (Item 1) [Figure 50-111-3] to the

center of the loader.
Lift the boot cover (Item 2) [Figure 50-111-3].

515 of 888
CONTROL HANDLE / LEVER (ACS) (CONT'D) Figure 50-111-6
Handle Sensor Removal And Installation (Cont'd)
Figure 50-111-4
1
P-21860
2
Remove the handle lock solenoid connector (Item1)
P-21836 [Figure 50-111-6] from the clip.
NOTE: Pry out with a small screw driver and push the
Disconnect the harness connector (Item 1) [Figure 50- connector down.
111-4] from the handle sensor connector.

Figure 50-111-7
Disconnect the harness connector (Item 2) [Figure 50-
111-4] from the handle lock solenoid connector. 1
Figure 50-111-5
5
2
1 4
1
P-21862
Remove one of the two mounting screws (Item 1) [Figure

P-21861 50-111-7] from the handle sensor.
Installation: Tighten screws to 32 - 38 in.-lb. (3,6 - 4,3

Remove the handle sensor connector (Item 1) [Figure N•m) torque.
50-111-5] from the clip.
While removing the mounting pin (Item 2) from the
NOTE: Pry out with a small screw driver and push the handle sensor, remove the one plastic spacer (Item 3),
connector down. the spring (Item 4) and washer (Item 5) [Figure 50-111-
7].

516 of 888
Handle Sensor Removal And Installation (Cont'd)

3
Figure 50-111-8 2
P-21878
1
Figure 50-111-11
P-21880
3
2
Remove one of the two mounting screws (Item 1) [Figure
50-111-8] from the handle sensor.

Installation: Tighten bolt to 32 - 38 in.-lb. (3,6 - 4,3 N•m)
torque.
Figure 50-111-9
4 1
3 8
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 50-111-10] & [Figure 50-
3 7 111-11] to assure proper return of the control handle to
neutral and minimize harness movement.
5 6
NOTE: Route wires (Item 2) [Figure 50-111-10] &
2
P-21882 [Figure 50-111-11] as shown away from stop
strap (Item 3) [Figure 50-111-10] & [Figure 50-
111-11] to avoid wire damage.
Remove the handle sensor (Item 1) [Figure 50-111-9]
from the handle assembly.
NOTE: The handle sensor (Item 1) [Figure 50-111-9]

can only be replaced as a complete assembly.
Check the spacer (Item 2) and screws (Item 3), mounting

pin (Item 4), spring (Item 5), washer (Item 6), bolt/nut
(Item 7), stop strap (Item 8) and replace as needed
[Figure 50-111-9].

517 of 888
Handle Removal And Installation
Figure 50-111-12
1
1 N-17384
Remove the rubber handle cover (Item 1) [Figure 50-

P-21879 111-14] from the handle.
Figure 50-111-15
Remove the handle sensor (Item 1) [Figure 50-111-12].
(See Handle Sensor Removal And Installation on Page

50-111-1.)
Figure 50-111-13 1
1 2 2
N-17385
Using a small screwdriver, hold the handle spacer (Item

1) and remove the allen head screws (Item 2) [Figure
P16534 50-111-15] from the handle assembly.
Installation: Tighten the allen head screws to 35 in.-lb.

Remove the switch handle (Item 1) [Figure 50-111-13]. (4 N•m) torque.
(See Switch Handle Removal on Page 60-130-4.)

518 of 888
CONTROL HANDLE / LEVER (ACS) (CONT'D) Lever Removal And Installation
Handle Disassembly And Assembly Figure 50-111-18
Figure 50-111-16
1
1
1
2
1 N-22667
N-17394
Disconnect the electrical connectors (Item 1) [Figure 50-
111-18] from the control lever switch handle.
Remove the handle sleeve (Item 1) and bushings (Item
2) from the handle [Figure 50-111-16]. Remove the electrical connectors from the control lever

switch handle. (See Handle Sensor Connector
Check all parts for wear and replace as needed. Disassembly And Assembly on Page 60-130-3.)
Figure 50-111-17
N-22796
Check the mounting bolt (Item 1) [Figure 50-111-17] that

connects the handle to the handle sensor for wear,
replace as needed.

519 of 888
Lever Removal And Installation (Cont'd)
Figure 50-111-19
2
1
P13734
2
The control lever (Item 1) [Figure 50-111-21] must be

N-22658 replaced as a complete unit.
The connector clip (Item 2) [Figure 50-111-21] can be

Figure 50-111-20 replaced separately from the control lever.

18.25”
B-16618
Loosen the two u-clamps (Item 1) [Figure 50-111-19]

nuts.
Installation: Tighten the u-bolts so the lever can not be

seat. Control lever end (Item 2) [Figure 50-111-19]
should be flush with bellcrank. Be sure the control lever
does not interfere with the operator cab when lowering or
raising the cab. The distance between handles should be
18.25 in. [Figure 50-111-20].
Remove the control lever from the cross shaft and control
panel.

520 of 888
CONTROL HANDLE / LEVER (ACS) (CONT'D)
Boot Removal And Installation
Figure 50-111-22
N-22659
To replace the rubber boot (Item 1) [Figure 50-111-22]

on the control panel, remove the control lever. (See Lever

Drill out the four rivets (Item 2) [Figure 50-111-22]

located on the flange of the rubber boot and remove the
old boot.
Install the new boot and reinstall the control lever. (See
Lever Removal And Installation on Page 50-111-5.)

521 of 888

522 of 888
CONTROL HANDLE / LEVER (SJC) Figure 50-112-2
Description

forward and reverse travel and the lift and tilt functions.

panel.
1
Joystick Testing
Figure 50-112-1
P-64298
At the back side of the control panel, locate the left

joystick wire connector (Item 1) [Figure 50-112-2].
Figure 50-112-3

1
P-28301
The tools listed will be needed to do the following 3

procedure:
2
MEL1608-Joystick Test Harness [Figure 50-112-1]
MEL1563 or 6689779-Remote Start Tool
Multimeter
P-28312
Disconnect the joystick harness connector (Item 1) from
Raise the operator cab. (See Raising on Page 10-30-2.) the loader wiring harness (Item 2) [Figure 50-112-3].
Connect the remote start tool to the loader. (See Install the test harness (Item 3) [Figure 50-112-3]
REMOTE START TOOL KIT-MEL1563 on Page 10-60- between the two connectors.
1.)
Turn the remote start key to ON position without starting
the loader.
Check the voltage between pin 3 and pin 5 on the joystick

test harness (Item 3) [Figure 50-112-3].
The voltage should be between 2.45 and 2.55 volts.

523 of 888
CONTROL HANDLE / LEVER (SJC) (CONT'D) Joystick Removal And Installation
Joystick Testing (Cont’d) When replacing joystick assemblies, they are available
as a complete assembly with the boot and lever already
Figure 50-112-4 attached. This procedure is shown so the electrical
connections can be checked at the bottom of the joystick,
if suspected to be loose or disconnected.

1
Figure 50-112-5
P-64328
1
Repeat the procedure at the right joystick wiring harness
connector (Item 1) [Figure 50-112-4]. (If needed.)

P-26220A
Roll the joystick rubber boot (Item 1) [Figure 50-112-5]

down from the joystick handle.
Figure 50-112-6
P-26221
Remove the two inside joystick mount bolts (Item 1)

[Figure 50-112-6].

524 of 888
CONTROL HANDLE / LEVER (SJC) (CONT'D) Figure 50-112-9
Joystick Removal And Installation (Cont'd)
Figure 50-112-7 1
P-26224
Disconnect the electrical harness (Item 1) [Figure 50-

P-26222 112-9] from the joystick.
Remove the joystick from the loader.

Remove the two outside joystick mount screws (Item 1)
[Figure 50-112-7].

Figure 50-112-8
P-26223A
Remove the joystick from the rubber boot [Figure 50-

112-8].

525 of 888
Joystick Removal And Installation (Cont’d)
Figure 50-112-10
1 P-73240
Disconnect the joystick connector (Item 1) [Figure 50-

P-73247 112-12] from the harness connector.
Lift the rubber boot (Item 1) [Figure 50-112-10].

Figure 50-112-11
1
1
P-73248
Remove the four screws (Item 1) [Figure 50-112-11] to

lift the joystick control from the base.

526 of 888
Joystick Removal And Installation (Cont’d)
Figure 50-112-13
1
P-64308
Remove the control lever from the loader [Figure 50-

112-15].

P-64328
Disconnect the joystick wiring harness connectors (Item

1) on both the right and left hand joysticks [Figure 50-
112-13].
Figure 50-112-14
P-64303
Remove the two control lever mounting bolts (Item 1)

[Figure 50-112-14].
The mounting bolts are secured with lock-nuts on the

back of the control panel. Once removed, they need to be
replaced with new.

527 of 888
CONTROL HANDLE / LEVER (SJC) (CONT'D) Joystick Mount Removal And Installation
Joystick Removal And Installation (Cont’d) Figure 50-112-18
Figure 50-112-16
1
P-64328
P-73245
Disconnect the joystick wiring harness connectors (Item
1) on both the right and left hand joysticks [Figure 50-
Disconnect both of the electrical harness connectors 112-18].
from the loader harness (Item 1) [Figure 50-112-16].

Figure 50-112-19
Figure 50-112-17
P-64303
P-73246
Remove the two control lever mounting bolts (Item 1)

Remove the bolts (Item 1) [Figure 50-112-17] to remove [Figure 50-112-14].
the control lever from the loader.
The mounting bolts are secured with lock-nuts on the
back of the control panel. Once removed, they need to be
replaced with new.

528 of 888
CONTROL HANDLE / LEVER (SJC) (CONT'D)
Joystick Mount Removal And Installation (Cont’d)
Figure 50-112-20
P-76992
Remove the control lever from the loader [Figure 50-

112-15].

Remove the bolts (Item 1) [Figure 50-112-20] to remove
the control lever from the loader.

529 of 888

530 of 888
ACCESS PANEL (INSIDE) Removal And Installation (Right)
Removal And Installation (Left) Figure 50-120-3
Figure 50-120-1
2 1
1
2
P-66819
P-66818
Remove the top mounting screw (Item 1), and loosen the
two bottom mounting screws (Item 2) [Figure 50-120-3]
Remove the top mounting screw (Item 1), and loosen the from the front access panel.
two bottom mounting screws (Item 2) [Figure 50-120-1]

from the front access panel. Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
N•m) torque. Remove the front access panel from the loader.
Remove the front access panel from the loader. Figure 50-120-4
Figure 50-120-2
2
1 1
1
1
1 P-66821
1
P-66820
Remove the seven mount screws (Item 1) [Figure 50-
120-4] from the rear access panel.
120-2] from the rear access panel. Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
N•m) torque. Remove the throttle lever assembly (Item 2) [Figure 50-
120-4]from the access panel.
Remove the rear access panel from behind the steering
panel, remove the panel from the loader. Remove the rear access panel from behind the steering
panel, remove the panel from the loader.

531 of 888

532 of 888
ACCESS PANEL (INSIDE) (SJC) Figure 50-121-2
Removal And Installation (Left)
device. (See Installing on Page 10-20-1.) 1 1
Figure 50-121-1
1 P-64310
2

121-2]
Installation: Tighten the screws to 15 - 20 ft.-lb. (20 - 27

N•m) torque.

P-64299 Move the lever assembly a slight amount toward the
center of the loader, to allow clearance for the panel to be
removed.
Remove the top mounting screw (Item 1) and loosen the
two bottom screws (Item 2) [Figure 50-121-1]. Remove the inside rear access panel from the loader.

N•m) torque.
Remove the inside front access panel from the loader.

533 of 888
ACCESS PANEL (INSIDE) (SJC) (CONT’D) Figure 50-121-5
Removal And Installation (Right)

2
1
Figure 50-121-3
P-64327
Loosen the two bottom mount screws (Item 1) [Figure

50-121-5] from the front inside access panel.
Remove the top mount screw (Item 2) [Figure 50-121-5]

from the front inside access panel.

P-64300 Installation: Tighten the screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
Remove the two mounting screws (Item 1) [Figure 50- Remove the inside front access panel from the loader.
121-3], from the foot throttle assembly.

N•m) torque.
Figure 50-121-4
P-64313
Disconnect the foot operated speed control linkage (Item

1) [Figure 50-121-4] from the hand operated speed
control lever arm.
Remove the foot operated speed control assembly from

the loader.

534 of 888
Removal And Installation (Right) (Cont’d)
Figure 50-121-6
1 2
P-34553A
Lift the speed control pin (Item 1) from the notch (Item 2)
P-34548 [Figure 50-121-8] in speed control rod.
Figure 50-121-9
Remove the two mount screws (Item 1) [Figure 50-121-
6] from the hand operated speed control lever.

N•m) torque.
Figure 50-121-7
P-34549
At the bottom right side of the control panel, remove the

keeper and pin (Item 1) [Figure 50-121-9] that connects
the speed control linkage arm to the speed control rod.
P-34551
Lift slightly on the speed control handle and move it

toward the front of the loader [Figure 50-121-7].

535 of 888
Removal And Installation (Right) (Cont’d)
Figure 50-121-10
1
1
1
2
P-64309
Remove the five mount screws (Item 1) [Figure 50-121-

P-34550 11] from the access panel.

Remove the mount bolt and nut (Item 1) [Figure 50-121- N•m) torque.
10] from the speed control linkage arm.

Move the lever assembly a slight amount toward the
Remove the speed control linkage arm (Item 2) [Figure center of the loader, to allow clearance for the panel to be
50-121-10] from the access panel. removed.
Remove the inside rear panel from the loader.

536 of 888
WINDOW (REAR) Installation (Split Molding)
Removal Clean the area before installing the rubber molding.
Figure 50-130-2
WARNING
Wear safety glasses to prevent eye injury when any
• Tools are being used. 1
W-2019-0907
Figure 50-130-1
P16014
Install the rubber molding (Item 1) [Figure 50-130-2]

around the edge of the rear opening in the operator cab.
1

If replacing the rubber molding (Item 1) [Figure 50-130-
2] cut off the excess molding.
Figure 50-130-3
P-64994
Pull on the tag (Item 1) [Figure 50-130-1] on the rear

window to remove the rubber cord.
1
Using gloves, push the rear window out the rear of the
operator cab.
NOTE: If rear window is broken, remove all glass

fragments from the rubber molding before P16015A
installing a new window.

Apply liquid soap on the rubber cord to make installation
easier. Install the rubber cord (Item 1) [Figure 50-130-3]
into the molding on the inside of the operator cab.
Install the safety tag in the top center of the cord.

537 of 888
WINDOW (REAR) (CONT’D) Figure 50-130-6
Installation (Split Molding) (Cont’d)
Figure 50-130-4
1 1
P16013
Use the plastic stick (Item 1) [Figure 50-130-6] to

P-64997 position the locking tab into the groove to secure the
window in the molding.
Apply liquid soap in the rubber molding (Item 1) [Figure Tapping the window corners will help seat the window in
50-130-4] to make installation easier. the molding.

Install the window from the outside of the operator cab.
Install a lower corner of the rear window into the corner of

the molding. [Figure 50-130-4].
Align the other lower corner of the window in the molding.
Work the window downward until the window is fully

seated in the lower portion of the molding.
Figure 50-130-5
P-64998
Use a plastic stick (Item 1) [Figure 50-130-5] under the

molding lip to guide the window into the molding groove.

538 of 888
WINDOW (REAR) (CONT’D) Figure 50-130-9
Installation (Continuous Molding)
Clean the area before installing the rear window

assembly.
Figure 50-130-7
1
1
P-64997
Install the rear window assembly from the outside of the

operator cab into the window frame.
Install a lower corner of the rear window assembly into

P-85229 the corner of the window frame (Item 1) [Figure 50-130-
9].

Install the rubber molding (Item 1) [Figure 50-130-7] Work the window assembly downward until the window is
around the edge of the rear window. fully seated in the lower portion of the window frame.
Figure 50-130-8
WARNING
2
Wear safety glasses to prevent eye injury when any
1 of the following conditions exist:
W-2019-0907
P-85228
Apply liquid soap to the rubber molding (Item 1) [Figure

50-130-8] to make installation easier.
NOTE: Install the window assembly with the narrow

edge (Item 2) [Figure 50-130-8] toward the
inside of the loader.

539 of 888
WINDOW (REAR) (CONT’D)
Installation (Continuous Molding) (Cont’d)
Figure 50-130-10
P-85230
Apply light pressure to the outside of the window

assembly holding it tight up against the window frame.

Use a multipurpose tool (Item 1) [Figure 50-130-10]
under the molding lip to guide the window assembly into
the window frame.
NOTE: Tapping the window with a rubber hammer

will help seat the window assembly in the
window frame.
Figure 50-130-11
P16015A
Apply liquid soap on the rubber cord to make installation

easier. Install the rubber cord (Item 1) [Figure 50-130-11]
with the safety tag into the molding on the inside of the
operator cab.
NOTE: Verify the safety tag is located in the top

center of the window.

540 of 888
WINDOW (TOP)
Figure 50-131-1
1 1
P-24378
Position the window in the recess area.

Install the bolts (Item 1) [Figure 50-131-1] through the
window grommets, the nylon bushings and through the
cab holes.
Figure 50-131-2
1
1
1
1
N-20950
From inside the operator cab, install and tighten the

knobs (Item 1) [Figure 50-131-2] on the window bolts.

541 of 888

542 of 888
WINDOW (SIDE) Figure 50-132-3
Figure 50-132-1
2
N-20814
NOTE: [Figure 50-132-3] is shown with the washer

P-66024 and knob removed to illustrate the direction of
movement.
Release the latch (Item 1) [Figure 50-132-1] and slide Move the window slide rail using the two thumb pads
the front window back towards the rear of the operator (Item 2) [Figure 50-132-2] and [Figure 50-132-3]

cab. towards the rear of the operator cab and then down
towards the bottom of the operator cab.
Figure 50-132-2
NOTE: The top of the window should come out of the
top slide rail at this time. Make sure the
window is secure and does not fall. Make sure
the slide rails are in alignment and the window
is positioned in the top track during
1 1 installation.
Remove the front side window from the operator cab.
2 2
P-66019
From inside the operator cab, loosen the knobs (Item 1)

[Figure 50-132-2] and [Figure 50-132-3] on the window
slide rail bolts.

543 of 888
WINDOW (SIDE) (CONT’D)
Figure 50-132-4
2
1
P-66021
Installation: When installing the window make sure the

slide rail (Item 1) adjoins the front stationary slide rail

(Item 2) [Figure 50-132-4].
Figure 50-132-5
P-66020
The rear side window sets in a recessed groove.
NOTE: The window should be secured to prevent

damage when the bolt (Item 1) [Figure 50-132-
5] is loosened.
Loosen the bolt (Item 1) [Figure 50-132-5] on the rear

side window.
Remove the rear side window.

544 of 888
WINDOW (CAB DOOR) Figure 50-133-3
Removal (Standard Window)
Figure 50-133-1
3
2
1
1 1
1 S0363
Push the window out at any corner of the window (Item 1)

P-66051 [Figure 50-133-3].
NOTE: The window may fall when pushing on the

Remove the wiper arm assembly (Item 1) [Figure 50- corners. Have a second technician assist you
133-1]. during the removal of the window.

Remove the two screws (Item 2) and the nut (Item 3)
[Figure 50-133-1].
Secure the wiper motor inside the cab.
Figure 50-133-2
N-20171
Pull the plastic loop (Item 1) [Figure 50-133-2] at the top

of the window to remove the rubber cord.

545 of 888
WINDOW (CAB DOOR) (CONT’D) Figure 50-133-6
Installation (Standard Window)
Clean the area before installing the rubber molding.
Figure 50-133-4
1
P-66059
Apply liquid soap in the rubber molding to make

installation easier.
P-66058 Install the window from the outside of the door frame.
Install a lower corner of the rear window (Item 1) [Figure

Install the rubber molding (Item 1) [Figure 50-133-4] 50-133-6] into the corner of the molding.
around the edge of the front door frame starting at the
bottom of the door frame. Align the other lower corner of the window in the molding.
If replacing the rubber molding (Item 1) [Figure 50-133- Work the window downward until the window is fully
4] cut off the excess molding. seated in the lower portion of the molding.
Figure 50-133-5 Figure 50-133-7
1
1
P-66651 P-66050
Apply liquid soap on the rubber cord to make installation Use a plastic stick (Item 1) [Figure 50-133-7] under the
easier. Install the rubber cord (Item 1) [Figure 50-133-5] molding lip to guide the window into the molding groove.
into the molding on the inside of the operator cab.

546 of 888
WINDOW (CAB DOOR) (CONT’D)
Installation (Standard Window) (Cont’d)
Figure 50-133-8
P-66049A
Use the plastic stick (Item 1) [Figure 50-133-8] to

position the locking tab into the groove to secure the

window in the molding.
Tapping the window corners will help seat the window in

the molding.
Figure 50-133-9
P-66051
Install the wiper motor (Item 1) and wiper arm assembly

(Item 2) [Figure 50-133-9].

547 of 888
WINDOW (FRONT DOOR) (CONT’D) Figure 50-133-10
Removal And Installation (Special Applications

Window)
1
Replace the Lexan glazing under the following
conditions:
• When the glazing is four years old;

• When the glazing becomes yellow or hazed;
• Is scratched on either side with scratches that can be
felt with the fingernail;
• Has cracks coming from the edges or mounting holes.
or fine cracks on the surface area;
P-66101
• Has contacted any fluids that have caused
cloudiness.
Remove window from loader.
NOTE: The Special Applications window is held on

by the brackets only, it does not sit in the
rubber molding. During Removal the window
may fall as the mounting bolts are loosened.

Remove the five mounting brackets and bolts (Item 1)
[Figure 50-133-10].

548 of 888
CAB DOOR Removal And Installation
The standard cab door is available as an option or dealer

installed kit. The Special Application Kit Door or Forestry
Door kit are available for use with certain attachments. 3
2
P-76520
Open the cab door.
Remove the gas spring (Item 1) [Figure 50-140-1] from

the threshold.
Disconnect the electrical harnesses (Items 2 and 3)

[Figure 50-140-1].
Disconnect the washer bottle hose (Item 4) [Figure 50-

140-1].
Figure 50-140-2
P-76526
Lift the door (Item 1) [Figure 50-140-2] off the hinges.

549 of 888
CAB DOOR (CONT’D) Aligning
Figure 50-140-3 WRONG WRONG
2 1
P-76523A P-76524A
Figure 50-140-5
CORRECT CORRECT

1
2
1
1
Remove the four bolts and nuts (Item 2) [Figure 50-140-
3] from the cab. P-76522A P-76525A
Remove the hinges (Item 1) [Figure 50-140-3] from the

cab. When the striker or latch is NOT adjusted properly there
will be a gap (Item 1) [Figure 50-140-4] between the
Installation: Install the hinges (Item 1) on the cab and door and the cab or the striker and the latch.
use the bolts and nuts (Item 2) [Figure 50-140-3] to
secure the hinges. Tighten to 7 - 7.9 ft.-lb. (9,6 - 10,7 If adjustment is needed. (See Adjusting on Page 50-140-
N•m) torque. 3.)
When the striker or latch is adjusted properly there will be

no gap (Item 1) [Figure 50-140-5] between the door and
the cab or the striker and the latch.
After verifying alignment check for proper operation. (See

Checking Operation on Page 50-140-3.)

550 of 888
CAB DOOR (CONT’D) Checking Operation
Adjusting Figure 50-140-8
Figure 50-140-6
1 P-76683
P-76521
Sit in operator’s seat. Turn key ON. (Standard Key
Panel), press RUN / ENTER button (Deluxe
Loosen the two bolts (Item 1) [Figure 50-140-6] and Instrumentation Panel), lower seat bar and close the
adjust the latch as needed. door. Press the PRESS TO OPERATE LOADER button
(Item 1) [Figure 50-140-8].

NOTE: For the initial adjustment, position the latch
towards the bottom of the door. Open the door. The LIFT & TILT VALVE light (Item 2)
[Figure 50-140-8] will flash, an audible tone will sound,
Figure 50-140-7 and the message [door] will appear in the display.
Close the door and the LIFT & TILT VALVE light (Item 2)
[Figure 50-140-8] will go out and the display will return to
machine hours.
P-76516
Loosen the striker and adjust as needed (Item 1) [Figure

50-140-7].
NOTE: For the initial adjustment, position the striker

towards the front of the machine.
After adjusting the striker and latch recheck the

alignment of the door sensor. (See Aligning on Page 50-
140-2.)

551 of 888

552 of 888
ELECTRICAL SYSTEM & ANALYSIS
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1
Alternator Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-3
Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1 SAFETY &
Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1 MAINTENANCE
Charging System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
High Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-4
Low Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-5
BACK-UP ALARM SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1 DRIVE

Adjusting Switch Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-2 SYSTEM
Alarm Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-1
Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-5
Troubleshooting (Joystick) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-210-4
Troubleshooting (Standard And ACS) . . . . . . . . . . . . . . . . . . . . . . 60-210-3
ELECTRICAL

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 SYSTEM &
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 ANALYSIS
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . 60-20-2
BOBCAT INTERLOCK CONTROL SYSTEM (BICS) . . . . . . . . . . . . . 60-100-1 SERVICE

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED -
Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting Deactivation Of Lift And Tilt Functions (ACS And SJC) 60-100-2 SPECIFICATIONS
Inspecting The BICS Controller (Engine STOPPED - Key ON). . . 60-100-2
Inspecting The Lift Arm Bypass Control. . . . . . . . . . . . . . . . . . . . . 60-100-2
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . 60-100-2
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . 60-100-2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
BOBCAT CONTROLLER (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1

Connector And Wire Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-71-3
BOBCAT CONTROLLER (GATEWAY AND AUXILIARY) . . . . . . . . . . . 60-70-1

Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-8

553 of 888
ELECTRICAL SYSTEM (CONT’D)
BOBCAT CONTROLLER (SJC) (DRIVE) . . . . . . . . . . . . . . . . . . . . . .60-72-1

Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-72-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-72-1
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-72-4
CALIBRATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Actuator Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-1
Hydrostatic Pump Calibration (SJC) . . . . . . . . . . . . . . . . . . . . . . 60-160-7
Lift And Tilt Calibration (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-3
Lift And Tilt Calibration (SJC). . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-160-5
CONTROL PANEL SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-180-1

Attachment Control Information (Deluxe Instrumentation Panel). 60-180-2
Right Panel Setup (Deluxe Instrumentation Panel) . . . . . . . . . . . 60-180-1
CONTROL SYSTEM (ACS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Actuator Connector Disassembly And Assembly. . . . . . . . . . . . .60-130-9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Foot Lock Solenoid Removal And Installation . . . . . . . . . . . . . .60-130-12
Foot Sensor Disassembly And Assembly . . . . . . . . . . . . . . . . . 60-130-11
Handle Lock Solenoid Disassembly And Assembly. . . . . . . . . .60-130-10
Handle Lock Solenoid Removal And Installation . . . . . . . . . . . .60-130-10
Handle Sensor Connector Disassembly And Assembly . . . . . . . 60-130-3
Switch Handle Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-6
Switch Handle Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-1

Viewing Service Codes (Deluxe Instrumentation Panel) . . . . . . . .60-90-1
Viewing Service Codes (Standard Key Panel) . . . . . . . . . . . . . . . .60-90-1
Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-2
ELECTRICAL / HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . .60-140-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
ELECTRICAL / HYDRAULIC CONTROLS (SJC) . . . . . . . . . . . . . . . 60-141-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-141-1

554 of 888
ELECTRICAL SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . 60-10-1

Deluxe Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-7
Fuse And Relay Location / Identification . . . . . . . . . . . . . . . . . . . . 60-10-9
Glossary Of Electrical Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Mainframe Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-6
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-10
Standard Cab Harness Connectors . . . . . . . . . . . . . . . . . . . . . . . . 60-10-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-8
FLYWHEEL RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1

Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-170-1
INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Alarm Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-10
Deluxe Instrumentation Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Front Panel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 60-50-6

Key Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 60-50-9
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Removal And Installation (Left And Right) . . . . . . . . . . . . . . . . . . . 60-50-7
Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Standard Key Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-3
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Cab Light Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
MAINTENANCE CLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-1
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-5
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-200-2
PASSWORD SETUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1

Changing The User Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2
Password Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-1
Password Lockout Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-190-2

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SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Bobcat Interlock Control System (BICS) Circuit Test . . . . . . . . . . 60-110-5
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-2
SERVICE PC (LAPTOP COMPUTER) . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Connecting Remote Start Tool . . . . . . . . . . . . . . . . . . . . . . . . . . .60-150-1
Connecting Remote Start Tool (Service Tool) . . . . . . . . . . . . . . . 60-150-1
SPEED SENSOR (SJC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-3
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-2

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-1
STEERING DRIFT COMPENSATION. . . . . . . . . . . . . . . . . . . . . . . . 60-161-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-161-1
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-120-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
Inspecting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-3

SPECIFIED.

MAY VARY.

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WIRING SCHEMATIC 7100
TO MAINFRAME
C TO OPTIONS
POWER BOB-TACH
SOLENOID
TO MAINFRAM
NC NO
ADDITIONAL
OPTIONS
C606
2650 A 7000 A A HARNESS
87A 87
F 9.8 ohms POWER / GROUND
30
A B C
C220B
D B B (ACCESSORY POWER) C B A
C103
6600 G 2760 TO BRAKE LIGHT SOURCE FOR KITS
C601
1730 6600
HARNESS 7151691 C489A C220A
BACK-UP E C C489B
T190 (S/N 531660001 AND ABOVE) 6410
C474
ALARM
C607
A B 7010 B B POWER BOB-TACH TO SJC HARNESS 4210 2730 A B C B A A B
A
6310
85
86
SOLENOID
(S/N 531760001 AND ABOVE) 6510 D E 2770 A A
2230
1520
6700
H
1500
2200
6200
1510
2210
9.8 ohms
2600 B BRAKE LIGHT HARNESS 7151696 TO TO
(PRINTED MAY 2008)
C407
6320 A A 6320
(FOR SJC MODELS ONLY) MAINFRAM TAILGATE
V-1235 POWER BOB-TACH HARNESS - TO HARNESS HARNESS
2620
TAILGATE
2610
6610
6320
6620
6410
6330
2640
6510
6700
7112290 HARNESS 7152344 OPEN F HARNESS BRAKE LIGHT
HARNESS 7151691
C103A C103B
Printable Version Click Here HARNESS (For
2670
6340
All Models A B C D E F G H A B C D E F G H
OPEN E C407A
F E D C B A 2630 6210 Except SJC)
E F C A B D D A
C270
2320 TO REAR A
OPEN
OPEN
OPEN
6530
6000
2000
7100
6210
6110
6010
6000
2010
7100
6230
6130
6320
C602 C603 LEFT WORK RIGHT WORK 7200 C TAIL LIGHTS A C230A
B A
E F C A B D F E D C B A 7260 B A
C800
B A
7240 A
6430
6500
(TO "D" PIN)
(TO "B" PIN)

RIGHT HEAD LIGHT HARNESS 7152108
C410
C431
DELUXE TAILGATE 4640 2 2 6810 6800 A F OPEN OPEN F A 6420
HARNESS - 7139785 LIGHT 6 6 2130 2130 B E OPEN 7200 E B 2110
C260
C170
SIDE MARKER 5 5 6830 6830 C D 7270 7250 D C 6220
STOP TURN TAIL STOP TAIL TURN REGISTRATION
LEFT TAILLIGHT RIGHT TAILLIGHT LAMP BLINKER 4 4 6820 6820 D C 7230 7220 C D 6440
3 3 OPEN OPEN E B 2310 2300 B E 6510 6530
ADVANCED HAND CONTROL 1 1 OPEN OPEN F A 7210 7210 A F OPEN

To Ground
TO MAINFRAME FLOAT HARNESS - 6727328 A 2 6810 6800 A A 7210 7210 A A 6330
7100 C LIGHT B 6 2130 2130 B B 2310 2300 B B 2120
C260
C180
2650 F SIDE MARKER C 5 6830 6830 C C 7230 7220 C C 6120
C103
G BLINKER D 4 6820 6820 D D 7270 7250 D D 6340 6320
BACK-UP E E 3 OPEN OPEN E E OPEN 7200 E E 6520

STROBE OR ALARM 6310 A F 1 OPEN OPEN F F OPEN OPEN F F OPEN
BEACON
D HARNESS 7152108
6310
2030
6410
2020
LEFT HEAD LIGHT
6200 H
7240 A
2600 B
2 1 SSL 7-PIN 7260 B
CAN CONNECTOR TO REAR 87A 87 86 87A 87 86
C270
C609 7200 C A B
TAIL LIGHTS
HARNESS 7153090
2620
KEY "RUN" D 9800 D 2320 D
2610
6320
6330
2640
2 1 TO
STROBE/BEACON UNSW POWER 2 1160 F OPEN E
6340
2670
HARNESS 7152344 30 85 30 85
TO OPTIONS CAN SHIELD C 9700 C OPEN F
2630 6210 To Mainframe
6700 E C668 OR C670 1 2 2 1 SW POWER 1 1710 E GROUNDS
Harness
2775
6300
6400
A C604 C605 CAN LOW B 9600 A 2010
TO OPTIONS LEFT WORK RIGHT WORK
(4 WAY FLASHER) C 1 2 2 1 CAN HIGH A 9500 B
1010
1400
1020
1410
2000 2020
2 2785 2780 D GROUND 3 2700 G 2030 REGISTRATION
C669
7-PIN
1 6440 F Connector
on Loader C666
ATTACHMENT
C426
3
EXTERIOR CAB HARNESS -

6540 B
STANDARD TAILGATE
HARNESS - 7109403
Boom
CONTROL HARNESS - 6718426

CONNECTOR

ROAD LIGHTS To Starter "B" Terminal
A B A B
LEFT TAILLIGHT RIGHT TAILLIGHT

(EUROPE ONLY) Left Marker Fuse 10A Right Marker Fuse 10A
6718872 FRONT WIPER
1010
HARNESS 7141369
M BOTTLE AND TANK
FRONT WIPER
SSL 7-PIN
C426 To Mainframe
MOTOR
C426 To Mainframe
Harness V SSL 7-PIN
CAN CONNECTOR D F C E A B G Harness
M CAN CONNECTOR D F C E A B G
C622
7200 or YEL
7150 or DGN
9800
1160
9700
1710
9500
9600
2710
2765 or BRN
9800
1160
9700
1710
9500
9600
2710
L X
KEY "RUN" D 9800 PUR C705 J1 - 8-PIN

KEY "RUN" D 9800 PUR C705 J1 - 8-PIN
UNSW POWER 2 1160 RED/WHT 2720 H GROUND TO OPTIONS F H
2745
UNSW POWER 1160 RED/WHT 2720 GROUND
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD (DELUXE ACCESSORY)
CAN SHIELD C 9710 PUR 9710 F CAN SHIELD
SW POWER 1 1730 RNG 1720 B SW POWER ACD 3 7310
SW POWER E 1730 RNG 9 1720 B SW POWER ACD
Machine
PARK
HIGH
CAN LOW B 9620 PUR 9610 E CAN LOW 2 2735 2755 B B Machine
C610
9
C667
Connector CAN LOW B 9620 PUR 9610 E CAN LOW
CAN HIGH A 9520 PUR 9510 D CAN HIGH 5 7160 C C Connector to
DOOR SENSOR CAN HIGH A 9520 PUR 14 9510 D CAN HIGH
1 7210 A A Engine
GROUND 3 2730 BLK C OPEN 13
GROUND G 2730 BLK C OPEN Compartment
7-PIN A 6 7180 2 7180
OPEN 2 2 2
C666 ATTACHMENT
CONNECTOR G OPEN 4 4710 1 1 4720 1 1
Connector
on Loader C666 ATTACHMENT
7-PIN A OPEN
CONNECTOR G OPEN
J Boom
BOOM-MOUNTED J
N
SW POWER K 1740
ACD CONNECTORS WIPER HARNESS DOOR HARNESS N
BOOM-MOUNTED
ACD CONNECTORS
SW POWER K 1740
GROUND B 2740 C703 J2 - 10-PIN BLACK 7117322 7104465 GROUND B 2740 C703 J2 - 10-PIN BLACK
E OUTPUT E 5100 5100 C E OUTPUT
TO E OUTPUT E 5100 5100 C E OUTPUT
F OUTPUT F 5350 5350 H F OUTPUT
MAINFRAME F OUTPUT F 5350 5350 H F OUTPUT
C404
G OUTPUT G 5400 5400 J G OUTPUT B G OUTPUT G 5400 5400 J G OUTPUT
H OUTPUT H 5050 5050 B H OUTPUT ACD
7100 A H OUTPUT H 5050 5050 B H OUTPUT ACD
Output
C OUTPUT C 5300 5300 G C OUTPUT Output
Connector C OUTPUT C 5300 5300 G C OUTPUT
D OUTPUT D 5150 5150 D D OUTPUT BACK-UP ALARM Connector to
SWITCHES
D OUTPUT D 5150 5150 D D OUTPUT
Engine
A OUTPUT A 5250 5250 F A OUTPUT
7110 TO A OUTPUT A 5250 5250 F A OUTPUT Compartment
M OUTPUT M 5200 5200 E B OUTPUT MAINFRAME M OUTPUT M 5200 5200 E B OUTPUT
ID (K TO L) L 5910 5000 A J OUTPUT
C402
1720 1730 A ID (K TO L) L 5910 5000 A J OUTPUT
ID (K TO P) P 5510 5450 K K OUTPUT 12
2720 B ID (K TO P) P 5510 5450 K K OUTPUT
C506 14-PIN BACK-UP ALARM C506

11
ATTACHMENT C704 J3 - 10-PIN GRAY
ADDITIONAL POWER
14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
CONNECTOR
5900 J ID #1 SWITCHES HARNESS - CONNECTOR Connector
on Loader
CONNECTOR
5900 J ID #1
C491
5500 A ID #2 B
B ID #3
7107544 1740 A
Boom 5500 A ID #2
ACD B ID #3
ACD
C ID #4 Input C ID #4 Input
D ID #0 Connector Connector to
D ID #0
E OPEN Engine
C433 DELUXE ATTACHMENT E OPEN
C433
F OPEN A RNG A Compartment
DOME LIGHT F OPEN
G OPEN C
B
LGN
BLK
C
B
TO OPTIONS SWITCH CONTROL HARNESS - G OPEN
H OPEN
C608
A
DELUXE ATTACHMENT CONTROL HARNESS - 6729380 K OPEN - + B
RED
BLK
6732730 H OPEN
K OPEN
Rev. none
DOME LIGHT
ADVANCED HAND CONTROL
JUMPER HARNESS - 6728742
TO ATTACHMENT
TO ATTACHMENT
B
B
J
J
N TO HORN
N CONNECTOR
P
C412
P LEFT RIGHT 2750 B
M TO OLDER
MODEL ATTACHMENTS M TO OLDER FLASHER FLASHER 1730 A
A HORN RELAY
LIGHT LIGHT
C506
MODEL ATTACHMENTS
C
C506
D WHT S 85 86
D S 2770 7200
C BRN LT 87
C623
A BRN LT 2750 30
C623
E BLK TM TO OPTIONS LEFT BLINKER RELAY 87A 2760 ADDITIONAL POWER

E BLK TM TO OPTIONS (DELUXE ACCESSORY) CONNECTOR
F DBL CENTER
2790
2795
(EXTERIOR CAB)
F DBL CENTER
C490
E 85 86 2740 B
G RED GD 2780 6415
G RED GD 6440 1 D 6410 6410
87
1740 A
C669
H YEL RT 30
C411
H YEL RT 2785 2 87A 6020

L RNG C RED = RED WIRES CONNECT BY BATTERY FEED 1000-1999 RED, RED/WHT, RNG
L 6540 3 RNG = ORANGE GROUND 2000-2999 BLK
K RNG B 6000
BLK = BLACK LETTER ACROSS MONITORING 3000-3999 LBL
K TO AWS TO MAINFRAME CONNECTORS
C401or
4 WAY FLASHER A 6510 B C A LBL = LIGHT BLUE HYDRAULIC 4000-4999 LGN
C402
GRADER HARNESS - RIGHT BLINKER CONTROLS A B ATTACHMENT CONTROLS 5000-5999 YEL
C489
2720 B DBL = DARK BLUE
GRADER HARNESS - HARNESS - 6718873
RELAY C497
1720 A
LGN = LIGHT GREEN B A
LIGHTS 6000-6999 PNK
ACCESSORIES 7000-7999 WHT
6707303 6706391 2790
85 86
6515
DGN = DARK GREEN
YEL = YELLOW
SOME CONNECTOR
ENGINE 8000-8999 TAN
COMMUNICATION 9000-9999 PUR
87 PNK = PINK
6510
562 of 888 87A
30
6010 WHT = WHITE
BRN = BROWN
BODIES NOT SHOWN
FOR DRAWING CLARITY
TAN = TAN
AWS HORN/BLINKER HARNESS - 6726662 PUR = PURPLE V-1235 (4-29-08)
GRY = GRAY
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.

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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 to
warn personnel.
BUZZER - Audible alarm. Sounds at

1 SWITCH - Light - Multi position switch a 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.)

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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

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Standard Cab Harness Connectors
C 212
C 434
C 482
408 C 499

C 479
C 129 C 480
C 209 S1
S2
T3
SW1
C 435
C 500
C 408
MS2660

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Deluxe Cab Harness Connectors
C 212
SW9
C670 SW8
SW7 C 483
S3
S4
C 611
C 630
C 635
T5 C 434
T6 *C 129 C 482
408 C 479

S1
C 40
T2 S2
C 209 C 40
T1
T3
SW1
SW2
C 480 SW3
C 435 SW4
C 408 SW5
SW6
MS2441

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Mainframe Harness Connectors
CC426
408
C 405
T1
T6
T8
C 486 T4
T5
C 112 C4
T3
C 108 C 350
408
C 408
C 113
C 135

C 107 C 446
C 407-1
C 407-2
C 103 C 478
C 105 C 489
C 406 C 423
C 606 C 415
J1
C 101 J2
C 413
C 414 C 126
C 416 C 419 C 404
C 417 C 420 C 409 C 410
C 418
C 421 C 411
C 422 C 412
C 425
C 492
MS2179

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Description
Figure 60-10-1
P-13849
P-76564
The loader has a 12 volt, negative ground alternator

charging system. The electrical system is protected by

fuses located in the cab on the steering control panel,
and a 100 amp master fuse [Figure 60-10-1] in the
engine compartment on the left side of the engine, under
the air cleaner. 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.

569 of 888
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
can cause injury or death.
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.

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ELECTRICAL SYSTEM INFORMATION (CONT’D) Figure 60-10-3
Fuse And Relay Location / Identification 11

1 9 13 15 17
5
Figure 60-10-2
2 6 18
1
3 7 19
8 16 20
4 10 12 14
7159779
P-76302
The electrical system is protected from overload by fuses

and relays under the fuse panel cover (Item 1) [Figure

60-10-2]. A decal is inside the cover to show location and
amp ratings. N-19660
Remove the cover to check or replace the fuses.

The location and sizes are shown below and [Figure 60-
10-3].
REF DESCRIPTION AMP REF DESCRIPTION AMP

1 Unswitched 25 11 Front & Marker R
Lights
2 ACS/AWS/SJC 5 12 Fuel Shutoff R
Switched
3 Alternator & 25 13 Rear Lights R
Accessories
4 Attachments 25 14 Traction R
5 Heater & Air 25 15 Glow Plugs R
Conditioning
6 Front & Marker 15 16 Starter R
Lights
7 Rear Lights 15 17 Traction 30
8 Bobcat Controller 25 18 Fuel Shutoff 30
9 Heater & Air R 19 Power Plug 15
Conditioning
10 Switch Power R 20 ACS/AWS/SJC 25
Unswitched
R - Relay

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Solenoid Testing
Figure 60-10-4
P9175

10-4]. Coil wires do not have polarity. Correct resistance

for the pressure relief (small) coil is 7-10 ohm and the
other coils 5-8 ohms.

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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
4 Install and tighten the battery hold down.

3
2 Install the harness clamp.
WARNING
1 AVOID INJURY OR DEATH
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
make final connection (negative) at machine frame.
P-37344
Do not jump start or charge a frozen or damaged
battery. Warm battery to 60°F (16°C) before
Remove the harness clamp (Item 1) [Figure 60-20-1]. connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
Disconnect the negative (-) battery cable (Item 2) [Figure lean over battery while boosting, testing or charging.
60-20-1].
Battery gas can explode and cause serious injury.
Remove the battery hold down clamp (Item 3) [Figure W-2066-0705
60-20-1].
Disconnect the positive (+) battery cable (Item 4) [Figure

60-20-1].
Remove the battery from the loader.

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BATTERY (CONT’D) BATTERY (CONT’D)
Servicing Using A Booster Battery (Jump Starting)
Figure 60-20-3 If it is necessary to use a booster battery to start the

engine, BE CAREFUL! There must be one person in the
operator's seat and one person to connect and
disconnect the battery cables.
The key switch must be OFF (Standard Key Panel) OR

the STOP button must be pressed (Deluxe
Instrumentation Panel). The booster battery must be 12
volt.
WARNING
P-09589 P-09590 AVOID INJURY OR DEATH
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery
The battery cables must be clean and tight [Figure 60-
make final connection (negative) at machine frame.
20-3]. Check the electrolyte level in the battery. Add

distilled water as needed. Remove acid or corrosion from
Do not jump start or charge a frozen or damaged
the battery and cables with a sodium bicarbonate and
battery. Warm battery to 60°F (16°C) before
water solution.
connecting to a charger. Unplug charger before
Put Battery Saver (6664458) or grease on the battery
lean over battery while boosting, testing or charging.
terminals and cable ends to prevent corrosion.
W-2066-0705

contact. Wear goggles, protective clothing and 2
4
In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807 1
3
P-31860A

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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.
Keep cables away from moving parts. Start the engine.
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-4] first. Remove the cable from
the positive terminal (Item 2) [Figure 60-20-4].
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.

• Battery cables are connected when using a fast
charger or when welding on the loader. (Remove
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285

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ALTERNATOR Belt Replacement
Belt Adjustment Stop the engine.
Stop the engine. Raise the operator cab. (See Raising on Page 10-30-2.)
Loosen the alternator mounting bolt (Item 1) and

adjustment bolt (Item 2) [Figure 60-30-1].
Figure 60-30-1 Move the alternator all the way toward the rear of the
loader.
Remove the belt and install new belt.

2
Move the alternator toward the front of the loader until the
belt has 5/16 in. (8,0 mm) movement at the middle of the
belt span with 15 lb. (66 N) of force.
Tighten the adjustment bolt and mounting bolt.

3.)
Check the belt tension after several hours of operation

1 and readjust as needed.
P-24543

Loosen the alternator mounting bolt (Item 1) and
adjustment bolt (Item 2) [Figure 60-30-1].
Move the alternator until the belt has 5/16 in. (8,0 mm)
movement at the middle of the belt span with 15 lb. (66
N) of force.
Tighten the adjustment bolt and the mounting bolt.

3.)

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ALTERNATOR (CONT’D) Figure 60-30-2
Charging System Inspection
WARNING
1
contact. Wear goggles, protective clothing and

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15 P-24547
minutes.
If the charging system malfunctions check the following:
If electrolyte is taken internally drink large quantities
of water or milk! DO NOT induce vomiting. Get Check the condition and tension of the alternator belt.
prompt medical attention. (See Belt Adjustment on Page 60-30-1.) If belt is worn or
W-2065-0807 deteriorated replace.
Inspect the alternator wiring harness and connectors at

alternator. Harness and connectors must be clean and
tight.
WARNING Check the fuse for the alternator in the fuse panel. If fuse
is burned, find the cause and repair/replace. If fuse is in
AVOID INJURY OR DEATH doubt, remove it and check for continuity.
Keep arcs, sparks flames and lighted tobacco away Check the electrolyte level in the battery. Add distilled
from batteries. When jumping from booster battery water as needed. (Does not apply to maintenance free
make final connection (negative) at machine frame. batteries.)
Do not jump start or charge a frozen or damaged Verify the charge of the battery. Make sure battery is fully
battery. Warm battery to 60°F (16°C) before charged.
connecting to a charger. Unplug charger before
Disconnect the battery cables (negative first, then
positive). Inspect the cable clamps and battery posts for
lean over battery while boosting, testing or charging.
corrosion. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate and water solution. Put
grease on the cable ends and battery terminals to
W-2066-0705
prevent corrosion. Reconnect the cable to the positive
terminal.
With the key off, connect a test light between the
negative battery post and the disconnected negative
IMPORTANT cable clamp.
1. If the test light does not light up, reattach the clamp
Damage to the alternator can occur if: and proceed to alternator voltage test. (See Below.)
• Engine is operated with battery cables 2. If the test light lights up, there is a short (drain) in the
disconnected. electrical system of the loader. The short must be
• Battery cables are connected when using a fast repaired before the charging system can be checked.
both cables from the battery.) 3. Disconnect the alternator B+ terminal (Item 1) and L
• Extra battery cables (booster cables) are & S terminal connector (Item 2) [Figure 60-30-2] and
connected wrong. if the test light goes out, the alternator is faulty. If the
I-2023-1285 test light stays on, find the short in the system and
repair it.

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ALTERNATOR (CONT’D) Low Voltage Testing
Alternator Voltage Testing Figure 60-30-4
Figure 60-30-3
P-66815
P-34676
Turn engine OFF and remove the L & S terminal
connector (Item 1) [Figure 60-30-4] off the alternator.
Open the 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 60-30-5
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 60-30-3]. 1
The voltage must be higher than 13.5 volts but lower than
14.7 volts at 70° F (Alternator Temperature).
If the voltage is higher that 14.7 volts, proceed to the

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 2
volts, proceed with the following low voltage test. P-66816
Check the voltage across the “L” terminal (Item 1) and a

good ground source (Item 2) [Figure 60-30-5]. 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 ok then remove alternator for
replacement or repair. To repair, (See Alternator Voltage
Testing on Page 60-30-3.) for further component testing.

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ALTERNATOR (CONT’D)
High Voltage Testing
Figure 60-30-6
P-34679 P-66817
Turn engine OFF and remove the L & S Terminal

connector (Item 1) [Figure 60-30-4] off the alternator.

Check the continuity between the “S” terminal (Item
1) [Figure 60-30-6] and the positive (+) terminal on
the battery or starter terminal (Item 2) [Figure 60-30-
6]. There should be continuity. If no continuity,
replace wire harness.
If voltage is still above 14.7 volts at 70° F (Alternator

Temperature), then remove alternator for replacement or
repair. To repair, (See Alternator Voltage Testing on Page
60-30-3.) for further component testing.

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ALTERNATOR (CONT’D) Raise the lift arms and install an approved lift arm support
Place jackstands under the rear corners of the loader.
Disconnect the negative (-) cable from the battery.
Figure 60-30-7
DANGER
P-90328
AVOID DEATH 1
can cause lift arms to drop. P-66815

unless supported by an approved lift arm Disconnect the red wire (Item 1) [Figure 60-30-7] from
support. Replace if damaged. the alternator which comes from the battery.
D-1009-0409
Disconnect the wiring harness connector (Item 2) [Figure
60-30-7] from the alternator.
Never work on a machine with the lift arms up unless 1

W-2059-0598
IMPORTANT 3
P-24543
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected. Remove the adjustment bolt (Item 1) [Figure 60-30-8]
• Battery cables are connected when using a fast from the mounting bracket.
both cables from the battery.) Remove the alternator belt (Item 2) [Figure 60-30-8]
• Extra battery cables (booster cables) are from the alternator pulley.
connected wrong.
I-2023-1285 Remove the mounting bolt (Item 3) [Figure 60-30-8].

581 of 888
ALTERNATOR (CONT'D)
Figure 60-30-9
1. Alternator 11. Bearing

2. Nut 12. Stator
3. Pulley 13. Housing 7
4. Spacer 14. Sleeve
5. Bolt 15. Regulator
6. Housing 16. Rectifier 1
7. Bolt 17. Cover
8. Bearing 18. Spacer 6
9. Retainer 19. Nut
10. Rotor
14
13
4 7
3
2
12 5
11
10

9
8
19
18
17
15 16
C-3529B

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STARTER Figure 60-40-2
Testing
Figure 60-40-1 Bat

S
M
Bat
S
M Cranking
Motor
Cranking
Motor
A-1991
Connect a jumper wire (of at least 4 gauge in size)

A-1992
between the M terminal and the BAT terminal [Figure 60-
40-2].
If the starter turns, the defect is in the solenoid.

The key switch must be in the OFF position.
If the starter does not turn, the starter is defective.

The battery must be at full charge.
The cable connections on the battery must be clean and

tight.
Connect a jumper wire between S terminal and BAT

terminal [Figure 60-40-1].
If the starter turns but does not turn the engine, the
starter drive has a defect.

583 of 888
STARTER (CONT’D)
Figure 60-40-3
4
2
1
P-34385

Remove the negative (-) and positive (+) cables from the
battery.
Disconnect the ground wire (Item 1) [Figure 60-40-3]

from the starter.
Disconnect the engine harness power wire and positive

(+) battery cable from the starter solenoid terminal (Item
2) [Figure 60-40-3].
Installation: Tighten the nut to 10.8 - 12.3 ft.-lb. (14,7 -

16,7 N•m) torque.
Disconnect the tan wire (Item 3) [Figure 60-40-3] from

the R terminal on the starter solenoid.
Disconnect the brown wire (Item 4) [Figure 60-40-3]

from the S terminal on the starter solenoid.
Remove the mounting bolts (Item 5) [Figure 60-40-3]

from the starter.
Remove the starter from the engine.
Installation: Tighten the three mounting bolts to 25 - 28

Reverse the removal procedure to install the starter.

584 of 888
STARTER (CONT'D)
1. Starter 30
2. Shaft 13. Lever
3. Gear 14. Gear
4. Washer 15. Bracket
5. Shaft 16. Spring
6. Stop Ring 34 17. Gear
33
7. Lever 18. Stop
8. Holder 19. Stop Ring
13
9. Spring 20. Ball
10. Spring 21. Armature
36 22. Washer
11. Plate
8* 11* 23. Seal
12. Seal 9*
10* 24. Yoke
31
21
32 7*
15
37
14

16 20
17
19 18
5 8
12
14
6
29
1 4
3
28
2
27
25. Holder
35 26. Bracket
27. Ring
28. Bolt
22 26
29. Bolt
30. Switch
23 25 31. Seal
32. Bolt
23 33. Washer
34. Nut
35. Boot
36. Bracket
24
37. Bearing
* Not serviceable parts B-16488

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INSTRUMENT PANELS
Left Panel
Figure OI-1
12
3
2
16
7
1
4 13
8 9 10 11 15
6
14
5
17 20

18 19
21 22
23
P-76459C
The left instrument panel [Figure OI-1] is the same for

both Standard Key Panel and Deluxe Instrumentation
Panel equipped machines.
The table on the facing page shows the DESCRIPTION

and FUNCTION / OPERATION for each of the
components of the left panel.

587 of 888
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 turn signals are ON.
3 GENERAL WARNING Malfunction with one or more machine functions. (See Service Codes*)
4 TWO-SPEED Not used.
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.
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 turn signals are ON.
13 SHOULDER BELT Not used.
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 engage the auxiliary hydraulics. (Left green LED will
light.) Press a second time to disengage.
20 INFORMATION Cycles through (after each button press):
• Hourmeter (On start up)
• Engine RPM
• Battery voltage
• Maintenance clock
• Service codes*
Press and hold for seven seconds to reset the maintenance clock.
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. 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 Steering Drift Compensation.
(See STEERING DRIFT COMPENSATION on Page 60-161-1.)
23 ALARM The alarm beeps when Error, Warning or Shutdown conditions exist.
* For further description on Service Codes (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)

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Standard Key Panel
Figure 60-50-2
S4498
This machine may be equipped with a Standard Key

Panel [Figure 60-50-2].

The Standard Key Panel is used to turn the loader’s
electrical system on and off, and to start and stop the
engine.

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INSTRUMENT PANELS (CONT'D) 10. Run / Enter Button: Used to turn on the loader’s
electrical system.
Deluxe Instrumentation Panel
Figure 60-50-4
Figure 60-50-3
1 6
ENTER PASSWORD
2 3 5
LANGUAGES
B-16165
The first screen you will see on your new loader will be as
8 shown in [Figure 60-50-4].
7 When this screen is on the display you can enter the

password and start the engine or change the Display
Screen setup features.

NOTE: Your new loader (with Deluxe Instrumentation
9 Panel) will have an Owner Password. Your
10 B-15553K dealer will provide you with this password.
This machine may be equipped with a Deluxe Change the password to one that you will
Instrumentation Panel [Figure 60-50-3]. easily remember to prevent unauthorized use
of your loader. (See Changing The User
1. Display Screen: The Display Screen is where all Passwords on Page 60-190-2.) Keep your
system setup, monitoring, troubleshooting and error password in a safe place for future needs.
conditions are displayed.
2. Bobcat Main Controller Error: Indicates Change Language: Press the Selection Button at the end
communication error between Bobcat Main Controller of the arrow [Figure 60-50-4] to go to the next screen.
and Deluxe Instrumentation Panel. (See
Use the Keypad to select the number of the language.
DIAGNOSTIC SERVICE CODES on Page 60-90-1.)
3. Display Error: Indicates communication error Press EXIT. The screen will return to [Figure 60-50-4].
between instrument panel and Bobcat controller.
You can then enter the password and start the engine.
(See DIAGNOSTIC SERVICE CODES on Page 60-
90-1.)
See CONTROL PANEL SETUP for further description of
4. Engine Air Filter Icon: Indicates engine air filter
screens to setup the system for your use. (See
requires service.
CONTROL PANEL SETUP on Page 60-180-1.)
5. Hydraulic Filter Icon: Indicates hydraulic filter
requires service.
NOTE: Pressing the EXIT key will go to the previous
6. Selection Buttons: The four Selection Buttons allow screen and you can continue pressing until
you to select items from the Display Screen and scroll you get to the initial (home) screen.
through screens.
SHORTCUT: Press the “0” (zero) key to get to
7. Stop Button: Used to stop the engine and shut down the home screen immediately.
the loader’s electrical system.
8. Keypad: The numeric keypad has two functions:
- To enter a number code (password) to allow starting
the engine.
- To enter a number as directed for further use of the
Display Screen.
9. Start Button: Used to start the engine.

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INSTRUMENT PANELS (CONT’D) Front Panel
Side Panel Figure 60-50-6
Figure 60-50-5 1 2 3 4 5 6 7 8
B-15993Q
OR
9
7 8 9
1 2 3 4 5 6
B-15993R
P-76602 NOTE: Parking Brake (Item 4) [Figure 60-50-6] is

standard on all loaders.
REF. REF.
DESCRIPTION FUNCTION / OPERATION DESCRIPTION FUNCTION / OPERATION
NO. NO.

1 POWER PORT Provides a 12 volt receptacle 1 ADVANCED Press the top to select Hand
for accessories. CONTROL Controls; bottom to select Foot
2 NOT USED --- SYSTEM (ACS) Controls.
3 FRONT WIPER Press the bottom of the switch (Option)
(Option) to start the front wiper (press 2 NOT USED ---
and hold for washer fluid). 3 POWER Press and hold the up arrow to
Press the top of the switch to BOB-TACH disengage the Bob-Tach
stop the wiper. (Option) wedges. Press and hold the
4 REAR WIPER Press the bottom of the switch down arrow to engage the
(Option) to start the rear wiper (press wedges into the mounting
and hold for washer fluid). frame holes.
Press the top of the switch to 4 PARKING BRAKE Press the top to engage the
stop the wiper. (Standard on all PARKING BRAKE; bottom to
5 NOT USED --- loaders) disengage.
6 NOT USED --- 5 HYDRAULIC Press the top to engage
7 FAN MOTOR Turn clockwise to increase fan BUCKET Hydraulic Bucket Positioning;
(Option) speed; counterclockwise to POSITIONING bottom to disengage.
decrease. There are four (Option)
positions; OFF-1-2-3. 6 HAZARD LIGHTS Press the top to turn the
8 AIR Press bottom of switch to start; (Option) HAZARD LIGHTS ON; bottom
CONDITIONING top to stop. Fan Motor (Item 7) to turn OFF.
SWITCH (Option) must be ON for A/C to operate. 7 ROTATING Press the top to turn the
9 TEMPERATURE Turn clockwise to increase the BEACON (Option) ROTATING BEACON ON;
CONTROL temperature; counterclockwise bottom to turn OFF.
(Option) to decrease. 8 NOT USED ---
9 SELECTABLE Press the top to select ‘ISO’
JOYSTICK Control Pattern; bottom to
CONTROLS select ‘H’ Control Pattern.
(SJC) (Option)

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Front Panel Removal And Installation
Figure 60-50-7
1
1
P-26255

7].

Installation: Be careful to not overtighten the front
accessory panel mounting bolts to prevent damage to the
plastic panel.
Figure 60-50-8
2
1
P-26251
Pull the front accessory panel down and disconnect the

wire harness connector(s) (Items 1 & 2) [Figure 60-50-8]
from the switches.
Remove the panel.
Reverse the procedure to install the front accessory

panel.

592 of 888
INSTRUMENT PANELS (CONT’D) Figure 60-50-11
Removal And Installation (Left And Right)
Figure 60-50-9
1
P-76985A

11].
P-76985
Installation: Be careful to not overtighten the instrument
Remove the two mounting bolts (Item 1) [Figure 60-50- panel mounting bolts to prevent stripping of the threaded
9]. holes in the panels.

Installation: Be careful to not overtighten the instrument Figure 60-50-12
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
Figure 60-50-10
1
N-20163
Pull the right instrument panel down and disconnect the

wire harness connector (Item 1) [Figure 60-50-12] from
P-76987 the panel.
Pull the right instrument panel down and disconnect the Remove the panel from the loader cab.
the panel.
Remove the panel from the loader cab.

593 of 888
INSTRUMENT PANELS (CONT’D) Figure 60-50-15
Removal And Installation (Left And Right) (Cont’d)
Figure 60-50-13
1
2
P-76982
Pull the left instrument panel down and disconnect the

N-20142 the loader alarm.
NOTE: The instrument panel (Item 1) [Figure 60-50- Disconnect the wire harness connector (Item 2 and 3)
13] must be replaced as a complete unit. [Figure 60-50-15] from the loader instrument panel.

Figure 60-50-14 Remove the instrument panel from the loader.
P-76986

14].
Installation: Be careful to not overtighten the instrument

panel mounting bolts to prevent stripping of the threaded
holes in the panels.

594 of 888
INSTRUMENT PANELS (CONT'D)
Key Switch Removal And Installation
Remove the right side instrument panel. (See Removal

And Installation (Left And Right) Page 60-50-7)
Disconnect the key switch wiring harness.
Figure 60-50-16

P-76989
Remove the ignition key (Item 1) from the switch.

Remove the ignition switch retaining nut (Item 2) [Figure
60-50-16] from the switch.
Remove the ignition switch from the control panel.

595 of 888
INSTRUMENT PANELS (CONT'D)
Alarm Removal And Installation
Figure 60-50-17
P-76988
Remove the left side instrument panel.
Remove the retaining nut (Item 1) [Figure 60-50-17]

from the loader alarm.
Remove the alarm from the loader instrument panel.

596 of 888
LIGHTS Figure 60-60-3
Front Removal And Installation
Figure 60-60-1
1 1
N-19351
Remove the bulb (Item 1) [Figure 60-60-3] from the

N-19348 socket.
Reverse the above procedure to install the bulb.

Open the rear door.

Disconnect the negative(-) cable from the battery. (See
Remove the light housing (Item 1) [Figure 60-60-1] from

the operator cab.
Figure 60-60-2
N-19349
Remove the bulb assembly (Item 1) [Figure 60-60-2]

from the light housing by turning bulb assembly a 1/4
turn.

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LIGHTS (CONT’D) Cab Light Removal And Installation
Rear Removal And Installation Figure 60-60-6
Figure 60-60-4
1
2 1
1
3
P-66221
P-68264
Remove the screws (Items 1) [Figure 60-60-6] from the
light cover.
Remove the bulb assembly (Items 1 & 2) from the light
housing (Item 3) [Figure 60-60-4] by turning bulb NOTE: The wires for the switch will hold the light

assembly a 1/4 turn. cover. Do not pull the light cover to far away
from the light housing to prevent damage to
Figure 60-60-5 the wires.
Move the light cover to allow access to the bulb.
Figure 60-60-7
N-19339
Using care press the rear light and housing from the door
[Figure 60-60-5].
P-66222
Reverse this procedure for installation.

Remove and replace the bulb (Item 1) [Figure 60-60-7]
from the light housing.

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BOBCAT CONTROLLER (GATEWAY AND
AUXILIARY)
Description
The Gateway and Auxiliary controller provide 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.

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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

600 of 888
AUXILIARY)) (CONT’D)
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

601 of 888
AUXILIARY) (CONT’D)
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

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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

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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

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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

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BOBCAT CONTROLLER (GATEWAY AND Figure 60-70-2
Removal and Installation

1
1
WARNING
W-2059-0598
P-76643
device. (See Installing on Page 10-20-1.) Remove the mount bolts (Item 1) [Figure 60-70-2] and
remove the panel.
Stop the engine. Raise the seat bar.
Figure 60-70-3
Page 10-10-1.)

Figure 60-70-1 2
1 1
1
P-76642
Unplug the two harness connectors (Item 1) [Figure 60-

70-3] from the Gateway controller.
P-76644 Unplug the two harness connectors (Item 2) [Figure 60-

70-3] from the Auxiliary controller.
Remove the mount bolts (Item 1) [Figure 60-70-1]. NOTE: The connectors are keyed and will only plug
in one way.
Remove the panel from the loader.

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Figure 60-70-4
1 1
2 2
P-66928A
Remove the controller mounting bolts (Item 1) [Figure

60-70-4] from the left fender.

Loosen the controller mounting bolts (Item 2) [Figure 60-
70-4].
Installation: Tighten the controller mounting bolts to 12 -

14 ft.-lb. (16 - 19 N•m) torque.
Lift and remove the Gateway and Auxiliary controllers

from the loader.

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608 of 888
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.
The ACS controller is located behind the right side

access panel near the operators right foot.

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BOBCAT CONTROLLER (ACS) (CONT’D)
Connector And Wire Identification
G H
J J1 J3
F K
E A
D J3
B
C G H
F J
K J2
F E
G D A
E H B
A C
B J2
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

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BOBCAT CONTROLLER (ACS) (CONT’D) Figure 60-71-7
Figure 60-71-5
P-48904

P-21839 7] from the controller.
Remove the controller from the loader.

Loosen the bottom bolts and remove the top bolt on the
right front panel [Figure 60-71-5]. NOTE: The calibration procedure must be followed

when replacing actuator or ACS Controller.
Remove the right front panel (Item 1) [Figure 60-71-5] (See CALIBRATION on Page 60-160-1.)
from the loader.
Figure 60-71-6
P-21843
Disconnect the wiring harness connectors (Item 1)

[Figure 60-71-6] from the controller.

611 of 888

612 of 888
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 used on the ACS
drive functions. 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 operators 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 Gateway controller in an SJC
system. All these controllers are capable of software
upgrades.
HYDRAULIC
RIGHT DRIVE MOTOR
HAND CONTROL
PANEL

ACS
CONTROL SPEED
LIFT / TILT SENSOR
ACTUATORS
INTERNAL CAN BUS
GEAR ENGINE
SERIAL TT BUS
PUMP
RIGHT
JOYSTICK
ISO
SWITCH FWD / REV
SWASH PLATE
SENSORS
LEFT
JOYSTICK
AUXILIARY DRIVE
LEFT PUMP
CONTROL
HAND SPEED
PANEL SENSOR
EXTERNAL
CAN BUS ACD
GATEWAY CONTROL
CONTROL HYDRAULIC
MOTOR MS2582S

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BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification
P-64295

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BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D)
Connector Identification (Cont'd)
P-64296

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BOBCAT CONTROLLER (SJC) (DRIVE) (CONT’D) Figure 60-72-9
Removal and Installation
WARNING 1

W-2059-0598
P-64322
Pull the controller out from the fender and loosen the
Raise the operator cab. (See Raising on Page 10-30-2.) connector screw (Item 1) [Figure 60-72-9] to release the
connector.
Remove the engine speed control. (See Removal And
Installation on Page 70-20-1.) Installation: Tighten the connector screw to 30 - 35 in.-
lb. (3,39 - 3,96 N•m) torque. DO NOT OVERTIGHTEN!

Remove the inside access panels (right side). (See
Removal And Installation (Right) on Page 50-121-2.)
Figure 60-72-8
P-66835
Remove the top controller mounting bolt (Item 1). Loosen

the two bottom controller mounting bolts (Item 2) [Figure
60-72-8] from the right side fender.
Lift and remove the controller from the fender.

(16 - 19 N•m) torque.

616 of 888
SPEED SENSOR (SJC) Testing
Figure 60-80-1
2
P-28302
P-64400
procedure:
The speed sensor (Item 1) [Figure 60-80-1] is used by
the loader’s controllers to sense if the drive motor is MEL1609-RPM Speed Sensor Test Harness [Figure 60-

rotating, on (SJC) equipped loaders. The end of the 80-2]
sensor is magnetic and counts the teeth on a serrated, MEL1563 or 6689779-Remote Start Tool
rotating disc in the drive motor, as the drive motor rotates. Multimeter
The speed sensor is sealed with an o-ring (Item 2) Raise the lift arms and install an approved lift arm support
[Figure 60-80-1] to keep hydraulic oil inside the drive device. (See Installing on Page 10-20-1.)
motor and keep dirt out.
The sensor tip must be within 1.2 mm of the serrated
rotating disc in the drive motor. Any dirt or debris on the Connect the remote start tool to the loader. (See
mating surfaces of the sensor or drive motor can cause REMOTE START TOOL KIT-MEL1563 on Page 10-60-
bad or no readings. 1.)
The sensor harness is protected with convoluted tubing

and shrink tube. Ensure this is in good shape.
The speed sensor can be replaced without removing the

drive motor from the loader. Track removal is necessary.

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SPEED SENSOR (SJC) (CONT'D) Figure 60-80-5
Testing (Cont’d)
Figure 60-80-3 1
P-64334
2 1
Connect the RPM speed sensor test harness connectors

P-64353 (Item 1) [Figure 60-80-5] in line, between the loader
wiring harness and the speed sensor harness.
Locate the electrical connector (Item 1) [Figure 60-80-3] Turn the remote start key to ON position without starting
for the left RPM speed sensor. the loader.

Locate the electrical connector (Item 2) [Figure 60-80-3] Take a voltage reading, with the multimeter, at the speed
for the right RPM speed sensor. sensor test harness, between pin 1 and pin 3 at the test
pins (Item 2) [Figure 60-80-5].
Figure 60-80-4
The voltage should be 5 volts.
Repeat the procedure for the opposite side speed

sensor. (If needed.)
P-64353
Disconnect the RPM speed sensor wire connector (Item

1), from the loader harness wire connector (Item 2)
[Figure 60-80-4].

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Raise the operator cab. (See Raising on Page 10-30-2.) 1
Remove the loader track/s. (See Track Removal And

Figure 60-80-6
P-64405
Figure 60-80-9
2
1

2
P-64394
Remove the three access cover mount screws (Item 1)

[Figure 60-80-6]. 1
Remove the access cover (Item 2) [Figure 60-80-6] from P-64397

the loader.
Remove the two access cover mount screws (Item 1)
N•m) torque.
[Figure 60-80-8] and [Figure 60-80-9].
Figure 60-80-7
Remove the speed sensor access cover (Item 2) [Figure
60-80-9] from the loader.
1 Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27

N•m) torque.
P-64395
At the back side of the hydrostatic motor mount (Item 1)

[Figure 60-80-7], locate the speed sensor access cover.

619 of 888
Figure 60-80-10
1
2 P-64405
1
Remove any zip ties (Item 1) [Figure 60-80-12] fastening

P-64399 the wiring harness.
Installation: Ensure wire harness is properly secured

Clean the area around the speed sensor, to prevent with zip ties and routed in such a way to prevent damage
contamination from getting into the hydrostatic motor to the wire harness during use. Trial fit access cover to

after the speed sensor is removed. ensure clearance with harness routing.
Remove the two speed sensor mount bolts (Item 1) Figure 60-80-13
[Figure 60-80-10].
Remove the speed sensor (Item 2) [Figure 60-80-10]

from the motor.
1
Figure 60-80-11
P-64406
Remove the zip tie (Item 1) [Figure 60-80-13] from the

1
wiring harness.
P-64401 Disconnect the speed sensor harness connector (Item 2)

[Figure 60-80-13] from the loader harness connector.
Installation: Lubricate the speed sensor O-ring (Item 1) Remove the speed sensor from the loader.
[Figure 60-80-11] with oil before installing.
Seat the sensor into the motor port prior to installing the
bolts. Tighten down the bolts, alternate tightening from
left to right to evenly load the o-ring.
Tighten the speed sensor mount bolts to 88 in.-lb. (9,94
N•m) torque.

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SPEED SENSOR (SJC) (CONT'D)
Figure 60-80-14
P-26293
The electrical connector can be replaced.

Remove the connector wedge (Item 1) [Figure 60-80-
14].
Figure 60-80-15
4 1
3 2
P-26294
With a thin screwdriver lift the tabs and remove the wires
from the connector (Item 1) [Figure 60-80-15].
Wire Code
1 Red
2 Purple
3 Black
4 Yellow
The pin numbers are located on the backside of the

connector body.

621 of 888

622 of 888
DIAGNOSTIC SERVICE CODES Viewing Service Codes (Deluxe Instrumentation
Panel)
Viewing Service Codes (Standard Key Panel)
The Service Codes will aid your dealer in diagnosing
Figure 60-90-1 conditions which can damage your machine.
3 4 Figure 60-90-2
Press TOOL / SETUP
2
B-16163
Press OWNER UTILITIES
B-24288
P-76461H Enter PASSWORD (owner or master)

1 P-76461P
on Keypad
P-76455G
then press ENTER
to Continue
Press the INFORMATION button (Item 1) to cycle the

B-24290
DATA DISPLAY (Item 2) [Figure 60-90-1] until the
service code screen is displayed. If more than one
SERVICE CODE is present, the codes will scroll on the
DATA DISPLAY. Press SERVICE CODES
NOTE: Corroded or loose grounds can cause

multiple service codes and/or abnormal B-24291
symptoms. All instrument panel lights

flashing, alarm sounding, headlights and
taillights flashing, could indicate a bad Press NEXT to view the next 8
ground. The same symptoms could apply if Service Codes. (A total of 40 Codes
can be stored.)
the voltage is low, such as loose or corroded
B-24298
battery cables. If you observe these
symptoms, check grounds and positive leads
first.
The Display Panel will list the Code Number, (CODE)
Service Codes may be either a word (Item 3) or a number hourmeter reading when the error occurred (HOUR), and
(Item 4) [Figure 60-90-1]. (See following pages for the User (USER) who was logged in to operate the
service codes.) machine when the error occurred [Figure 60-90-2].
The following word errors may be displayed. A total of 40 Codes can be stored. When more than 40
[REPLY] One or both instrument panel(s) not codes occur, the oldest code will disappear and the
communicating with the controller. newest code will be in the number 1 position.
[CODE] The controller is asking for a password.

(Deluxe Instrumentation Panel only.)
[ERROR] The wrong password was entered.

(Deluxe Instrumentation Panel only.)
[SHTDN] A shutdown condition exists.
[DOOR] Operator cab door is open. (Lift and Tilt

functions will not operate.)

623 of 888
DIAGNOSTIC SERVICE CODES (CONT'D)
Service Codes List
CODE DESCRIPTION CODE DESCRIPTION

A3623 ACD not programmed D3907 Left joystick Y-axis not in neutral
A8002 ACD output ‘A’ error ON D4007 Right joystick Y-axis not in neutral
A8003 ACD output ‘A’ error OFF D7501 CAN joystick communication error
A8005 ACD output ‘A’ short to battery D7509 Operating mode switch short to ground or battery
A8006 ACD output ‘A’ short to ground D7513 Right front wheel angle sensor unresponsive
A8007 ACD output ‘A’ open circuit D7514 Left front wheel angle sensor unresponsive
A8032 ACD output ‘A’ overcurrent D7515 Right rear wheel angle sensor unresponsive
A8102 ACD output ‘B’ error ON D7516 Left rear wheel angle sensor unresponsive
A8103 ACD output ‘B’ error OFF D7517 Left swash plate not in neutral
A8105 ACD output ‘B’ short to battery D7518 Right swash plate not in neutral
A8106 ACD output ‘B’ short to ground D7523 Right front wheel angle sensor out of range high
A8107 ACD output ‘B’ open circuit D7524 Left front wheel angle sensor out of range high
A8132 ACD output ‘B’ overcurrent D7525 Right rear wheel angle sensor out of range high
A8202 ACD output ‘C’ error ON D7526 Left rear wheel angle sensor out of range high
A8203 ACD output ‘C’ error OFF D7527 Left swash plate out of position
A8205 ACD output ‘C’ short to battery D7528 Right swash plate out of position
A8206 ACD output ‘C’ short to ground D7533 Right front wheel angle sensor out of range low
A8207 ACD output ‘C’ open circuit D7534 Left front wheel angle sensor out of range low

A8232 ACD output ‘C’ overcurrent D7535 Right rear wheel angle sensor out of range low
A8302 ACD output ‘D’ error ON D7536 Left rear wheel angle sensor out of range low
A8303 ACD output ‘D’ error OFF D7537 Sensor supply 1 out of range low
A8305 ACD output ‘D’ short to battery D7538 Sensor supply 2 out of range low
A8306 ACD output ‘D’ short to ground D7539 Left swash plate sensor out of range high
A8307 ACD output ‘D’ open circuit D7540 Left swash plate sensor out of range low
A8332 ACD output ‘D’ overcurrent D7541 Right swash plate sensor out of range high
A8402 ACD output ‘E’ error ON D7542 Right swash plate sensor out of range low
A8403 ACD output ‘E’ error OFF D7543 Left forward drive short to battery
A8405 ACD output ‘E’ short to battery D7544 Left reverse drive short to battery
A8406 ACD output ‘E’ short to ground D7545 Right forward drive short to battery
A8407 ACD output ‘E’ open circuit D7546 Right reverse drive short to battery
A8432 ACD output ‘E’ overcurrent D7547 Right front steer extend short to battery
A8502 ACD output ‘F’ error ON D7548 Left front steer extend short to battery
A8503 ACD output ‘F’ error OFF D7549 Right rear steer extend short to battery
A8505 ACD output ‘F’ short to battery D7550 Left rear steer extend short to battery
A8506 ACD output ‘F’ short to ground D7551 Steer pressure short to battery
A8507 ACD output ‘F’ open circuit D7552 Back-up alarm error ON
A8532 ACD output ‘F’ overcurrent D7553 Left forward drive short to ground
A8602 ACD output ‘G’ error ON D7554 Left reverse drive short to ground
A8603 ACD output ‘G’ error OFF D7555 Right forward drive short to ground
A8605 ACD output ‘G’ short to battery D7556 Right reverse drive short to ground
A8606 ACD output ‘G’ short to ground D7557 Right front steer extend short to ground
A8607 ACD output ‘G’ open circuit D7558 Right front steer retract short to ground
A8702 ACD output ‘H’ error ON D7559 Left front steer extend short to ground
A8703 ACD output ‘H’ error OFF D7560 Left front steer retract short to ground
A8705 ACD output ‘H’ short to battery D7561 Right rear steer extend short to ground
A8706 ACD output ‘H’ short to ground D7562 Right rear steer retract short to ground
A8707 ACD output ‘H’ open circuit D7563 Left rear steer extend short to ground
D7564 Left rear steer retract short to ground
D3905 Left joystick X-axis not in neutral D7565 Steer pressure short to ground

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Service Codes List (Cont’d)

D7566 Back-up alarm error OFF H2606 Front base solenoid short to ground
D7567 No communication from Gateway controller H2607 Front base solenoid open circuit
D7568 Angle sensors not calibrated H2632 Front base solenoid overcurrent
D7569 Battery voltage out of range high H2705 Front rod solenoid short to battery
D7570 Interrupted power H2706 Front rod solenoid short to ground
D7571 Battery voltage out of range low H2707 Front rod solenoid open circuit
D7572 Drive pump not calibrated H2732 Front rod solenoid overcurrent
D7573 Operating mode switch flipped while operating H2805 Diverter rod solenoid short to battery
D7574 Right speed uncommanded motion H2806 Diverter rod solenoid short to ground
D7575 Left speed uncommanded motion H2807 Diverter rod solenoid open circuit
D7577 Left speed sensor out of range high H2905 High-flow solenoid short to battery
D7578 Right speed sensor out of range high H2906 High-flow solenoid short to ground
D7579 Left speed sensor out of range low H2907 High-flow solenoid open circuit
D7580 Right speed sensor out of range low H2932 High-flow solenoid overcurrent
D7581 Right front steer retract short to battery H3128 Interrupted power failure
D7582 Left front steer retract short to battery H3648 ACD multiple
D7583 Right rear steer retract short to battery H3913 Left joystick grip no communication
D7584 Left rear steer retract short to battery H3916 Left joystick not connected

D7585 Sensor supply 1 out of range high H3928 Left joystick failure
D7586 Sensor supply 2 out of range high H3948 Left joystick multiple
D7587 Software update required H4013 Right joystick grip no communication
D7588 Switched power stuck ON H4016 Right joystick not connected
D7591 Left Swash Sensor Reversed H4028 Right joystick failure
D7592 Right Swash Sensor Reversed H4048 Right joystick multiple
D7593 Right speed sensor unresponsive H4423 Auxiliary not programmed
D7594 Left speed sensor unresponsive H4721 Sensor supply 1 out of range high
D7595 Left speed sensor reversed H4722 Sensor supply 1 out of range low
D7596 Right speed sensor reversed H7314 Remote control failure
D7597 Controller programmed H7328 Remote control no signal
D7598 In drive calibration mode H7404 Main controller no communication
D7599 In angle calibration mode H7604 Left hand panel no communication
H1221 Right Primary out of range high L0102 Left panel button 1 error ON
H1222 Right Primary out of range low L0202 Left panel button 2 error ON
H1224 Right Primary not in neutral L0302 Left panel button 3 error ON
H1321 Left Primary out of range high L0402 Left panel button 4 error ON
H1322 Left Primary out of range low L7404 Left panel main controller no communication
H1324 Left Primary not in neutral L7672 Left panel programming error
H2305 Rear base solenoid short to battery
H2306 Rear base solenoid short to ground M0116 Air filter not connected
H2307 Rear base solenoid open circuit M0117 Air filter plugged
H2332 Rear base solenoid overcurrent M0216 Hydraulic/Hydrostatic filter not connected
H2405 Rear rod solenoid short to battery M0217 Hydraulic/Hydrostatic filter plugged
H2406 Rear rod solenoid short to ground M0309 Battery voltage low
H2407 Rear rod solenoid open circuit M0310 Battery voltage high
H2432 Rear rod solenoid overcurrent M0311 Battery voltage extremely high
H2505 Rear aux relief short to battery M0314 Battery voltage extremely low
H2506 Rear aux relief short to ground M0322 Battery voltage out of range low
H2605 Front base solenoid short to battery M0409 Engine oil pressure low

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M0414 Engine oil pressure extremely low M1707 Hydraulic lock valve solenoid open circuit
M0415 Engine oil pressure shutdown M1732 Hydraulic lock valve solenoid overcurrent
M0421 Engine oil pressure out of range high M1805 Lift spool lock short to battery
M0422 Engine oil pressure out of range low M1806 Lift spool lock short to ground
M0509 Hydraulic charge pressure low M1807 Lift spool lock open circuit
M0510 Hydraulic charge pressure high M1832 Lift spool lock overcurrent
M0511 Hydraulic charge pressure extremely high M2005 Two-speed primary short to battery
M0514 Hydraulic charge pressure extremely low M2006 Two-speed primary short to ground
M0515 Hydraulic charge pressure shutdown M2007 Two-speed primary open circuit
M0521 Hydraulic charge pressure out of range high M2032 Two-speed primary overcurrent
M0522 Hydraulic charge pressure out of range low M2102 Glow plug output error ON
M0610 Engine speed high M2103 Glow plug output error OFF
M0611 Engine speed extremely high M2107 Glow plug output open circuit
M0613 Engine speed no signal M2128 Glow plug output failure
M0615 Engine speed shutdown M2202 Starter output error ON
M0618 Engine speed out of range M2203 Starter output error OFF
M0710 Hydraulic oil temperature high M2207 Starter output open circuit
M0711 Hydraulic oil temperature extremely high M2228 Starter output error failure

M0715 Hydraulic oil temperature shutdown M2302 Starter relay error ON
M0721 Hydraulic oil temperature out of range high M2303 Starter relay error OFF
M0722 Hydraulic oil temperature out of range low M2402 Fuel pull relay error ON
M0810 Engine coolant temperature high M2403 Fuel pull relay error OFF
M0811 Engine coolant temperature extremely high M2502 Traction pull relay error ON
M0815 Engine coolant temperature shutdown M2503 Traction pull relay error OFF
M0821 Engine coolant temperature out of range high M2602 Glow plug relay error ON
M0822 Engine coolant temperature out of range low M2603 Glow plug relay error OFF
M0909 Fuel level low M3128 Interrupted power failure
M0921 Fuel level out of range high M3204 Workgroup no communication
M0922 Fuel level out of range low M3505 Hydraulic fan short to battery
M1016 Hydraulic charge filter not connected M3506 Hydraulic fan short to ground
M1017 Hydraulic charge filter plugged M3507 Hydraulic fan open circuit
M1121 Seat bar sensor out of range high M3532 Hydraulic fan overcurrent
M1122 Seat bar sensor out of range low M3705 Two-speed secondary short to battery
M1305 Fuel hold solenoid short to battery M3706 Two-speed secondary short to ground
M1306 Fuel hold solenoid short to ground M3707 Two-speed secondary open circuit
M1307 Fuel hold solenoid open circuit M3732 Two-speed secondary overcurrent
M1402 Fuel pull output error ON M4109 Alternator low
M1403 Fuel pull output error OFF M4110 Alternator high
M1407 Fuel pull output open circuit M4404 Auxiliary no communication
M1428 Fuel pull output failure M4621 5 volt sensor supply out of range high
M1502 Traction lock pull output error ON M4622 5 volt sensor supply out of range low
M1503 Traction lock pull output error OFF M4721 8 volt sensor supply out of range high
M1507 Traction lock pull output open circuit M4722 8 volt sensor supply out of range low
M1528 Traction lock pull output failure M4802 Front light relay error ON
M1605 Traction lock hold solenoid short to battery M4803 Front light relay error OFF
M1606 Traction lock hold solenoid short to ground M4807 Front light relay open circuit
M1607 Traction lock hold solenoid open circuit M4902 Rear light relay error ON
M1705 Hydraulic lock valve solenoid short to battery M4903 Rear light relay error OFF
M1706 Hydraulic lock valve solenoid short to ground M4907 Rear light relay open circuit

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M5002 Front light output error ON W3231 Tilt actuator fault
M5003 Front light output error OFF W3234 Tilt actuator not in neutral
M5007 Front light output open circuit W3235 Tilt handle / pedal not in neutral
M5028 Front light output failure W3236 Lift actuator fault
M5102 Rear light output error ON W3239 Lift actuator not in neutral
M5103 Rear light output error OFF W3240 Lift handle / pedal not in neutral
M5107 Rear light output open circuit W3249 Lift actuator short to ground
M5128 Rear light output failure W3250 Tilt actuator short to ground
M5202 PTOL switch error ON W3251 Lift actuator short to battery
M5221 PTOL switch out of range high W3252 Tilt actuator short to battery
M5222 PTOL switch out of range low W3253 Lift handle / pedal short to ground
M5305 PTOL LED short to battery W3254 Tilt handle / pedal short to ground
M5306 PTOL LED short to ground W3255 Lift handle / pedal short to battery
M5405 Tilt spool lock short to battery W3256 Tilt handle / pedal short to battery
M5406 Tilt spool lock short to ground W3257 Lift actuator reduced performance
M5407 Tilt spool lock open circuit W3258 Tilt actuator reduced performance
M5432 Tilt spool lock overcurrent W3259 Lift actuator wrong direction
M6402 Switched power relay error ON W3260 Tilt actuator wrong direction

M6403 Switched power relay error OFF W3261 Handle lock short to ground
M7002 Switched power output error ON W3262 Handle lock short to battery
M7003 Switched power output error OFF W3263 Pedal lock short to ground
M7007 Switched power output open circuit W3264 Pedal lock short to battery
M7028 Switched power output failure W3265 Sensor supply out of range
M7304 Remote control no communication W3266 Battery voltage out of range
M7423 Main controller unprogrammed W3267 Handle/pedal switch flipped while operating
M7504 Drive no communication W3275 Recovery mode error
M7604 Left display panel no communication W3276 CAN joystick information error
M7748 Key switch multiple W3277 Remote control information error
M7974 Door open W3905 Left joystick X-axis not in neutral
W4005 Right joystick X-axis not in neutral
W3223 ACS calibration required W4007 Right joystick Y-axis not in neutral
W3224 ACS calibration performed

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628 of 888
BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
Description
Figure 60-100-1
1 2 3
P-76459A
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.

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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 Controller (Engine STOPPED - PRESS TO OPERATE LOADER button and raise
Key ON) seat bar fully. Move steering levers slowly forward
and backward. The TRACTION lock must be
Figure 60-100-2 engaged. Lower the seat bar. Press the PRESS TO
OPERATE LOADER button.
1 2 3
7. Engage parking brake and move steering levers
slowly forward and backward. The TRACTION lock
must be engaged.
NOTE: The PARKING BRAKE light on the left

6 instrument panel will remain ON until the
engine is started, the PRESS TO OPERATE
LOADER button is pressed and the parking
brake is disengaged.
5 Inspecting The Lift Arm Bypass Control
4 8. Raise the lift arms 6 feet (2 meters) off the ground.
Stop engine. Turn lift arm bypass control knob
clockwise 1/4 turn. Pull up and hold lift arm bypass
P-76459A control knob until lift arms slowly lower.

1. Sit in operator’s seat. Turn key to RUN (Standard Key Inspecting Deactivation Of Lift And Tilt Functions
Panel) or press RUN / ENTER button (Deluxe (ACS And SJC)
Instrumentation Panel). Lower seat bar and 9. Sit in operator’s seat and fasten seat belt. Lower seat
disengage parking brake. Press the PRESS TO bar, start engine and press the PRESS TO OPERATE
OPERATE LOADER button (Item 4). Two BICS™ LOADER button.
lights (Items 1 and 2) [Figure 60-100-2] [SEAT BAR
AND LIFT & TILT VALVE] on left instrument panel 10. Raise lift arms about 6 feet (2 meters) off the ground.
must be OFF. The PRESS TO OPERATE LOADER
button will light. 11. Turn key OFF (Standard Key Panel), press STOP
button (Deluxe Instrumentation Panel), and wait for
2. Raise seat bar fully. All three BICS™ lights (Items 1, the engine to come to a complete stop.
2 and 3) [Figure 60-100-2] [SEAT BAR, LIFT & TILT
VALVE AND PARKING BRAKE] on left instrument 12. Turn key ON (Standard Key Panel), press RUN /
panel must be ON. The PRESS TO OPERATE ENTER button (Deluxe Instrumentation Panel). Press
LOADER button light will turn OFF. the PRESS TO OPERATE LOADER button, move the
control (foot pedal, hand control or joystick) to lower
Inspecting Deactivation Of The Auxiliary Hydraulics the lift arms. Lift arms must not lower.
System (Engine STOPPED - Key ON)
3. Sit in operator’s seat, lower seat bar and press the 13. Move the control (foot pedal, hand control or joystick)
PRESS TO OPERATE LOADER button (Item 4). to tilt the bucket (or attachment) forward. The bucket
Press the auxiliary hydraulics button (Item 5). The (or attachment) must not tilt forward.
auxiliary hydraulics light will be ON (Item 6) [Figure
60-100-2]. Raise the seat bar. The light must be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING)

WARNING
4. Sit in operator’s seat, lower seat bar, engage parking
brake and fasten seat belt. AVOID INJURY OR DEATH
5. Start engine and operate at low idle. Press the The Bobcat Interlock Control System (BICS) must
PRESS TO OPERATE LOADER button. While raising deactivate the lift, tilt and traction drive functions. If it
the lift arms, raise the seat bar fully. The lift arms must does not, contact your dealer for service. DO NOT
stop. Repeat using the tilt function. modify the system.
W-2151-0394

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BOBCAT INTERLOCK CONTROL SYSTEM (BICS)
(CONT'D)
The following troubleshooting guide is provided for
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#
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.

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632 of 888
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.

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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

N-18463 the sensor tester, check the tester or wiring harness.
Figure 60-110-4
Use Sensor Tester (MEL1428) and seat bar sensor tester
adatper (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
1
Lower the seat bar. The Sensor Test light (Item 1)

N-19557 [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
N-19558 sensor.
Disconnect the Sensor Tester.

Connect the Sensor Tester (Item 1) [Figure 60-110-2]
inline, to the seat bar sensor connectors. See inset Replace the Seat Bar Sensor. (See Removal And
[Figure 60-110-2]. 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 60-110-5.)
The toggle switch (Item 2) [Figure 60-110-3] can be in
either the Absent or Present position.

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Figure 60-110-5
2
N-19224
Remove the seat bar (Item 1) [Figure 60-110-5] from the


N-19219
Remove the mounting bolt (Item 1) from the seat bar

mount (Item 2) [Figure 60-110-6].
Installation: Tighten the mounting bolt to 50 - 70 in.-lb.

(5,6 - 7,9 N•m) torque.
Remove the sensor mounting bolt (Item 3) [Figure 60-

110-6] and nut.

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SEAT BAR SENSOR (CONT'D)
Figure 60-110-7
2
1
3
N-19383
Remove the keyed plastic bushing (Item 1) magnetic

bushing assembly (Item 2) and sensor bracket (Item 3)

[Figure 60-110-7].
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 60-110-7]
of the seat bar.
Inspect all parts for damage and wear and replace if

necessary.
Reverse the removal procedure to install the seat bar

sensor.

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Bobcat Interlock Control System (BICS) Circuit Test
Figure 60-110-8
3
1
1
P-4703
Connect Sensor Tester (Item 1) [Figure 60-110-9] inline

N-18463 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 60-110-9] on the sensor tester to
[Figure 60-110-8]. the Present position.
NOTE: The sensor test light (Item 3) [Figure 60-110-9]

is only activated by the seat bar. It will be off
with the seat bar up or on with the seat bar
down.

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SEAT BAR SENSOR (CONT'D)
Bobcat Interlock Control System (BICS) Circuit Test

(Cont’d)
Figure 60-110-10
P-76459
The BICS seat bar indicator light (Item 1) [Figure 60-110-

10] should illuminate.
Figure 60-110-11
P-4699
Move the toggle switch (Item 1) [Figure 60-110-11] on

the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-110-10] should go

off.
If the above test fails, there is a problem with the Bobcat

controller or the wiring harness.

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TRACTION LOCK
Description
Figure 60-120-1

1 2 3 4
B-15551G
The Traction Lock Control System will lock the traction

drive system when the engine stops. The Traction Lock
Control System is incorporated into the BICS System
[Figure 60-120-1].

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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#
Traction lock stays engaged. 1, 2, 3, 4, 5, 6,7,11
Intermittent activation of traction lock. 8, 9,10,11
1. Make sure brake switch is not engaged.

2. Check the dash display for an error code. (See Electrical System Service Manual.)
3. If all the lights indicate the brake should be released, but it doesn’t, check the brake 30 amp. fuse.
4. When checking the fuse, also check other fuses. Check the fuse block for correct orientation and location of
fuses. (See Electrical System Service Manual)

5. Test the solenoid, the coil should be about 9.8 ohms.
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 flywheel RPM Sensor and wiring.

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TRACTION LOCK (CONT'D) Figure 60-120-3
Inspecting
Figure 60-120-2
1
P-48521
Check the wire connections at the engine flywheel rpm

speed sensor (Item 1) [Figure 60-120-3].
NOTE: When the Traction Lock Override Button is

activated, the Traction Lock Override Control
System will NOT engage the Traction Lock if

the engine stops.
See 60-170-1 for Flywheel RPM Adjusting.
1 2 3 4
B-15551G
Fasten the seat belt, disengage the parking brake button,

press the PRESS TO OPERATE LOADER Button (Item
1) [Figure 60-120-2] and raise the Seat Bar fully. Move
the steering levers slowly forward and backward. The
TRACTION lock (Item 4) [Figure 60-120-2] should be
engaged. Lower the Seat Bar. Press the PRESS TO
OPERATE LOADER Button (Item 1) [Figure 60-120-2].
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 OFF until the engine is
started, the PRESS TO OPERATE LOADER
Button is pressed and the parking brake is
disengaged.

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CONTROL SYSTEM (ACS)
Description
The (ACS) Actuator Control System system is an option

that allows the operator to quickly switch between foot
and hand control modes.
The ACS control uses the electric actuators on the main

hydraulic control valve to control the lift and tilt spools in
the hydraulic control valve, foot sensors, handle sensors
and a specially designed control handle.
Hand controls contain a locking solenoid which lock

when the switch on the center control panel is switched
to foot mode.
Foot controls also contain solenoids which lock when the

switch on the center control panel is switched to hand
mode.
Both the hand and foot controls contain sensors that

relay information to the ACS controller as to which
function should be activated and how far the spool should

be moved.

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CONTROL SYSTEM (ACS) (CONT'D)
Troubleshooting
The Advanced Control System (ACS) has a built-in diagnostic function which uses an icon on the left instrument panel to
indicate the condition of the ACS SYSTEM. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle sensor and then
the lift actuator. If no problems are present, it will then check the tilt handle sensor and the tilt actuator. The system will
stop its check at the first problem and then illuminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
To see what error occurred. (See DIAGNOSTIC SERVICE CODES on Page 60-90-1.)

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CONTROL SYSTEM (ACS) (CONT'D) Figure 60-130-3
Handle Sensor Connector Disassembly And

Assembly
Figure 60-130-1
2
3
1
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, using the 1-Terminal - Red
following procedure.
2-Terminal - Black
Figure 60-130-2
3-Terminal - Green
1
1
P13725 P13732
Remove the wedge (Item 1) [Figure 60-130-2] from the

connector.

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Switch Handle Removal
Figure 60-130-4
1
3
2
P13735
1
2
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.
Figure 60-130-5 1
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.

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Switch Handle Removal (Cont'd)
Figure 60-130-8
2 3
1 4
3 1
2
N-17772
1
Disconnect the left switch handle connectors (Items 1, 2,
P13735 3 & 4) [Figure 60-130-10] from the loader wiring harness
connectors.
Using 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
N-22783
2
N-17779 Roll the pistol grip handle cover (Item 1) [Figure 60-130-
11] down.
Disconnect the right switch handle connectors (Items 1 & Using a small screwdriver, lift the handle tabs (Item 2)
2) [Figure 60-130-9] from the loader wiring harness [Figure 60-130-11] and slightly rotate the switch handle.
connectors.

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CONTROL SYSTEM (ACS) (CONT'D) Switch Handle Installation
Switch Handle Removal (Cont'd) Figure 60-130-14
Figure 60-130-12
2 Tape 1/2 of Wires

Tape back 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 in. piece of heat shrink

tubing placed over the end of the wires. Remove the heat
Cut the wires (Item 2) [Figure 60-130-12] below the shrink tube from the end of the wires before routing the
switch handle and remove switch handle. harness 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 and harness up through the top through the control lever tube.
of the lever tube.
Figure 60-130-13
P-24234
If the harness has been cut: pull the harness (Item 1)

[Figure 60-130-13] out through the bottom of the control
lever tube.

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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
1 C-Terminal - White/Black
D-Terminal - White/Red
E-Terminal - Dk. Green
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-21700A 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
2 B-Terminal - Black/White
C-Terminal - Purple/White
Two-Pin Connector
A-Terminal - Black
B-Terminal - Red
Five-Pin Connector
1 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

in. of heat shrink tube (Item 1) [Figure 60-130-16]
approximately 3 in. 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.

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Switch Handle Installation (Cont'd)
Figure 60-130-17
3 1
2
P13735
1 Install the wires into the connectors as listed below:

N-17779
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
1
Figure 60-130-20
3 1
N-17772
2
Connect the handle harness connectors (Item 1) [Figure

60-130-17] & [Figure 60-130-18] to the loader harness
connectors.
P13735
Left and Right Control Lever Switch Handle [Figure 60-

130-20]
1-Terminal - Yellow/Red
2-Terminal - Open
3-Terminal - Orange/Black

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CONTROL SYSTEM (ACS) (CONT'D) Actuator Connector Disassembly And Assembly
Switch Handle Installation (Cont'd) NOTE: Actuator shown removed for clarity. Not
necessary for procedure.
Figure 60-130-21
Figure 60-130-22
P-21804
P-66842
Connect the handle harness connectors to the sensor

and lock solenoid connectors [Figure 60-130-21]. Check the actuator wiring harness connector (Item 1)

[Figure 60-130-22] and replace if broken.
Figure 60-130-23
N-17741
Installation: Install the wires into the connector as listed

below. The terminal numbers are written on the back of
the connector (Item 1) [Figure 60-130-23].
Lift and Tilt Actuator

1. Terminal-Black/Green-Larger diameter wire (16
gauge)
2. Terminal-Green-Larger diameter wire (16 gauge)
3. Terminal-Red/Green-Larger diameter wire (16
gauge)
4. Terminal-Open
5. Terminal-Red-Smaller diameter wire (18 gauge)
6. Terminal-Open
7. Terminal-Open
8. Terminal-Black-Smaller diameter wire (18 gauge)

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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
P-21878A
1
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 35 - 40 ft.-lb. (47 - 54 N•m) lubed
Disconnect the harness connector (Item 2) [Figure 60- torque.
130-24] from the handle lock solenoid connector.
Figure 60-130-27
Figure 60-130-25
1 P-21789
P-21832
Check the O-ring (Item 1) [Figure 60-130-27] for

Remove the two screws (Item 1) [Figure 60-130-25] damage. Replace as necessary.
holding the handle lock solenoid to the handle.
Installation: Tighten the screws to 32 - 38 in.-lb. (3,6 -

4,3 N•m) torque.
Remove handle lock solenoid assembly from handle.

652 of 888
CONTROL SYSTEM (ACS) (CONT'D)
Foot Sensor Disassembly And Assembly
Figure 60-130-28
1
P-24269
Remove the two bolts (Item 1) [Figure 60-130-28] from

the end of the foot sensor.

Installation: Tighten the bolts to 90 in.-lb. (10,2 N•m)
torque. Apply Loctite® 242 to the threads.
Figure 60-130-29
3
2
1
P-24270
Remove the boot retainer (Item 1), boot (Item 2), spool
stop plate (Item 3), O-ring (Item 4) [Figure 60-130-29].
NOTE: Do not disassemble the sensor assembly

(Item 5) [Figure 60-130-29]. The sensor
assembly is a calibrated assembly and cannot
be serviced. Order through Bobcat Parts.

653 of 888
Foot Lock Solenoid Removal And Installation
Figure 60-130-30
P-21790
Check the O-ring (Item 1) [Figure 60-130-32] for

1
P-21938 damage. Replace as necessary.
Remove the two bolts (Item 1) [Figure 60-130-30] from

the foot sensor shield.

Installation: Tighten the bolts to 80 - 90 in.-lb. (9,0 - 10,2
N•m) torque.
Figure 60-130-31
P-21939
Disconnect the foot lock solenoid connector (Item 1)

[Figure 60-130-31] from the harness.
Remove foot lock solenoid (Item 2) [Figure 60-130-31].
Installation: Apply a drop of oil on the solenoid threads

and tighten the solenoid to 35 - 40 ft.-lb. (47 - 54 N•m)
lubed torque.

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ELECTRICAL / HYDRAULIC CONTROLS
Attachment
xxxxxxxxx Harness
Switch Solenoid Number Attachment Harness
Terminal
Number Activated Connector
Left Side Activated Right Side
Control Handle Control Handle
Switches RH HFH Fourteen Pin Switches
Connector Viewed
1 1 1 1, 8 K from front
2 2 2 2 K (pin side of
connector)
3 1 1 1, 8 K of loader.
4 2 2, 3 6, 7 K, A, D
5 1 1, 3 5, 7 K, A, C
6 1 1, 3 5, 7 K, E
7 1 1, 3 5, 7 K, F
8 1 1, 3 5, 7 K, G
9 1 1, 3 5, 7 K, H
B-16449
B-16447 10, 11, 12, - -- -- K
B-16448
13, 14

1
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). (If so equipped as a dealer installed
kit.)
The ACD (Attachment Control Device) automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
RH - Loaders with Rear Hydraulics Option.

HFH - Loaders with High Flow Hydraulics Option.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
* Terminal K is activated with Key switch ON.

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ELECTRICAL / HYDRAULIC CONTROLS (CONT’D)
Identification Chart (Cont’d)
Solenoid Hydraulic Wiring

Number Coupler Number
T190
Front
1 Female 4340
(Base)
6
4 Front
1 2 Male 4330
2
(Rod)
Diverter &
3 4450/4480
Bleed
Rear Aux
4 4440
3 5 Base
5 Rear Aux Rod 4430
6 High Flow 4460

NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in
at the front auxiliary coupler block.
The Hydraulic Pressure Release Button will activate solenoid number 3 at the diverter valve, shut down
the loader, and bleed the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so
equipped.)
The High-Flow Button in the left side instrument panel must be pushed ON to activate solenoid number 6
at the High Flow Valve.

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ELECTRICAL / HYDRAULIC CONTROLS (SJC)
1 2 3 4 5 13 14 15 16 17
8
10 11
18
6 7 19
12
B-19873A / B-15546K / B-19874A
REF. NO. DESCRIPTION

1 TWO-SPEED CONTROL (Option)

Also: SPEED MANAGEMENT
2 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
3 REAR AUXILIARY HYDRAULICS (Option)
Also: ATTACHMENT FUNCTION CONTROL
4 STEERING DRIFT COMPENSATION
Also: DRIVE RESPONSE
5 ATTACHMENT FUNCTION CONTROL
6 SPEED MANAGEMENT
7 HORN (Option)
8 JOYSTICKS
9 FOOTRESTS
10 ENGINE SPEED CONTROL (FOOT)
11 ENGINE SPEED CONTROL (HAND)
12 LIFT ARM BYPASS CONTROL
13 ATTACHMENT FUNCTION CONTROL
14 NOT USED
15 FRONT AUXILIARY HYDRAULICS
16 NOT USED
17 TURN SIGNALS (Option)
18 FLOAT CONTROL
19 CONTINUOUS FLOW CONTROL FOR AUXILIARY HYDRAULICS

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ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
xxxxxxxxx Attachment Right Side

Left Side
Control Handle Switch Solenoid Number Activated Harness Control Handle
Switches Number Terminal Switches
Activated
STD RH HFH HRH 8
1 1 1 1, 6 1, 6 K
5 2 2 2 2 2 K
4 6
3 1 1 1, 6 1, 6 K 9
1
4 2 3, 5 2 3, 5 K, A, D 2
5 1 3, 4 1 3, 4 K, A, C
7 6 1 3, 4 1 3, 4 K, E
7 1 3, 4 1 3, 4 K, F
8 1 3, 4 1 3, 4 K, G
3
9 1 3, 4 1 3, 4 K, H
Attachment Harness Connector

Fourteen Pin
Connector Viewed
from front
(pin side of
connector)
of loader. 1
B-16449
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1). (If so equipped as a dealer installed
kit.)
The ACD (Attachment Control Device) automatically recognizes the use of the seven or fourteen pin
connector when connected.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
RH - Loaders with Rear Hydraulics Option.

HFH - Loaders with High Flow Hydraulics Option.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
* Terminal K is activated with Key switch ON.
HRH - Loaders with High Flow and Rear Hydraulics Option.

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ELECTRICAL / HYDRAULIC CONTROLS (SJC) (CONT’D)
T190 Solenoid
Number
Hydraulic
Coupler
Wiring
Number
Front
1 Female 4340
6 (Base)
4 2 Front
1
2 Male 4330
(Rod)
Diverter &
3 4450/4480
Bleed
5 4 Rear Aux Base 4440
3
5 Rear Aux Rod 4430
6 High Flow 4460
NOTE: Front Auxiliary Pressure Release is accomplished by manually pushing the male and female couplers in

at the front auxiliary block.
The Hydraulic Pressure Release Button will activate solenoid number 4 at the diverter valve, shut down
the loader, and bleed the rear auxiliary (If so equipped.) and also the right side front auxiliary. (If so
equipped.)
The Hi-Flow Button in the left side instrument panel must be pushed ON to activate solenoid number 5 on
the Hi-Flow valve.

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660 of 888
SERVICE PC (LAPTOP COMPUTER) Connecting Remote Start Tool (Service Tool)
Connecting Remote Start Tool Figure 60-150-2
Figure 60-140-1
1 2
2
3
1
P-76450
P16119
procedure:
procedure: Order from Bobcat Parts P/N: 6689779 - Remote Start

Tool (Service Tool) Kit
MEL1565 - Service Tool Harness Control Kit Includes:
MEL1566 - Service Tool Harness Communicator 6689778 - Remote Start Tool (Service Tool)
(Computer Interface) 6689747 - Loader Service Tool Harness
6689746 - Computer Service Tool Harness
NOTE: Make all connections with the key in the OFF 6689745 - BOSS® Service Tool Harness
position.
NOTE: Make all connections with the key in the OFF
The Service PC (Item 1) with the Remote Start Tool (Item position.
2) [Figure 60-140-1]. When connected to the loader, the
Service PC is used to monitor, conduct diagnostics, and The Service PC (Item 1) with the Remote Start Tool
upgrade software. (Service Tool) (Item 2) [Figure 60-150-2]. When
connected to the loader, the Service PC is used to
Connect the Service Tool Harness Communicator monitor, conduct diagnostics, and upgrade software.
(MEL1566) (Item 3) [Figure 60-140-1] to the designated
serial port on the Service PC. Connect the Remote Start Tool (Service Tool) Computer
Service Tool Harness (Item 3) [Figure 60-150-2] to the
NOTE: The recommended serial cable length should designated serial port on the Service PC.
not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing NOTE: The recommended serial cable length should
communication errors. not exceed 15 feet. A serial cable longer than
15 feet will create a degraded signal causing
Connect the other end to the connector on the Remote communication errors.
Start Tool.
Connect the other end to the connector on the Remote
Connect the remote start tool to the loader. (See Start Tool (Service Tool).
1.) Connect the Remote Start Tool (Service Tool) to the
loader. (See REMOTE START TOOL (SERVICE TOOL)
KIT - 6689779 on Page 10-61-1.)

661 of 888

662 of 888
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 [Figure 60-160-1] Excessive actuator loading can occur
to the ACS controller to actuate the lift and tilt valve. The if the actuator and valve spool components are
Lift 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 60-160-5.) or (See Lift And Tilt
points to the Drive controller to actuate the hydrostatic Calibration (ACS) on Page 60-160-3.).
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 can not be attained or replacing the 72° F (22° C), 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).

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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 both bolts are tight.
to neutral too slowly.
The pin may be too large. Oversized pins exceeding
• Actuator did not fully extend/retract. During the 0.248 in. (6,30 mm) in diameter should be replaced.
test, the spool was not able to fully stroke in both
directions. If the Actuator Test failed due to a slow return to neutral
after checking the probable causes in Column 1 [Figure
• Actuator out of neutral. The spool did not return to 60-160-2], check the following probable causes in
the neutral window during the test. Column 2 [Figure 60-160-2].

NOTE: A time out will occur if the test cannot be • Contamination in the spool.
completed within 8 seconds. If this happens,
retry the test. • The spool end cap may be defective or the centering
spring may be broken. Inspect the end cap and the
Figure 60-160-2 centering spring, replace if necessary.
Run Actuator Test
• The wire harness or connectors may have an
intermittent short. Check the connections and wire
Pass Fail harnesses.
Retest With Warm Hydraulic Oil • The controller may be defective, replace the
controller.
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.

664 of 888
CALIBRATION (CONT’D) Lift And Tilt Calibration (ACS)
Actuator Testing (Cont’d) The controller uses a calibration sequence to optimize

the control system. The optimizing ensures full spool
If the initial Actuator Test results in the fail mode actuator stroke (full flow) while preventing over stroke (loading) of
did not fully extend / retract, check the following. the actuator and resets the calibration points in the
controller.
• The actuator connectors may be reversed between
the lift and tilt actuator. Reverse the connectors and NOTE: The Actuator Test is the preferred method to
rerun the Actuator Test. calibrate the lift and tilt actuator. (See
Actuator Testing on Page 60-160-1.)
• The actuator may be weak, replace the actuator.
NOTE: This calibration procedure must be followed
• The spool end cap may be defective or the centering when replacing a hydraulic control valve,
spring may be broken. Inspect the end cap and the actuator or ACS controller. Failure to calibrate
centering spring, replace if necessary. after component replacement may result in
poor performance or reduced life of
• Contamination in the spool. actuator(s).
If the initial Actuator Test results in the fail mode actuator Figure 60-160-3
out of neutral, check the following.
• The actuator may be defective, replace the actuator.

• The spool end cap may be defective or the centering
spring may be broken. Inspect the end cap and the
centering spring, replace if necessary.
1
• Contamination in the spool.
P-24826
Update the loader service software to the latest version.
Place the rocker switch (Item 1) [Figure 60-160-3] in the

hand control mode.

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CALIBRATION (CONT’D) Figure 60-160-6
Lift And Tilt Calibration (ACS) (Cont’d)
Figure 60-160-4 Stroke Both Handles Fully In and Hold Them
1
B-16628
1
P-76601 P-76597A
Fully stroke both control handles in toward the center of
the cab and hold the handles [Figure 60-160-6].
Close the cab door. (If loader is equipped.) Lift the seat bar, high enough for the PRESS TO
OPERATE light (Item 2) [Figure 60-160-6] to go OFF.
With the seat bar down, turn the ignition key ON (Item 1)
(Deluxe Instrumentation Panel press RUN/ENTER) (Item Lower the seat bar.

1) [Figure 60-160-4].
Figure 60-160-7
NOTE: Do not start the engine.
Figure 60-160-5
P-76683
1
Push the PRESS TO OPERATE button (Item 1) [Figure
P-76683
60-160-7] to begin calibration.
Push the PRESS TO OPERATE button (Item 1) [Figure NOTE: The ACS icon will light up and if you listen
closely the cycling of the actuators can be
60-160-5] to unlock the hand controls.
heard. The ACS icon will stay lit until the
ignition key is cycled or the loader is started
and a function is operated.
NOTE: During the calibration cycle, the system will

beep three times. Once the calibration is
complete code 32-24 (Calibration Performed)
will be generated.
Release the control handles.
Calibration is complete.

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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
1
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-45240
or tilt actuator, or drive controller. Failure to
calibrate after component replacement may
result in poor performance or reduced life of With an operator in the seat and the seat bar down.
actuator(s).
Close the cab door. (If loader is equipped.)
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-8] in the ISO position.

Figure 60-160-9
B-19874
P-28063
Move the right joystick to the forward-right corner position

[Figure 60-160-9] and hold in position.

667 of 888
Lift And Tilt Calibration (SJC) (Cont’d)
Figure 60-160-10
1
1
P-76683
1
P-76601 P-76597A At the left panel, press the PRESS TO OPERATE Button
(Item 1) [Figure 60-160-11] while holding the right
joystick in position.
With the seat bar down, turn the ignition key ON (Deluxe
Instrumentation Panel press RUN/ENTER) [Figure 60- Release the joystick.
160-10].

NOTE: During the calibration cycle, the system will
NOTE: Do not start the engine. beep three times. Once the calibration is
complete code W3224 (Calibration
The loader Control Pattern Switch (Item 1) [Figure 60- Performed) will be generated.
160-10] will start flashing and will continue to flash until
the calibration procedure is completed. The ACS controller will cycle the actuators.
The lift and tilt calibration is complete.

668 of 888
CALIBRATION (CONT'D) Figure 60-160-13
Hydrostatic Pump Calibration (SJC)
WARNING
Failure to use jackstands can allow the machine to 1
W-2017-0286
1
P-76601 P-76597A
10-10-1.)
With the seat bar down, turn the ignition key ON (Deluxe
Operator must be in the seat and the seat bar down. Instrumentation Panel press RUN/ENTER) [Figure 60-
160-13].
Figure 60-160-12
NOTE: Do not start the engine.

1
P-45238
Close the cab door. (If loader is so equipped.)
Place the loader Control Pattern Switch (Item 1) [Figure

60-160-12] in the ISO position.
Verify the parking brake (Item 2) [Figure 60-160-12] is

OFF.

669 of 888
Hydrostatic Pump Calibration (SJC) (Cont'd)
Figure 60-160-14
P-76683
Press the PRESS TO OPERATE LOADER Button (Item

P-45238 1) [Figure 60-160-16] while holding the left joystick in
position.
The Control Pattern ISO Switch (Item 1) [Figure 60-160- Three audible beeps will sound.
14] will start flashing.

Figure 60-160-17
Figure 60-160-15
B-19873
B-19873
P-26476
P-26476
Move the left joystick to the reverse-right corner position

Move the left joystick to the forward-left corner position [Figure 60-160-17] and hold in position.
[Figure 60-160-15] and hold in position.

670 of 888
Figure 60-160-18
P-76683
1
P-76683 1) [Figure 60-160-20].
Three audible beeps will sound.

1) [Figure 60-160-18] while holding the left joystick in Start the engine from the RUN, RUN/ENTER position.

position. DO NOT TURN TO OFF POSITION. This would cancel
the calibration mode and the procedure would have to be
Three audible beeps will sound. repeated.
Figure 60-160-19 Figure 60-160-21
P-26474 P-45238
Allow the left joystick to go to the neutral position [Figure The Control Pattern ISO Switch (Item 1) [Figure 60-160-
60-160-19]. 21] will stop flashing, and will remain ON for the rest of
the calibration procedure.

671 of 888
Figure 60-160-22
B-19873
P-26482
Move and hold the left joystick to the forward position

P-68134 [Figure 60-160-23] until the forward calibration is
completed.
Move the throttle (Item 1) [Figure 60-160-22] to high idle. Figure 60-160-24

NOTE: If at any time, during calibration, the operator
needs to stop the loader, turn the key OFF, lift
the seat bar, or return the joystick to the 1
neutral position. 2
The calibration procedure will stop.
To return to calibration mode, the operator

must start the complete procedure from the
beginning.
WARNING P-64321
Put jackstands under the front axles and rear corners The loader speed will “ramp up” quickly (Item 1)
of the frame before running the engine for service. [Figure 60-160-24] and slow down 3 times in a row.
fall or move and cause injury or death. The loader will then “stair step” the speed (Item 2)
W-2017-0286
[Figure 60-160-24] 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.
Forward calibration is complete.
NOTE: If the wheels or tracks do not stop moving in

Full Speed Forward in 2 minutes or less, there
was an error in the calibration procedure. The
operator must shut the loader OFF, and start
the calibration procedure from the beginning.

672 of 888

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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 enable 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.
NOTE: Raising the seat bar or changing drive control
• Driving on uneven terrain such as crowned road patterns (ISO / H) will cause the machine to
surfaces. disengage from steering drift compensation.
The current settings will remain in effect until
Figure 60-161-1 the STOP button is pressed (Deluxe

Instrumentation Panel) or the key is turned
STEERING DRIFT COMPENSATION OFF (Standard Key Panel).
[S-L10] [S----] [S-R10]
[S-L10] [S----] [S-R10]
B-23580B
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].

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STEERING DRIFT COMPENSATION (CONT’D) NOTE: The display will revert back to hourmeter after
a brief period of time. The machine will remain
Operation (Cont’d) in steering drift compensation and continue at
the current setting. Pressing the upper left or
Figure 60-161-2 upper right button on the left joystick will
adjust steering drift compensation
accordingly and cause the new setting to
appear in the display.
Figure 60-161-3
1 2
3 4 5
P-76456F 1 2
P-76461L
P-76461N
P-76461M
Left Joystick Right Joystick

3 4
P-76456F
P-76461K
P-76461O
6 7 The current setting can be saved by pressing and holding

the PRESS TO OPERATE LOADER button (Item 1) for
P-24820B P-24802B
three seconds. [SET] (Item 3) will appear in the data
display (Item 2) [Figure 60-161-3] and the machine will
disengage from steering drift compensation.
Press and hold the PRESS TO OPERATE LOADER
button (Item 1) for three seconds to engage steering
drift compensation. The current steering drift OR
compensation setting will appear in the data display (Item
2) [Figure 60-161-2]. Press the PRESS TO OPERATE LOADER button to
disengage from steering drift compensation without
Press the upper left button (Item 6) on the left joystick to saving the current setting. [DONE] (Item 4) will appear in
adjust the machine left. [S-L01] (Item 3) through a the display (Item 2) [Figure 60-161-3] and the upper left
maximum of [S-L10] will appear in the data display (Item and upper right buttons on the left joystick will no longer
2) [Figure 60-161-2]. The number will increase by one make changes to steering drift compensation. The
each time you press the button. The higher the number, current settings will remain in effect until the STOP button
the greater the amount of steering drift compensation to
is pressed (Deluxe Instrumentation Panel) or the key is
the left. Adjustments to steering drift compensation will
be effective immediately. turned OFF (Standard Key Panel). The machine will
revert back to the last saved settings the next time it is
Press the upper right button (Item 7) on the left joystick to started.
adjust back toward center. The display will decrease
down to neutral displayed as [S----] (Item 4). Another
press of the upper right button will cause [S-R01] (Item 5)
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.

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FLYWHEEL RPM SENSOR Figure 60-170-2
Description 2
The flywheel RPM sensor has a magnet located on the 1

end of the sensor which senses breaks between the ring
gear teeth, the sensor relays this information back to the
main Bobcat 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.
Code 06-13 will occur if the main Bobcat controller loses

the signal for the flywheel RPM sensor.
P-68137
The inability to unlock the traction lock (brake) is a
symptom of losing the flywheel RPM sensor signal. Not
being to read engine speed on the service tool or deluxe Turn the RPM sensor and the jam nut out from the
display panel is also a symptom of losing the flywheel flywheel. Set a clearance of 0.050 in. (1,27 mm) between
RPM sensor signal the jam nut and the housing with a feeler gauge (Item 1)
[Figure 60-170-2].
Adjusting
NOTE: New RPM sensors have a plastic tip which is

Figure 60-170-1 used as a gauge during installation. The
plastic tip is designed to come off after the
engine is started.
Tighten the jam nut (Item 2) [Figure 60-170-2] to 12 - 17

ft.-lb. (16 - 23 N•m) torque, while holding the sensor from
1 turning.
P-68136
When installing the RPM sensor, turn the rpm sensor

(Item 1) [Figure 60-170-1] in until it makes contact with
the engine flywheel.
Turn the jam nut (Item 2) [Figure 60-170-1] until it

contacts the flywheel housing. The jam nut should not be
tightened, it needs to turn with the RPM sensor when the
sensor is turned back out for adjustment.

677 of 888

678 of 888
CONTROL PANEL SETUP Examples
Right Panel Setup (Deluxe Instrumentation Panel) Figure 60-180-2

Icon Identification
Figure 60-180-1
Press
TOOL / SETUP
SELECTION
EXAMPLE
BUTTONS
Press
LOADER FEATURES
B-16162
Make selection by pressing the SELECTION BUTTON

adjacent to the icon [Figure 60-180-1].
ICON DESCRIPTION

Press
LOCK / UNLOCK: Allows machine to be DISPLAY OPTIONS
locked / unlocked. You must lock machine to
activate security system.
When system is unlocked, the user can press
RUN / ENTER then press START to begin
operation.
A valid password will need to be entered at
startup to run a locked machine.
TOOL / SETUP: Access system options.
Use to set clock, check system warnings,
select language, set passwords, etc. Press
ADJUST CONTRAST
? HELP: Access help on current menu item.
EXIT EXIT returns you to previous level menu.

11:23 CLOCK / JOB CLOCK: Press to clear or lock
0.0 job clock; TOOL / SETUP to set time.
UP ARROW: Goes backward one screen.
DOWN ARROW: Goes forward one screen. Press
UP OR DOWN
OUTLINE ARROWS: No screen available Arrow to
(backward / forward). change
contrast
SELECTION ARROW: Use to select menu
Press EXIT to
item. return to
NEXT Goes to the NEXT screen in series. previous level
menu
EXAMPLE: the next Active Warning screen.
INFO Goes to more information about attachments. B-16163/B-24288/B-16161A/B-16166/B-16167
YES / NO Answer yes / no to current setup question.

CLEAR Removes previously installed password.
SET Set accepts current installed password.

679 of 888
CONTROL PANEL SETUP (CONT’D) Attachment Control Information (Deluxe
Instrumentation Panel)
Right Panel Setup (Deluxe Instrumentation Panel)
(Cont’d) The Deluxe Instrumentation Panel allows the user to
view information concerning the operation of Bobcat
More Examples attachments.
Clocks Figure 60-180-3
Press . . .
TOOL / SETUP Press
LOADER FEATURES
DISPLAY OPTIONS TOOL / SETUP
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN / ENTER to set clock.
Press EXIT to return to previous level menu.
Press
RESET JOB CLOCK (Password required) LOADER FEATURES
(Job Clock keeps a running total for job hours)
Press CLEAR to reset Job Clock to zero.
Press LOCK / UNLOCK to unlock.
Enter Password and press RUN / ENTER.
Languages

Press . . . Press
TOOL / SETUP ATTACHMENTS
LOADER FEATURES
DISPLAY OPTIONS
LANGUAGES
Select the language, press RUN / ENTER.
Press EXIT to return to previous level menu.
Vitals (Monitor the engine, hydraulic / hydrostatic, Press

electrical functions when engine is running.) RUN / ENTER BUTTON
on keypad
Press . . .
TOOL / SETUP
LOADER FEATURES.
Press
VITALS UP OR DOWN
Press SELECTION ARROW to select METRIC or Arrow to
ENGLISH (M / E) readouts scroll through
attachments
You can monitor real-time readouts of:
Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Hydraulic Oil Temperature Press
System Voltage the keypad number
Engine Speed
of a switch to view
a description of the
The Deluxe Instrumentation Panel is easy to use. attachment function
Continue to set your own preferences for running / of the switch
monitoring your Bobcat loader.
B-16163/B-24288/B-16161A/B-15753A/B-15754A/B-15755A
Attachments are listed alphabetically [Figure 60-180-3].

Press the exit button to return one screen or press the “0”
(zero) key to return to the home screen immediately.

680 of 888
PASSWORD SETUP Changing The Owner Password
Password Setup is available on machines with a Deluxe Figure 60-190-1

Instrumentation Panel.
Password Description Press TOOL / SETUP
All new machines with a Deluxe Instrumentation Panel

arrive at Bobcat dealerships with the keypad in locked
mode. This means that a password must be used to start
the engine.
For security purposes, your dealer may change the

password and also set it in the locked mode. Your dealer
will provide you with the password.
Master Password: Enter PASSWORD (owner or master)

on Keypad
A permanent, randomly selected password set at the then press ENTER
factory which cannot be changed. This password is to Continue
used for service by the Bobcat dealer if the owner
password is not known; or to change the owner
Press PASSWORD UTILITIES
password.

Owner Password:
Allows for full use of the loader and to setup the

Deluxe Instrumentation Panel. There is only one Press MODIFY OWNER
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.
User Password:
Enter new OWNER
Allows starting and operating the loader; cannot PASSWORD on Keypad
change password or any of the other setup features. then press ENTER
to Continue
For the procedures to change passwords (See Changing
the Owner Password on this Page) (See Changing The
User Passwords on Page 60-190-2.) Re-Enter new OWNER
PASSWORD on Keypad
then press ENTER
to Continue
OWNER PASSWORD procedure

is now complete
B-16163/B-24288/B-24290/B-24291/B-16171/B-24292/B-24293/B-24294

681 of 888
PASSWORD SETUP (CONT’D) Password Lockout Feature
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.
Figure 60-190-3
Press TOOL / SETUP
Press
LOCK / UNLOCK
Enter PASSWORD (owner or master)

on Keypad Enter OWNER
then press ENTER PASSWORD
to Continue on Keypad
then press ENTER
to Continue
Press PASSWORD UTILITIES

Press MODIFY USER Press
UNLOCK MACHINE
Enter USER number

on Keypad (There can be up to 8
different Users, each with their
own password)
then press ENTER to Continue
Press
Enter USER PASSWORD EXIT
on Keypad
then press ENTER to Continue
USER PASSWORD procedure Machine is now

is now complete. Enter UNLOCKED and
another USER number can be started
without using a
OR password
Press EXIT
B-16163/B-24288/B-24290/B-24291/B-16171/B-24295/B-24296/B-24297A
B-16163/P-76075/P-76076/P-76076A/P-76077

682 of 888
MAINTENANCE CLOCK Figure 60-200-2
Description
The Maintenance Clock alerts the operator when the next

service interval is due. EXAMPLE: The Maintenance
Clock can be set to a 250 hour interval as a reminder for
the next 250 hour planned maintenance.
Figure 60-200-1
1
2 P-76122
1 The Deluxe Instrumentation Panel, if equipped, will

display a message (Item 1) [Figure 60-200-2] alerting
the operator to service the machine. This message will
3 remain for 10 seconds before reverting back to the
previous screen and will appear for 10 seconds every
time the machine is started until the maintenance clock is
P-76461R reset.

NOTE: Standard Key Panel machines will not display
During machine operation, a two beep alarm will sound the BobCARESM PM message on the right
when there are less than 10 hours until the next planned panel.
maintenance.
The remaining hours before maintenance is required will

appear in the data display (Item 1) for five seconds while
the service icon (Item 3) and hourmeter icon (Item 2)
[Figure 60-200-1] flash.
NOTE: The display will show negative numbers after

counting down to zero.
The display will then revert back to the previous display

and will appear for 5 seconds every time the machine is
started until the maintenance clock is reset.

683 of 888
MAINTENANCE CLOCK (CONT’D) Figure 60-200-5
Setup
Figure 60-200-3
P-76110
P-64243A
Select Install (Item 1) [Figure 60-200-5] to begin

The first analyzer screen has an added bar for the sending the dealer information to the controller.
Maintenance Clock. The clock will remain OFF until
activated. Click Continue (Item 1) [Figure 60-200-3] to Figure 60-200-6
view the next analyzer screen.

Figure 60-200-4
1
1
P-76113
3 Click SEND TO MACHINE (Item 1) [Figure 60-200-6] 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 60-200-4] the information is now stored. This will
be displayed on Deluxe Instrumentation Panel equipped
loaders when the maintenance clock is less than 10
hours until next planned maintenance.

684 of 888
Setup (Cont’d)
Figure 60-200-7
P-76112
1
Click the right arrow (Item 1) [Figure 60-200-9] to scroll
P-76114
through the tabs.
Figure 60-200-10
A green COMPLETE (Item 1) [Figure 60-200-7]

message will be displayed when the dealer information
1
has been transferred to the machine controller.
Click Back (Item 2) [Figure 60-200-7] to return to the

Bobcat Service Analyzer screen. 3
Figure 60-200-8 4 2
P-76111
Click the Maintenance tab (Item 1) [Figure 60-200-10]

to view the maintenance clock screen.
Click ON/OFF (Item 2) to turn the maintenance clock on

or off [Figure 60-200-10].
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
new interval. Click SET/RESET (Item 4) [Figure 60-200-
Select Warnings (Item 1) [Figure 60-200-8]. 10] to reset and set the maintenance clock.

685 of 888
Setup (Cont’d)
Figure 60-200-11
1
2
P-76110
Select Program / Update (Item 1) [Figure 60-200-13] to

P-76111 view the maintenance clock.
Figure 60-200-14
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 can not be changed. If an entry is made
and the interval is not correct, make another entry and
click SET/RESET (Item 2) [Figure 60-200-11].
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
and right instrument panel display screens.
P-64244A
Figure 60-200-12
After the maintenance clock has been activated, the first

analyzer screen shows the hours remaining on current
maintenance interval (Item 1) [Figure 60-200-14]. If past
1 the interval, the number will reflect negative hours.
P-76111
Select Back (Item 1) [Figure 60-200-12] to return to the

main menu.

686 of 888
MAINTENANCE CLOCK (CONT’D)
Reset
Figure 60-200-15
P-76455H
Press the information button (Item 2) until the display

screen (Item 1) [Figure 60-200-15] shows the
maintenance clock.

Press and hold the information button (Item 2) for seven
seconds until [RESET] appears in the display screen
(Item 1) [Figure 60-200-15].
The maintenance clock can also be reset by clicking Set /

Reset (Item 4) [Figure 60-200-10] in service analyzer.
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, alternating hour
interval and [SEr] will NOT be removed from
the left and right instrument panel display
screens.

687 of 888

688 of 888
BACK-UP ALARM SYSTEM Inspecting
This machine may be equipped with a back-up alarm

system. The back-up alarm will sound when the operator
moves both steering levers or joystick(s) in the reverse 1
position. Slight movement of the steering levers in the
reverse position is required with hydrostatic
transmissions, before the back-up alarm will sound.
P-76108
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) in 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.
Figure 60-210-2
P-69346
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 2)
[Figure 60-210-3] for tightness and damage. Repair or
replace any damaged components.
If the back-up alarm switches require adjustment, (See

Adjusting Switch Position on page 60-210-2.)

689 of 888
BACK-UP ALARM SYSTEM (CONT’D)
Adjusting Switch Position
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.
Standard Controls and ACS (If Equipped)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 60-210-3
Switch Rollers contacting Bellcranks

2 2
1 1

P-62915
Place the steering levers in the neutral position.
Loosen the screws (Item 1) [Figure 60-210-3] securing

the back-up alarm switches.
Position the back-up alarm switch rollers so that they just

make contact with bellcranks without compressing the
switch springs [Figure 60-210-3]. Torque the screws
(Item 1) [Figure 60-210-3] securing the switches to the
bracket to 14 - 19 in.-lb. (1,6 - 2,1 N•m).
Lower the operator cab (See Lowering on Page 10-30-3.)

Inspect back-up alarm system for proper function. (See
Inspecting on Page 60-210-1.)

690 of 888
Troubleshooting (Standard And ACS) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves both steering levers in 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 alarm or back-up switch wires are disconnected.
5. Check the fuses.
6. The wiring is damaged.
7. The back-up alarm switches need adjusting.

691 of 888
Troubleshooting (Joystick) WARNING

W-2003-0807
PROBLEM CAUSE
Back-up alarm will not sound when the operator moves joystick(s) in 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.

692 of 888
BACK-UP ALARM SYSTEM (CONT’D) Switch Removal And Installation
Alarm Removal And Installation NOTE: Joystick equipped machines do not have
back-up alarm switches and can not be
Stop the engine and open the tailgate. adjusted.
Figure 60-210-4 Standard Controls and ACS (If Equipped)
Stop the engine and raise the operator cab. (See Raising
on Page 10-30-2.)
Figure 60-210-6
1
2 2
1 1
P-69346
Mark the wires for ease of assembly. Disconnect the

wires (Item 1) [Figure 60-210-4] from the alarm.

Installation: Make sure the wire harness ends do not P-62915
touch the mounting bolts during assembly.

Place the steering levers in the neutral position.
Figure 60-210-5
Loosen the screws (Item 1) securing the back-up alarm
switches. Slide the switch assemblies (Item 2) [Figure
60-210-6] off the mounting bracket.
1
1 Installation: Slide the alarm switches onto the mounting
bracket so the threaded plates are under the mounting
bracket. The rollers will face to the inside. During
installation of switches, adjusting the switches (See
Adjusting Switch Position on Page 60-210-2.) and
inspecting back-up alarm operation (See Inspecting on
Page 60-210-1.) are required.
P-69345
Remove the two hex head bolts, washers, and lock nuts
(Item 1) [Figure 60-210-5]. Remove the alarm from the
mounting bracket.

693 of 888
Switch Removal And Installation (Cont’d)
Figure 60-210-7
1
3
2
3
P-62917
Mark the wires for ease of assembly.

Disconnect the Orange wire from the common terminal
(Item 1) [Figure 60-210-7].
Disconnect the White wire from the normally open

terminal (Item 2) [Figure 60-210-7].
Disconnect the remaining White wires to the other switch

terminals (Item 3) [Figure 60-210-7].
Remove the switches.

694 of 888
ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 70-40-1
SAFETY &
CAMSHAFT AND TIMING GEARS. . . . . . . . . . . . . . . . . . . . 70-100-1 MAINTENANCE
Camshaft - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Idler Gear And Camshaft Removal And Installation . . . . 70-100-4
Idler Gear And Shaft Servicing . . . . . . . . . . . . . . . . . . . . 70-100-6
Timing Gearcase Cover Removal And Installation . . . . . 70-100-1
Timing Gears Backlash-Checking . . . . . . . . . . . . . . . . . . 70-100-3
CRANKSHAFT AND PISTONS. . . . . . . . . . . . . . . . . . . . . . . . 70-90-1 DRIVE

Connecting Rod Alignment . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5 SYSTEM
Crankshaft And Bearings Removal And Installation . . . . . 70-90-6
Crankshaft And Bearings - Servicing . . . . . . . . . . . . . . . . . 70-90-8
Crankshaft Gear Removal And Installation . . . . . . . . . . . . 70-90-6
Cylinder Bore - Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-5
Piston And Connecting Rod Removal And Installation . . . 70-90-1
Piston And Connecting Rod - Servicing. . . . . . . . . . . . . . . 70-90-2

ELECTRICAL
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1 SYSTEM &
Cylinder Head Disassembly And Assembly. . . . . . . . . . . . 70-80-7 ANALYSIS
Cylinder Head Removal And Installation . . . . . . . . . . . . . . 70-80-4
Cylinder Head - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-7
Cylinder Head Top Clearance . . . . . . . . . . . . . . . . . . . . . . 70-80-8 ENGINE
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . 70-80-1 SERVICE
Glow Plugs - Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
Reconditioning The Valve And Valve Seat. . . . . . . . . . . . . 70-80-9
Rocker Arm And Shaft Checking . . . . . . . . . . . . . . . . . . . 70-80-12
Push Rod Alignment - Checking . . . . . . . . . . . . . . . . . . . 70-80-13 SPECIFICATIONS
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . 70-80-2
Valve Guide-Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-8
Valve Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-11
Valve Tappets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-12
Valve Timing, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-3
ENGINE INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1

Compression - Checking . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-16
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Engine Mount Replacement. . . . . . . . . . . . . . . . . . . . . . . 70-10-15
Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-2
Engine Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-6

695 of 888
ENGINE SERVICE (CONT’D)
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Blower Housing Removal And Installation . . . . . . . . . . . . . 70-50-5
Hydraulic Fan Description . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
Hydraulic Fan Disassembly And Assembly . . . . . . . . . . . . 70-50-4
Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 70-50-7
Hydraulic Fan Motor Removal And Installation . . . . . . . . . 70-50-7
Radiator Removal And Installation. . . . . . . . . . . . . . . . . . . 70-50-1
Thermostat - Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-10
Thermostat Housing Removal And Installation . . . . . . . . . 70-50-9
Water Pump Disassembly And Assembly . . . . . . . . . . . . . 70-50-8
Water Pump Removal And Installation . . . . . . . . . . . . . . . 70-50-8
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

ENGINE SPEED CONTROL (SJC). . . . . . . . . . . . . . . . . . . . . 70-21-1


FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . 70-120-1
Flywheel Removal And Installation . . . . . . . . . . . . . . . . . 70-120-1
Housing Removal And Installation . . . . . . . . . . . . . . . . . . 70-120-2
Ring Gear Removal And Installation . . . . . . . . . . . . . . . . 70-120-1
FUEL SYSTEM (CONT’D) . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-8

Fuel Camshaft Removal And Installation . . . . . . . . . . . . . . 70-70-8
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Fuel Injection Pump Removal And Installation . . . . . . . . . 70-70-3
Fuel Injector Nozzle Pressure - Checking . . . . . . . . . . . . 70-70-12
Fuel Injector Removal And Installation . . . . . . . . . . . . . . 70-70-10
Fuel Shutoff Solenoid - Checking . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Shutoff Solenoid Removal And Installation . . . . . . . . 70-70-1
Fuel Injection Pump - Timing . . . . . . . . . . . . . . . . . . . . . . . 70-70-8
Governor Disassembly And Assembly. . . . . . . . . . . . . . . . 70-70-7
Nozzle Spraying Condition. . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
Valve Seat Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-13

696 of 888
ENGINE SERVICE (CONT’D)
LUBRICATION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1

Engine Oil Pressure - Testing . . . . . . . . . . . . . . . . . . . . . . 70-60-3
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . 70-60-1
Oil Pump Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-2
Oil Pump Removal And Installation . . . . . . . . . . . . . . . . . . 70-60-1
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-110-1


ITEMS MAY VARY.

697 of 888

698 of 888
ENGINE INFORMATION Figure 70-10-1
Description
The T190 has a Kubota direct injected V2403-M-DI-T

turbo diesel engine [Figure 70-10-1] with a displacement
of 148.5 cu.in. (2,4 L). The engine is rated at an SAE Net
61 HP (45.5 kW) and has an open crankcase ventilation
system.
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.
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.
P-66085
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.

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ENGINE INFORMATION (CONT'D)
Engine Specifications
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
Fuel Injection Nozzles

Opening Pressure 2702 - 2916 PSI (18.6 - 20.1 MPa)
Fuel Tightness Nozzle Seat Dry Nozzle at 2418 PSI (16.67 MPA)
Fuel Injection Pump

Injection Timing 6.0 - 7.5 degrees B.T.D.C.
High Idle 2760 - 2900 RPM
Low Idle 1075 - 1225 RPM
Cylinder Head
Cylinder Head Surface Distortion 0.002 (0,05) Max.
Top Clearance (Piston to Head) 0.0236 - 0.0276 (0,60 - 0,70)
Compression 427 - 469 PSI (2944,1 - 3233,6 kPa)
Allowable Limit 341 PSI (2351,1 kPa)

Difference Between Cylinders 10% or less
Valves
Valve Seat Width (Intake & Exhaust) 0.0835 (2,12)
Valve Seat Angle Intake 60 degrees, exhaust 45 degrees
O.D. of Valve Stems 0.3134 - 0.3140 (7,96-7,98)
I.D. of Valve Guides 0.3156 - 0.3161 (8,015-8,03)
Clearance Between Valve Stem & Guide 0.0016 - 0.0028 (0,04-0,07)
Allowable Limit 0.0039 (0,1)
Valve Clearance (Cold) 0.0071 - 0.0087 (0,18-0,22)
Valve Recessing (Protrusion) 0.002 (0,05)
(Recess) 0.0059 (0,15)

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Engine Specifications (Cont’d)
parentheses.
Valve Springs
Free Length 1.6417 - 1.6614 (41,7 - 42,2)
Fitted Length 1.378 (35,0)
Compress to Fitted Length 26.4 lb. (117,6 N)
Allowable Limit 22.5 lb. (100,0 N)
Tilt Allowable Limit 0.039 (1,0)
Valve Timing
Intake Valve (Open) 9 degrees B.T.D.C.
(Close) 45 degrees A.B.D.C.
Exhaust Valve (Open) 50 degrees B.B.D.C.
(Close) 12 degrees A.T.D.C.

Rocker Arms
O.D. of Rocker Arm Shaft 0.5501 - 0.5506 (13,973 - 13,984)
I.D. of Rocker Arm Bushings 0.5512 - 0.5519 (14,0 - 14,018)
Clearance Between Rocker Arm & Bushing 0.0006 - 0.0018 (0,016 - 0,045)
Camshaft
Journal O.D. 1.5722 - 1.5728 (39.934 - 39,95)
Bearing I.D. 1.5748 - 1.5758 (40,0 - 40,025)
Oil Clearance 0.002 - 0.0036 (0,05 - 0,091)
Alignment Allowable Limit 0.0004 (0,01)
Cam Lobe Height (Intake) 1.3346 (33,90)
Allowable Limit (Intake) 1.3327 (33,85)
Cam Lobe Height (Exhaust) 1.3346 (33,90)
Allowable Limit (Exhaust) 1.3327 (33,85)
Side Clearance 0.0028 - 0.0087 (0,07 - 0,22)
Tappet
Clearance Between Tappet & Guide 0.0008 - 0.0024 (0,02 - 0,062)
Tappet O.D. 0.9433 - 0.9441 (23,959 - 23,98)
Tappet Guide I.D. 0.9449 - 0.9457 (24,0 - 24,021)

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parentheses.
Cylinder Liner
Cylinder Bore I.D. 3.4252 - 3.4261 (87,000 - 87,022)
Allowable Limit +0.0059 (+0,15)
Oversized Cylinder Liner (Bore) I.D. 3.4350 - 3.4359 (87,250 - 87,272)
Allowable Limit +0.0059 (+0,15)
Piston Rings
Ring Gap (Top Ring) 0.0079 - 0.0138 (0,2 - 0,35)
Ring Gap (2nd Ring) 0.0157 - 0.0217 (0,4 - 0,55)
Ring Gap (Oil Ring) 0.0098 - 0.0177 (0,25 - 0,45)

Side Clearance of Ring Groove:
Second Ring 0.0037 - 0.0050 (0,093 - 0,128)
Oil Ring 0.0008 - 0.0021 (0,02 - 0,060)
Pistons
Piston Pin Bore 0.9843 - 0.9848 (25,0 - 25,013)
Connecting Rod
Piston Pin O.D. 0.9843 - 0.9847 (25,002 - 25,011)
Small End Bushing I.D. 0.9852 - 0.9858 (25,025 - 25,04)
Clearance Between Piston Pin & Small End Bushing 0.0006 - 0.0015 (0,014 - 0,038)
Connecting Rod Alignment Allowable Limit 0.002 (0,05)
Oil Pump
Oil Pressure @ Rated RPM 43 - 64 PSI (294 - 441 kPa)
Allowable Limit 36 PSI (245 kPa)
Idle Speed Allowable Limit 7 PSI (49 kPa)
Clearance Between Inner Rotor & Outer Rotor 0.0012 - 0.0055 (0,03 - 0,14)
Clearance Between Outer Rotor & Pump Body 0.0043 - 0.0075 (0,11 - 0,19)
End Clearance Between Inner Rotor & Cover 0.0041 - 0.0059 (0,105 - 0,15)

702 of 888
parentheses.
Crankshaft
Crankshaft Alignment Allowable Limit 0.00079 (0,02)
Oil Clearance Between Crankshaft Journal & Bearing #1 0.0016 - 0.0047 (0,04 - 0,118)
Crankshaft Journal O.D. #1 2.3591 - 2.3598 (59,921 - 59,940)
Crankshaft Bearing I.D. #1 2.3614 - 2.3637 (59,98 - 60,039)
Oil Clearance Between Crankshaft Journal & Bearing #2 0.0016 - 0.0041 (0,04 - 0,104)
Crankshaft Journal O.D. #2 2.3591 - 2.3598 (59,921 - 59,940)
Crankshaft Bearing I.D. #2 2.3614 - 2.3632 (59,98 - 60,025)
Oil Clearance Between Crank Pin & Bearing 0.0010 - 0.0034 (0,025 - 0,087)
Crank Pin O.D. 1.8488 - 1.8494 (46,959 - 46,975)

Crank Pin Bearing I.D. 1.8504 - 1.8522 (47,0 - 47,046)
Crankshaft Side Clearance 0.0059 - 0.0138 (0,15 - 0,35)
Timing Gear
Timing Gear Backlash:
Crank Gear-Idle Gear 0.0016 - 0.0044 (0,0415 - 0,1122)
Idle Gear-Cam Gear 0.0016 - 0.0045 (0,0415 - 0,1154)
Idle Gear-Injection Pump Gear 0.0016 - 0.0045 (0,0415 - 0,1154)
Crank Gear-Oil Pump Gear 0.0016 - 0.0043 (0,0415 - 0,1090)
Clearance Between Idle Gear Shaft & Idle Gear Bushing: 0.001 - 0.0026 (0,025 - 0,066)
Idle Gear Bushing I.D. 1.4961 - 1.4970 (38,0 - 38,025)
Idle Gear Shaft O.D. 1.4944 - 1.4951 (37,959 - 37,975)
Idle Gear Side Clearance 0.0047 - 0.0189 (0,12 - 0,48)
Thermostat
Valve Opening Temperature 176.9° - 182.3° F (80.5° - 83.5° C)
Valve Fully Open 203° F (95° C)

703 of 888
Engine Torque Values
Thread Size Material

(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M5 x 0.8 3 - 4 ft.-lb.
(4 - 5 N•m)
M6 x 1.0 6 - 7 ft.-lb. 6 - 9 ft.-lb.
(8 - 9 N•m) (8 - 12 N•m)
M8 x 1.25 6 - 9 ft.-lb. 11 - 16 ft.-lb. 18 - 25 ft.-lb.
(8 - 12 N•m) (15 - 22 N•m) (24 - 34 N•m)
M10 x 1.25 13 - 18 ft.-lb. 22 - 30 ft.-lb. 36 - 50 ft.-lb.
(18 - 24 N•m) (30 - 41 N•m) (49 - 68 N•m)
M12 x 1.25 22 - 30 ft.-lb. 40 - 54 ft.-lb. 69 - 87 ft.-lb.
(30 - 41 N•m) (54 - 73 N•m) (94 - 118 N•m)
M14 x 1.5 36 - 50 ft.-lb. 58 - 80 ft.-lb. 116 - 137 ft.-lb.
(49 - 68 N•m) (79 - 108 N•m) (157 - 186 N•m)
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
Engine will not start. 2, 5, 6, 7, 8, 9, 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

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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

705 of 888
ENGINE INFORMATION (CONT'D) Remove the muffler. (See Removal And Installation on
Page 70-30-1.)
Figure 70-10-2
DANGER 3
5
4
P-90328 2
AVOID DEATH
• Disconnecting or loosening any hydraulic P-66869

can cause lift arms to drop. Remove the nut from the speed control linkage (Item 1)
• Keep out of this area when lift arms are raised and unplug the rear door harness connector (Item 2)
unless supported by an approved lift arm [Figure 70-10-2].

D-1009-0409 Remove the bracket mounting screws (Item 3) and nut
(Item 4) [Figure 70-10-2] so the belt shield (Item 5) can
be removed.
WARNING Installation: Tighten screws and nut to 15 - 20 ft.-lb. (20 -

27 N•m) torque.
Never work on a machine with the lift arms up unless Figure 70-10-3
W-2059-0598
Put jackstands under the rear corners of the loader.
Replacing Hydraulic Fluid on Page 10-120-2.) and (See
Removing And Replacing Case Drain Filters on Page 10- P-66870
120-4.)
Disconnect the steering linkage. Remove the mounting screw (Item 1) to remove the oil
filter drip shield (Item 2) [Figure 70-10-3].
Remove the battery from the loader. (See Removal And
Installation on Page 60-20-1.) The drip shield is snapped into place on the filter
housing.
Drain the engine coolant from the cooling system. (See
Removing And Replacing Coolant on Page 10-90-2.) Installation: Tighten screw to 15 - 20 ft.-lb. (20 - 27 N•m)
Remove the air cleaner. (See Housing Removal And torque.

706 of 888
ENGINE INFORMATION (CONT’D) Figure 70-10-6
Figure 70-10-4
1
1
2
P-26965
3
Remove battery cable bracket (Item 1) [Figure 70-10-6].
P-66871
Figure 70-10-7
Disconnect the temperature sender connector (Item 1)

[Figure 70-10-4] from the filter housing.

Disconnect the wire connector (Item 2) [Figure 70-10-4]
for the differential pressure switch on the filter housing.

10-4].
Figure 70-10-5
1
1
P-66877
Disconnect the engine ground strap (Item 1) [Figure 70-

10-7].
P-66872
Disconnect radiator hose (Item 1) [Figure 70-10-5].

707 of 888
Figure 70-10-8
2
1 P-66876
Disconnect glow plug wire (Item 1) [Figure 70-10-10].

P-66879
Disconnect and plug fuel return line (Item 2) [Figure 70-
10-10].
Disconnect fuel line (Item 1) [Figure 70-10-8] for lift
pump. Remove the tie strap (Item 3) [Figure 70-10-10] from

wiring harness clamp and move the wire harness to the
Figure 70-10-9 left side of loader to allow clearance for engine removal.
Figure 70-10-11
P-66878
P-66875
Mark and disconnect fuel shut-off solenoid connector
(Item 1) [Figure 70-10-9].
Disconnect engine coolant hose (Item 1) [Figure 70-10-
Disconnect engine oil pressure sender connector (Item 2) 11].
[Figure 70-10-9].
Cap or plug all hoses and fittings.
Cut tie-strap (Item 3) [Figure 70-10-9].

708 of 888

1
Figure 70-10-12
P-66884
Mark and disconnect the charge pump/fan filter outlet

P-66881 hose (Item 1) [Figure 70-10-14].

Disconnect drain hose (Item 1) [Figure 70-10-12] from
the hydraulic cooling fan. Figure 70-10-15

1
Figure 70-10-13
P-66886
3
2
Mark and disconnect the hydraulic fan motor inlet hose
P-66882 (Item 1) [Figure 70-10-15].

Disconnect gear pump inlet hose (Item 1) [Figure 70-10-
13].
Disconnect supply hose (Item 2) [Figure 70-10-13] from

hydraulic fluid reservoir.
Disconnect gear pump outlet hose (Item 3) [Figure 70-

10-13].

709 of 888
Figure 70-10-16 1
1 1
P-66885
2
Remove the mounting bolt and nut (Item 1) [Figure 70-

P-68391 10-17] from the right front engine mount.
Installation: Tighten the mounting bolt to 70 ft.-lb. (95

Mark and disconnect the drive motor hoses (Item 1) N•m) torque.
[Figure 70-10-16].

Figure 70-10-18
NOTE: Due to the left drive motor hoses orientation,

hoses may not be completely removed from
fittings until the engine and pump are partially
removed. 2
P-28231
Installation: Install the left drive motor hoses prior to
alignment with engine mount bolts.
NOTE: The hydraulic fittings (Item 2) [Figure 70-10- 1

16] on the hydrostatic pump must be
tightened to 115 - 125 ft.-lb. (156 - 170 N•m)
torque.
P-28139

and nut from the left front engine mount.
Installation: Slide the engine mount slot (Item 2) [Figure

70-10-18] in between engine mount washer and nut.
Tighten the mounting bolt to 70 ft.-lb. (95 N•m) torque.
NOTE: To aid in the removal of the left front engine

mount bolt, remove the control panel. (See
Use 1/2 in. drive impact wrench, with a 12 in.

extension, on a 3/4 in. flex socket.
Removal will be accomplished by reaching under

the hydraulic reservoir to the engine mount bolt.

710 of 888
Removal And Installation (Cont'd) 13”
Figure 70-10-19
2.5”
1-1/2” I.S. Dia.

2-1/2” O.S. Dia.
2.5”
1/4” (4)
1-1/2” Square Tubing
1/4” Wall Thickness Thick Gusset
1”
16”
4”
P-48583 2”
45° 9”
1”
10-19] from the right rear engine mount.

Installation: Tighten the mounting bolt to 70 ft.-lb. (95 4”
N•m) torque. 2”
Figure 70-10-20 .5” 1”
.375”
Use Two 3/8”x 1-1/4” Bolts
MC-1799C
for Drilled and Tapped Holes.
A tool needs to be fabricated to use in the removal

procedure. This tool allows the engine/hydrostatic pump
assembly to be lifted evenly for easier removal. Use the
1
dimensions shown in [Figure 70-10-21] to make the
engine removal tool.
Figure 70-10-22
P-66887

10-20] from the left rear engine mount.
Installation: Tighten the mounting bolt to 70 ft.-lb. (95

N•m) torque. 1
P-48594
Fasten securely one end of the chain to the lifting eye

(Item 1) [Figure 70-10-22].

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Figure 70-10-23
P-48592
Fasten securely one end of the chain to the other lifting P-48596
eye (Item 1) [Figure 70-10-23].

NOTE: You may need to adjust the chain which Install the chain hoist on the eyelet [Figure 70-10-24] of
fastens to the engine a couple of times to the removal tool.
reach the correct lifting position.
Fasten a chain to other end of the removal tool with two
bolts as shown in (Item 1) [Figure 70-10-24].

loader.
Reverse the removal procedure to install the engine.

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Engine Mount Replacement

Engine
Figure 70-10-25 Mounting
Washer Bracket
1
2
Loader
3 Frame Engine
Mount
4
5 Snubbing Spacer
Washer
MC-1765A
6
7 Install the new engine mount as shown in the cut away

MC-1771A side view [Figure 70-10-26].
Tighten the mounting bolts to 70 ft.-lb. (95 N•m) torque.

Use the following procedure to install new engine
mounts:

Remove the existing mount from the engine. Refer to
engine removal and installation for engine mount
locations.
Replace all four engine mounts two front and two rear.
Use the parts shown to install the new engine mounts

[Figure 70-10-25]:
Square Nut - (Item 1) - Used on left side engine mounts
Hex Nut - (Item 2) - Used on right side engine mounts
Mount Washer - (Item 3)
Engine Mount - (Item 4)
Tube Spacer - (Item 5)
Snubbing Washer - (Item 6)
Mounting Bolt - (Item 7)

713 of 888
Compression - Checking
Figure 70-10-27
P-48710
Connect the compression gauge to the adapter [Figure

P-48709 70-10-28].
Make sure the engine speed control is fully backward

The tools listed will be needed to do the following (engine idle).
procedure:
Disconnect the fuel stop solenoid.

MEL10630 - Engine Compression Kit
Crank the engine with the starter cranking rpm.
MEL1631 - Compression Adapter
If the measurement is below the allowable limit, check
The engine must be at operating temperature. the cylinder, piston ring, top clearance, valve and cylinder
head.
Remove the glow plugs. (See Glow Plugs Removal And
Installation on Page 70-80-1.) Compression Pressure should be 427-469 PSI (29,4-
32,3 bar)
Install the correct compression adapter (Item 1) [Figure Allowable Limit (minimum) is 341 PSI (23,5 bar)
70-10-27] into the cylinder head.
No more than 10% variance among cylinders.
Figure 70-10-29
P-48711
Push the button on the compression gauge to release

pressure [Figure 70-10-29].
Connect the fuel stop solenoid.

714 of 888
ENGINE SPEED CONTROL Raise the lift arms and install an approved lift arm device.
(See Installing on Page 10-20-1.)

DANGER 20-1] from the speed control mounting bracket.

N•m) torque.
Installation: Tighten the mounting bolts (Item 2) [Figure

70-20-1] evenly until the speed control lever moves back
and forth at a comfortable tension.
Figure 70-20-2
P-90328
AVOID DEATH

D-1009-0409
1
WARNING P-4072

the lift arms are secured by an approved lift arm Pull the speed control away from the loader frame and
support device. Failure to use an approved lift arm disconnect the speed control rod (Item 1) [Figure 70-20-
support device can allow the lift arms or attachment 2] from the control.
W-2059-0598 Installation: Be sure to install the speed control rod in
the bottom hole of the speed control lever.
Figure 70-20-1
1
1
P-68555

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ENGINE SPEED CONTROL (CONT’D)
Figure 70-20-3
P-34156
Installation: Install the stop bracket (Item 1) [Figure 70-

20-3] in the same location. It is necessary for the front

and rear stop on the bracket to be located correctly.
Reverse the removal procedure to install the engine

speed control.

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ENGINE SPEED CONTROL (SJC) Figure 70-21-2
2
Figure 70-21-1 1
P-34545
Loosen the two lower access panel mount screws (Item

1) [Figure 70-21-2].
Remove the upper mount screw (Item 2) [Figure 70-21-

1 2].

P-64300 Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
N•m) torque.
Remove the two mounting bolts (Item 1) [Figure 70-21- Figure 70-21-3
1] from the right side foot rest.
Remove the foot rest, from the loader.
P-64313
Disconnect the foot speed control linkage (Item 1)

[Figure 70-21-3] from the hand control pivot arm.
Remove the foot speed control assembly from the loader.

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ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-6

1
Figure 70-21-4 2 4 4
6
1 3 5 3
P-34654
The parts that go into the pivot arm (Item 1) are the bolt
P-34550 (Item 2), washers (Items 3), fiber washers (Items 4),
spacer (Item 5) and nut (Item 6) [Figure 70-21-6].
Remove the bolt and nut (Item 1) [Figure 70-21-4] from Figure 70-21-7
the hand speed control pivot arm.

Figure 70-21-5
1
1
P-34548
P-34549 Remove the two screws (Item 1) [Figure 70-21-7] from

the hand speed control lever assembly.
Remove the keeper and pin (Item 1) [Figure 70-21-5] Installation: Tighten screws to 15 - 20 ft.-lb. (20 - 27
that attaches the pivot arm to the speed control cable. N•m) torque.
Remove the speed control pivot arm from the loader.

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ENGINE SPEED CONTROL (SJC) (CONT'D) Disassembly And Assembly
Figure 70-21-8
P-64305
P-34551
foot speed control assembly.
At the bottom side of the control panel, move the speed
control linkage toward the rear of the loader. Figure 70-21-11

Slide the hand speed control lever (Item 1) [Figure 70-
21-8] forward and lift, and disconnect the assembly from
the speed control cable.
Figure 70-21-9
P-64305A
2
Remove the bushing/nut (Item 1) [Figure 70-21-11] from
the pedal lever.
P-34553A
Installation: When installing the hand speed control to

the speed control cable, be sure the speed control lever
(Item 1) fits in the notch (Item 2) [Figure 70-21-9] of the
speed control rod clevis.

719 of 888
ENGINE SPEED CONTROL (SJC) (CONT'D) Figure 70-21-14
Figure 70-21-12 1
P-34659
1
Remove the pivot bolt (Item 1) [Figure 70-21-14] from
P-34657 the speed control.
Figure 70-21-15
Remove the fiber washer (Item 1) [Figure 70-21-12] from
the bushing/nut.

Remove the foot pedal lever (Item 2) and linkage rod
(Item 3) [Figure 70-21-12].
Figure 70-21-13
P-64307
1
The pivot assembly shown disassembled [Figure 70-21-

15].
NOTE: No lubrication is necessary or recommended

P-34658 on the engine speed control.
Reverse the disassembly procedure to assemble the

Remove the fiber washer (Item 1) and washer (Item 2) (SJC) speed control.
[Figure 70-21-13] from the pivot bolt.

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MUFFLER
Figure 70-30-1
3
3
2
1

P-48866
Open the rear door and raise the rear grill.
Remove the exhaust pipe clamp (Item 1) from the muffler (Item 2) [Figure 70-30-1].
Disconnect the exhaust pipe from the muffler.
Remove both muffler mounting bolts (Item 3) [Figure 70-30-1] from the muffler.
Installation: Tighten the muffler mounting bolts to 25 - 28 ft.-lb. (34 - 38 N•m) torque.
Remove the muffler from the loader.
Reverse the removal procedure to install the engine muffler.

721 of 888

722 of 888
AIR CLEANER Figure 70-40-3
Figure 70-40-1
1
1
2 2
P-28915
Remove the lower mounting bolt (Item 1) [Figure 70-40-

P-48893 3] and engine harness mounting bracket (Item 2) [Figure
70-40-3] from the air cleaner.
Disconnect the wire harness connector (Item 1) [Figure Installation: Tighten the three mounting bolts to 25 - 28
70-40-1] from the air cleaner sensor on the air cleaner. ft.-lb. (34 - 38 N•m) torque.

Loosen the clamp (Item 2) [Figure 70-40-1] from the Remove the air cleaner from the engine compartment.
hose on the engine manifold.
Reverse the removal procedure to install the air cleaner.
Figure 70-40-2
2
1
P-34450
Loosen the hose clamp (Item 1) [Figure 70-40-2] on the

air cleaner hose.

2] from the top mount of the air cleaner.

723 of 888

724 of 888
ENGINE COOLING SYSTEM Figure 70-50-2
Radiator Removal And Installation

1
Remove the rear grill. (See Removal And Installation on
Page 50-60-1.)
Remove the oil cooler. (See Removal And Installation on

Page 20-100-1.)
WARNING
P-48551
AVOID BURNS
Do not remove radiator cap when the engine is hot. Open the drain valve (Item 1) [Figure 70-50-2] on the
You can be seriously burned. engine block and drain the coolant into a container.
W-2070-1203
Figure 70-50-3
Figure 70-50-1

1
1
P-48242
P-45245
Remove the two sta-straps (Item 1) [Figure 70-50-3]

Loosen the radiator cap (Item 1) [Figure 70-50-1] from holding the pressurized expansion tank fill hose (Item 3)
the pressurized expansion tank. [Figure 70-50-4].

725 of 888
ENGINE COOLING SYSTEM (CONT'D) Figure 70-50-6
Radiator Removal And Installation (Cont'd)
Figure 70-50-4
1
1
3
2
2
P-48570
P-48554
Remove the hose clamp (Item 1) [Figure 70-50-6] from

P-45245 the inlet hose.
Remove the radiator mounting bolt and block off plate

Remove the two pressurized expansion tank mounting (Item 2) [Figure 70-50-6].
bolts (Item 1) [Figure 70-50-4].

Installation: Tighten the radiator mounting bolt to 11 - 13
Disconnect the pressurized expansion tank fill hose (Item ft.-lb. (15 - 17 N•m) torque. Use sealant on the block off
3) [Figure 70-50-4] at the radiator end. plate and bolt head (Item 2) [Figure 70-50-6].
Remove the pressurized expansion tank (Item 2) with the

pressurized expansion tank fill hose (Item 3) attached.
[Figure 70-50-4].
Figure 70-50-5
P-48552
Remove the hose clamp (Item 1) [Figure 70-50-5] from

the outlet hose.

726 of 888
ENGINE COOLING SYSTEM (CONT'D) Figure 70-50-8
Radiator Removal And Installation (Cont'd)
Figure 70-50-7
2 P-48841
1
Remove the hydraulic fill tube (Item 1) [Figure 70-50-8].
P-48553
Lift the radiator up and remove it from the loader.
Remove the clamp (Item 1) [Figure 70-50-7] from the Reverse the above procedure to install the radiator.
hydraulic fill tube.

Remove the radiator mounting bolt (Item 2) [Figure 70-
50-7].
Installation: Tighten the radiator mounting bolt to 11 - 13

Remove the two hydraulic fill tube mounting screws (Item

3) [Figure 70-50-7].

N•m) torque.

727 of 888
ENGINE COOLING SYSTEM (CONT’D) Hydraulic Fan Disassembly And Assembly
Hydraulic Fan Description Figure 70-50-9
The hydraulic fan is used to cool the engine and

hydraulic/hydrostatic systems. The hydraulic fan consist
of a fan and hydraulic motor that is controlled by a 2
proportioning valve.
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.
NOTE: The proportioning valve is factory set and can

not be adjusted accurately in the field. The
adjustment screw is sealed with a tamper 1
evident white material, if this screw has been P-68126
adjusted the proportioning valve must be
replaced.
NOTE: The seals, O-rings and coil nut on the
If the flow from the proportioning valve is proportioning valve (Item 1) are available by
determined inaccurate it must be replaced ordering from Bobcat Service Parts. The fan
with a new one from Bobcat Service Parts. motor (Item 2) [Figure 70-50-9] must be

replaced as an assembly if damaged.
The fan speed is determined by the engine coolant
temperature and the hydraulic fluid temperature.
Depending on these temperatures the fan speed (RPM’s)
can range from 0 to 4000 RPM’s.
The hydraulic fan speed at cold engine startup will range

from 0 to 500 RPM’s until the engine coolant and the
hydraulic fluid reach basic operating temperatures.
During normal operating temperatures the fan speed may

range from approximately 1900 to 3500 RPM’s.

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ENGINE COOLING SYSTEM (CONT'D) Remove the charge filter housing. (See Charge Filter
Housing Removal And Installation on Page 20-80-3.)
Blower Housing Removal And Installation
Figure 70-50-10
DANGER 1 2
P-90328 3
AVOID DEATH
• Disconnecting or loosening any hydraulic P-66610

can cause lift arms to drop. Remove the fan motor inlet hose (Item 1) and outlet hose
• Keep out of this area when lift arms are raised (Item 2) [Figure 70-50-10].

Remove the fan case drain hose (Item 3) [Figure 70-50-
D-1009-0409 10].

50-10].

1
W-2059-0598
IMPORTANT
P-66840
tubelines and ports to keep dirt out. Dirt can quickly Remove zip-ties (Item 1) [Figure 70-50-11] attached to
damage the system. blower housing.
I-2003-0888

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ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-13
Blower Housing Removal And Installation (Cont’d)
Figure 70-50-12
1
1
1
P-66649
2
NOTE: The picture shows the blower housing and fan
P-66611 assembly removed. Two of the mounting
bolts (Item 2) [Figure 70-50-12] have clips
(Item 1) [Figure 70-50-13] to hold the bolts
Remove the four mounting bolts (Item 1) and (Item 2) from falling out during installation of the
and spacer tubes. The only visible spacers are on the blower housing and fan together.

outside two mounting bolts (Item 2) [Figure 70-50-12].
Remove the blower housing from the loader.
NOTE: Remove the two rear mounting bolts first.
Reverse the removal procedure to install the blower
housing.

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ENGINE COOLING SYSTEM (CONT’D) Figure 70-50-15
Fan Removal And Installation

2
Figure 70-50-14
1
P-54419
Use the following procedure to remove the fan from the

P-54418 shaft:
Install the nut (Item 1) [Figure 70-50-15] on the tapered

Remove the lock nut and spacer (Item 1) [Figure 70-50- shaft to protect the shaft and threads.
14].

Install the puller on the fan as shown [Figure 70-50-15].
N•m) torque. As the center bolt (Item 2) [Figure 70-50-15] is tightened,
periodically strike the bolt head to loosen the fan from the
shaft.
Remove the fan from the tapered shaft [Figure 70-50-

15].
Hydraulic Fan Motor Removal And Installation
Figure 70-50-16
1 1
P-54421A
To remove the blower housing mounting plate, remove

the two bolts (Item 1) [Figure 70-50-16].

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ENGINE COOLING SYSTEM (CONT'D) Water Pump Disassembly And Assembly
Water Pump Removal And Installation Figure 70-50-18
Drain the cooling system.

2
Remove the alternator belt.
1
Remove the water pump bolts.
3
Figure 70-50-17 4
B-14424
Remove the flange (Item 1) [Figure 70-50-18].
Press the shaft (Item 2) and impeller (Item 3) [Figure 70-

50-18] out the impeller side of the water pump.

B-5318 Remove the impeller (Item 3) [Figure 70-50-18] from the
shaft.
Remove the water pump [Figure 70-50-17]. Remove the seal (Item 4) [Figure 70-50-18].
Installation: Always use a new gasket when installing Install a new seal (Item 4) [Figure 70-50-18] when
the water pump. assembling the water pump.

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ENGINE COOLING SYSTEM (CONT'D)
Thermostat Housing Removal And Installation
Figure 70-50-19
1 2 1
6 4
5 7

9
8
10
9
7 P-47253
Remove the bolts (Item 1), housing (Item 2), gasket (Item
3) and thermostat (Item 4) [Figure 70-50-19].
Remove clamps (Item 5) and hose (Item 6) [Figure 70-

50-19].
Remove bolts (Item 7), nut (Item 8), top and bottom
housing (Item 9), and gasket (Item 10) from the cylinder
head [Figure 70-50-19].

733 of 888
ENGINE COOLING SYSTEM (CONT’D)
Thermostat - Checking
Figure 70-50-20
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-
20].
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 0.315 in. (8 mm).
If the measurement is not acceptable, replace the

thermostat.
Thermostat’s valve Factory 74.5° - 78.5° C

opening spec. 166.1° - 173.3° F
temperature
Temperature at Factory 90° C
which thermostat spec. 194° F
completely opens

734 of 888
LUBRICATION SYSTEM Oil Pump Removal And Installation
Oil Pan Removal And Installation Remove the timing gearcase cover. (See Timing
Gearcase Cover Removal And Installation on Page 70-
Remove the engine and hydrostatic pump assembly from 100-1.)
the loader. (See Removal And Installation on Page 70-
10-8.) Remove the crankshaft gear.
The engine will have to be on an engine stand or Figure 70-60-3

suspended in the air safely to remove the oil pan.
Figure 70-60-1 1
2
2
B-3658

1
P-66843 Remove the nut from the oil pump shaft. Use a puller to
remove the oil pump gear (Item 1) [Figure 70-60-3].
Remove oil pan bolts securing oil pan (Item 1) [Figure Remove the oil pump mounting bolts. Remove the oil
70-60-1]. Slightly tapping on the oil pan with a soft mallet pump (Item 2) [Figure 70-60-3].
will break loose the oil pan from the engine block.
Installation: Tighten the oil pump mounting bolts to 60 -
Installation: Use a liquid gasket adhesive to the oil pan 72 in.-lb. (6,9 - 8,1 N•m) torque.
side of the oil pan gasket. Tighten oil pan bolts to 29 - 33
Figure 70-60-2
P-66844
Remove the oil strainer (Item 1) and O-ring (Item 2)

[Figure 70-60-2] from the engine block.
Installation: Apply oil to O-ring.

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LUBRICATION SYSTEM (CONT'D) Figure 70-60-6
Oil Pump Inspection
Figure 70-60-4
PI-10009
Put a piece of press gauge on the rotor face [Figure 70-

B-3616 60-6].
Install the cover and tighten the bolts.

Measure the clearance between the lobes of the inner
rotor and outer rotor [Figure 70-60-4]. Remove the cover carefully. Measure the width of the

press gauge [Figure 70-60-6].
Clearance Between Inner 0.0012 - 0.0055 in.
& Outer Rotor (0,03 - 0,14 mm) If the clearance exceeds the allowable limit replace the
oil pump.
Figure 70-60-5
End Clearance 0.0041 - 0.0059 in. (0,11 - 0,15 mm)
A-2732
Measure the clearance between the outer rotor and

pump body [Figure 70-60-5].
If the clearance exceeds the allowable limit, replace the

oil pump.
Clearance Between 0.0043 - 0.0075 in.

Outer Rotor & Body (0,11 - 0,19 mm)

736 of 888
LUBRICATION SYSTEM (CONT'D)
Engine Oil Pressure - Testing
Remove the oil pressure sender.
Figure 70-60-7
PI-10010

Install a pressure gauge [Figure 70-60-7].
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 Limit 7 PSI (0.50 Bar)

At Rated Speed 43-64 PSI (2.94-4.41 Bar)
Allowable Limit 36 PSI (2.45 Bar)

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FUEL SYSTEM Figure 70-70-3
Fuel Shutoff Solenoid - Checking
Figure 70-70-1
P-48586

P-48586
Disconnect the connector (Item 1) [Figure 70-70-3].
Stop the engine and open the rear door [Figure 70-70-1]. Figure 70-70-4

Disconnect the connector (Item 1) [Figure 70-70-1] from
the fuel shutoff solenoid.
Use an ohmmeter to check the fuel shutoff solenoid.
Figure 70-70-2
P-48704
Remove the mounting nuts (Item 1) [Figure 70-70-4] of

the fuel shutoff solenoid.
Remove ground strap held on by the nuts.

P-48706
Reverse the above procedure to install the fuel shutoff
solenoid.
The reading between electrical connector terminal C and
terminal A must be between approximately 15.6 ohms
[Figure 70-70-2].
The reading between electrical connector terminal C and

terminal B must be between approximately 0.35 - 0.4
ohm.
Fuel Shutoff Solenoid Removal And Installation

739 of 888
FUEL SYSTEM (CONT'D) Turn the flywheel to increase the pressure. If the
pressure can not reach the allowable limit, replace the
Fuel Injection Pump - Checking injection pump assembly.
The injection pump contains parts which have a very Fuel Tightness of Pump 2702 - 2916 PSI
close tolerance and its operation has a direct effect on Element Allowable Limit (186 - 201 bar)
the performance of the engine.
With the speed control lever at the low engine idle
position, turn the flywheel until the pressure is at 2702-
WARNING 2916 PSI (186-201 bar).
Turn the flywheel back approximately one-half turn. Keep

AVOID INJURY OR DEATH the flywheel at this position, and measure the time it
Diesel fuel or hydraulic fluid under pressure can takes the pressure to decrease from 1850 PSI (127.5
penetrate skin or eyes, causing serious injury or bar).
Use a piece of cardboard or wood to find leaks. Do Fuel Tightness of Delivery 5 Seconds
not use your bare hand. Wear safety goggles. If fluid Valve Allowable Limit
W-2072-0807

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].
Move the speed control lever to the high engine idle

position.

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FUEL SYSTEM (CONT'D) Cap the inlets on the injection pump vent where the
hoses were removed [Figure 70-70-7].
Fuel Injection Pump Removal And Installation
Remove the four oil fill tube bolts (Item 3) [Figure 70-70-
Figure 70-70-6 7].
Figure 70-70-8
1
1
P-48700
P-48730
Clean the area around the injection pump thoroughly.

Disconnect the high pressure fuel lines (Item 1) [Figure Remove the high pressure fuel lines (Item 1) [Figure 70-
70-70-6] from the fuel injectors. 70-8] from the injection pump.
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 70-70-7
3
P-48705
Disconnect the fuel inlet hose (Item 1) and the fuel return
hose (Item 2) from the injection pump vent [Figure 70-
70-7].

741 of 888
FUEL SYSTEM (CONT'D) Installation: Tighten the high-idling body to 32.6 - 36.3
(Cont'd) Figure 70-70-11
Figure 70-70-9
1 2
2
1 P-4357
P-48826
Remove the four mounting bolts (Item 1) and two nuts
(Item 2) [Figure 70-70-11] from the injection pump.
Remove the seven mounting bolts (Item 1) from the

intake manifold (Item 2) [Figure 70-70-9]. Installation: Tighten the mounting bolts to 16 - 20 ft.-lb.
(22 - 27 N•m) torque.
(22 - 27 N•m) torque.
Remove the intake manifold from the engine.
Installation: Replace the manifold gasket if it is worn or

damaged.
Remove the fuel shutoff solenoid. (See Fuel Shutoff

Solenoid Removal And Installation Page 70-70-1.)
Figure 70-70-10
P-51683
Remove the high-idling body (Item 1) [Figure 70-70-10]

from the engine block.

742 of 888
FUEL SYSTEM (CONT'D) Figure 70-70-14

INCORRECT
(Cont'd)
Figure 70-70-12
2
2
1 1
P-51627
1
Installation: Check to see if the stop solenoid guide (Item
1) [Figure 70-70-13] and [Figure 70-70-14] touches the
P-51626 boost lever (Item 2) [Figure 70-70-13].
NOTE: Before removing the injection pump

assembly, be sure to remove the stop
solenoid and high idling body. Also check to
see if the stop solenoid guide (Item 1) touches
the boost lever (Item 2) [Figure 70-70-12].
Remove the injection pump and shim(s) from the engine.
Figure 70-70-13
CORRECT 2
1
P-51628

743 of 888
FUEL SYSTEM (CONT'D)

(Cont'd) IMPORTANT
Figure 70-70-15 Do not attempt to maintain or adjust unless you are
trained and have the correct equipment.
I-2028-0289
P-4364
Install the shim(s) (Item 1) [Figure 70-70-15] on the

injection pump mounting surface. For information on the
number of shims used. (See Fuel Injection Pump -
Timing on Page 70-70-8.)
Figure 70-70-16
P-64218
Install the injection pump in the engine.
Ensure the control rack pin (Item 1) is to the left side of

the fork lever (Item 2) [Figure 70-70-16].

744 of 888
FUEL SYSTEM (CONT’D)
Governor Disassembly And Assembly
The governor serves to keep the engine speed constant by automatically adjusting the amount of fuel supplied to the
engine according to changes in the load.
Figure 70-70-17

1. Start Spring
2. Governor Spring
3. Governor Spring
4. Fork Lever
5. Fork Lever
6. Fork Lever Shaft
7. Fork Lever Holder
8. Governor Lever
9. Fuel Camshaft
10. Governor Ball Case
11. Steel Balls
12. Governor Sleeve
13. Steel Ball PI-10008
Disassemble and assemble the governor and fuel

camshaft as shown in figure [Figure 70-70-17].
Check all the parts for wear or damage and replace as

needed.

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FUEL SYSTEM (CONT’D) Fuel Injection Pump - Timing
Fuel Camshaft Removal And Installation
Remove the timing gearcase cover. (See Timing

Gearcase Cover Removal And Installation on Page 70- IMPORTANT
100-1.)
Do not attempt to maintain or adjust unless you are
Remove the idler gear. (See Idler Gear And Camshaft trained and have the correct equipment.
Removal And Installation on Page 70-70-4.) I-2028-0289
Figure 70-70-1 Timing the injection pump is done by changing the

number of shims between the injection pump and the
injection pump mounting surface.
2 Disconnect the number one cylinder high pressure line

from the injection pump.
Figure 70-70-3

1 1
P-47265
Remove the three bolts (Item 1) [Figure 70-70-1]. 1
Remove the two bolts and fuel camshaft retainer plate

(Item 2) [Figure 70-70-1].
P-68360
Figure 70-70-2
Turn the fuel supply lever (Item 1) [Figure 70-70-3] to the

ON position.
P-47266
Remove the fuel camshaft and fork lever assembly at the

same time [Figure 70-70-2].

746 of 888
FUEL SYSTEM (CONT'D) NOTE: The flywheel has three timing marks.
Fuel Injection Pump - Timing (Cont’d) The first mark to appear in the window with
the rotation is 9.25 degrees which is used for
Figure 70-70-4 loaders with the Kubota V2003T engine.
The second mark to appear in the window is

8.2 degrees which is used for loaders with the
Kubota V2203 engine.
1
The third mark to appear in the window is 6.75
degrees which is used for loaders with the
Kubota V2403 engine.
Rotate slowly until fuel just starts to flow upward into the
plastic tube.
At this instant, 6.75 degrees BTDC on the flywheel

should be aligned with the mark in the window (Item 1)
P-4361 [Figure 70-70-5]
Install a short plastic tube (Item 1) [Figure 70-70-4] in the

number one cylinder port of the injection pump. The tube
should fit securely in the port and point upward.

Figure 70-70-5
Rotation
Direction
1
P-48726
Rotate the engine in the direction shown [Figure 70-70-

5].
Continue rotation until flywheel timing mark just appears

in the window (Item 1) [Figure 70-70-5].

747 of 888
FUEL SYSTEM (CONT'D) Fuel Injector Removal And Installation
Fuel Injection Pump - Timing (Cont’d)
Figure 70-70-6
IMPORTANT
Your Landscape Rake attachment is delivered
complete with Bob-Tach mounting bracket or 3-point
1 hitch mounting system. If your machine mounting
does not easily fit into the Landscape Rake
attachment bracket, do not try to force it to fit. This
will result in damage to the rake attachment and/or
your machine. See your dealer for repair or
replacement.
I-2072-0595
Figure 70-70-8
P-4364
Add or subtract shim(s) (Item 1) [Figure 70-70-6] as

needed to adjust the fuel delivery timing. 1 1

2
NOTE: Adding or removing one shim will vary the
timing by 1.5 degrees. Adding shims retards
timing.
Figure 70-70-7
P-48712
The following are some problems caused by faulty

1 injectors:
-Engine is hard to start or will not start

-Rough engine operation and idle
-Engine will not have full power
-Excessive exhaust smoke
Disconnect the fuel return hoses (Item 1) [Figure 70-70-

P-48779 8] from the injectors.
Disconnect the high pressure fuel lines (Item 2) [Figure

The size of shims are identified by a symbol on the shims
70-70-8] from the fuel injectors and from the injection
(Item 1) [Figure 70-70-7].
pump.
(1) Two holes means 0.008 in. (0,20 mm) shim.
Remove the high pressure fuel lines from the engine.
(2) One hole means 0.010 in. (0,25 mm) shim.
(3) Without hole means 0.012 in. (0,30 mm) shim.
(4) Three holes means 0.014 in. (0,35 mm) shim.

748 of 888
FUEL SYSTEM (CONT'D) Pull on the injector nozzle to remove the injector nozzle
from the cylinder head.
Fuel Injector Removal And Installation (Cont'd)
Installation: Tighten the nozzle holder bolt to 18.8 - 21.7
ft.-lb. (25.5 - 29.4 N•m) torque.
IMPORTANT Figure 70-70-11
Do not bend the high pressure fuel injection tubes

when removing or installing them.
I-2029-0289
1
Figure 70-70-9 2
P-37583

[Figure 70-70-11] shows the injector nozzle removed
2 from the cylinder. Inspect the injector and replace if
necessary.
P-48727 Check and replace the injector nozzle O-rings (Item 1)

and the nozzle washer (Item 2) before installing new or
used injectors. [Figure 70-70-11].
Remove the four retainer bolts from the top of the fuel
injectors (Item 1) [Figure 70-70-9].
Remove the fuel return tube (Item 2) [Figure 70-70-9]

from the fuel injectors.
Figure 70-70-10
P-48728
Remove the injector nozzle holder bolt (Item 1) [Figure

70-70-10] from the cylinder head.

749 of 888
FUEL SYSTEM (CONT'D) Nozzle Spraying Condition
Fuel Injector Nozzle Pressure - Checking The tool listed will be needed to do the following
procedure:
procedure: OEM1064 - Injector Nozzle Tester
OEM1064 - Injector Nozzle Tester Figure 70-70-13
Figure 70-70-12 Correct Incorrect
3EEABAC1P013A

3EEABAC1P012A
[Figure 70-70-13] Set the injection nozzle to a nozzle
tester, and check the nozzle spraying condition.
[Figure 70-70-12] Set the injection nozzle to the nozzle
tester. If the spraying condition is defective, replace the injection
nozzle assembly.
Slowly move the tester handle to measure the pressure
at which fuel begins jetting out from the nozzle.
If the measurement is not within the factory

specifications, replace the injection nozzle assembly.
NOTE: Injection nozzle gasket must be replaced

when the injection nozzle is removed for
checking.
Injection Fac- 18.6 to 20.1 MPa

pressure tory 190 to 205 kgf/cm²
spec. 2702 to 2916 PSI

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FUEL SYSTEM (CONT'D)
Valve Seat Tightness

procedure:
OEM1064 - Injector Nozzle Tester
Figure 70-70-14

3EEABAC1P014A
[Figure 70-70-14] Set the injection nozzle to a nozzle

tester.
Raise the fuel pressure, and keep at 16.67 MPa (170 kgf/
cm², 2418 PSI) for 10 seconds.
If any fuel leak is found, replace the injection nozzle

assembly.
Valve seat Factory No fuel leak at 16.67 MPa

tightness spec. 170 kgf/cm²
2418 PSI

751 of 888

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CYLINDER HEAD Glow Plugs Removal And Installation
Glow Plugs - Testing Figure 70-80-3
Figure 70-80-1
2 3
P-48698
P-48702
Disconnect the negative (-) cable from the battery.
Disconnect the glow plug cables and leads. Remove the nut (Item 1) [Figure 70-80-3] from the top of
each glow plug.

Use an ohmmeter to check the glow plugs [Figure 70-80-
1].The resistance should be approximately one ohm. Disconnect the engine harness wire (Item 2) [Figure 70-
80-3] from the glow plug.
Figure 70-80-2
Remove the glow plug connecting strap (Item 3) [Figure
70-80-3].
Figure 70-80-4
1
P-48701
Touch one probe to the end of the glow plug and the
other probe to the body of glow plug (Item 1) [Figure 70-
P-48699
80-2].
Repeat the procedure for each glow plug. Loosen and remove the glow plug (Item 1) [Figure 70-
80-4].
Installation: Tighten the glow plug to 14.5 - 18.1 ft.-lb.

(19,6 - 24,5 N•m) torque.

753 of 888
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
B-5568
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 valve stem tip (Item 3) [Figure
70-80-6].

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CYLINDER HEAD (CONT'D) Valve Timing, Checking
Valve Clearance Adjustment (Cont’d) Figure 70-80-9
Figure 70-80-7
4
3
1 2 3 4 5 6 7 8 1
2
(1) Idle Gear
(2) Idle Collar
(3) External Snap Ring
(4) Cam Gear
(5) Camshaft B-14341
B-05569
Figure 70-80-8 Remove the engine. (See Removal And Installation on

Page 70-10-8.)

Cylinder Number 1 2 3 4 Remove the timing gearcase cover. (See Timing
100-1.)
Valve Number 1 2 3 4 5 6 7 8
Make sure the timing marks are in correct alignment
[Figure 70-80-9].
Valve
I=Intake I E I E I E I E
E=Exhaust
Adjust the valve clearance as follows:
0.0071 - 0.0087 in. (0,18 - 0,22 mm) Intake &

Exhaust
Use the following sequence to set the valves [Figure 70-

80-7] & [Figure 70-80-8]:
1. With the rocker arm rocking (valves 7 & 8) on No. 4

cylinder set clearance at No. 1 cylinder (valves 1 & 2).




755 of 888
CYLINDER HEAD (CONT'D) Figure 70-80-12
Cylinder Head Removal And Installation
Figure 70-80-10
2 4 1
2
3
P-47243
Remove the glow plugs (Item 1) and fuel injector holder

P-47241 assemblies (Item 2) [Figure 70-80-12].
Installation: Tighten the glow plugs to 11 - 14.5 ft.-lb. (15

Remove the glow plug lead (Item 1), breather hose (Item - 19.6 N•m) torque.
2), and valve cover bolts (Item 3) [Figure 70-80-10].

Tighten the injector holders to 19 - 22 ft.-lb. (25.5 - 29.4
Remove the valve cover (Item 4) [Figure 70-80-10] and N•m) torque.
gasket.
Figure 70-80-13
Installation: Gradually tighten the valve cover bolts to 5 -
8 ft.-lb. (7 - 11 N•m). Tighten center bolts first, then work
your way to the front and back of the valve cover.
1
Figure 70-80-11
2
2
2
2
B-14332
Remove the rocker arm bolts and remove the rocker arm
assembly (Item 1) [Figure 70-80-13].
P-47242
Installation: Tighten the bolts to 17 - 20 ft.-lb. (23.5 -
27.5 N•m) torque.
Loosen the bolts on the clamps (Item 1) and remove the
injection tubes (Item 2) [Figure 70-80-11]. Remove the pushrods (Item 2) [Figure 70-80-13].
Remove the overflow tube assembly.

756 of 888
Cylinder Head Removal And Installation (Cont'd) 14 6 3 11

18 10 2 7 15
Figure 70-80-14
2
17 9 1 8 16
13 5 4 12
P-47247
Remove the cylinder head bolts in order of #18 to #1

P-47245 [Figure 70-80-16].
NOTE: (A) is the water pump side, (B) is the flywheel

Installation: The push rod (Item 1) must be seated in the side.
tappet (Item 2) [Figure 70-80-14] correctly or the push

rods will be damaged. Installation: Put oil on the bolt threads. Tighten the bolts
in the correct sequence in order of #1-#18 to 68 - 72 ft.-
After installing the rocker arm assembly and push rods, lb. (93 - 98 N•m).
the valve lash must be adjusted. (See Valve Clearance
Adjustment on Page 70-80-2.) NOTE: Re-tighten the cylinder head bolts in the
correct sequence after the engine has been
Figure 70-80-15 run for 30 minutes.
Figure 70-80-17
1
1
2
P-47246
P-47248
Remove the clamps (Item 1) and remove the hose (Item
2) [Figure 70-80-15] from the thermostat housing.
Remove the cylinder head (Item 1) and gasket (Item 2)
[Figure 70-80-17].

757 of 888
Cylinder Head Removal And Installation (Cont'd) Gasket Size

Piston Protrusion
(Number)
Figure 70-80-18 0.475 to 0.525 mm
15
0.0187 to 0.0207 in.
0.525 to 0.575 mm
20
0.0207 to 0.0226 in.
25 0.575 to 0.625 mm
0.0226 to 0.0246 in.
0.625 to 0.067 mm
30
0.0246 to 0.0266 in.
35 0.675 to 0.725 mm
0.0266 to 0.0285 in.
Select the correct gasket size (thickness) from the chart

1 [Figure 70-80-20].
P-47249A
Find the measurement of the highest piston protrusion

and the lowest piston protrusion (recorded earlier) for
When replacing just the gasket, use a new gasket that each piston.
has the same mark (Item 1) [Figure 70-80-18] as the

original gasket. If the highest measurement exceeds the piston
protrusion of the selected gasket, use the gasket which is
one size larger. If the measurement exceeds gasket size
When replacing the gasket after an engine rebuild, the
35, the engine must be disassembled, clearances
piston protrusion must be measured. checked, and reassembled.
(See Cylinder Head Top Clearance on Page 70-80-8.) If the measurement is two sizes smaller than the selected
gasket or smaller than gasket size 15, the engine must
Figure 70-80-19 be disassembled, clearances checked, and
reassembled.
After the gasket and cylinder head have been installed,

turn the crankshaft by hand to be sure there is no
1 interference between the piston, cylinder, and valves.
P-47252
Measure and record the protrusion of each piston in the

four places shown (Item 1) [Figure 70-80-19]. Find the
average of each piston, then find the combined average
of the four pistons.

758 of 888
CYLINDER HEAD (CONT'D) Cylinder Head - Servicing
Cylinder Head Disassembly And Assembly Clean the surface of the cylinder head.
Figure 70-80-21 Figure 70-80-23
PI-9987 P-51629
Use a valve spring compressor to compress the valve Put a straight edge (Item 1) [Figure 70-80-23] on the
spring [Figure 70-80-21]. cylinder head.

Figure 70-80-22 NOTE: Do not put the straight edge across
combustion chambers.
Put a feeler gauge (Item 2) [Figure 70-80-23] between

the straight edge and the surface of the cylinder head.
Figure 70-80-24
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 70-80-21] & [Figure 70-80-22].
Remove the valve spring retainer (Item 3) and the spring

PI-9988
(Item 4) [Figure 70-80-21] & [Figure 70-80-22].
Remove the seal (Item 6) and the valve (Item 5) [Figure Put the straight edge on the cylinder head's four sides
70-80-21] & [Figure 70-80-22]. and two diagonal as shown in figure [Figure 70-80-24].
The maximum distortion of the head surface is ± 0.002 in.

(± 0,05 mm). If the measurement exceeds the
specification, replace the cylinder head.

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CYLINDER HEAD (CONT'D) Valve Guide-Checking
Cylinder Head Top Clearance Remove the valve and spring from the cylinder head.
(See Cylinder Head Disassembly And Assembly on Page
Figure 70-80-25 70-80-7.)
Remove the carbon from the valve guide.
2 Figure 70-80-26
1 3
P-51631
Install the cylinder head gasket. Put the piston (Item 1)

[Figure 70-80-25] being checked at T.D.C.
B-14335

Put 3 pieces of 0.06 in. (1,5 mm) diameter solder (Item 2)
[Figure 70-80-25] on the top of the piston. Use grease to Measure the valve stem O.D. [Figure 70-80-26].
hold them in position.
Measure the valve guide I.D. [Figure 70-80-26].
NOTE: Put the solder in position so they do not touch
the valves. Calculate the clearance. If the clearance exceeds the
allowable limit, replace the valve and/or valve guide.
Turn the piston to bottom dead center.
Valve Guide I.D. 0.3156 - 0.3161 in.
Install the cylinder head and tighten to the correct torque (8,015 - 8,03 mm)
in the correct sequence. (See Cylinder Head Removal
Valve Stem O.D. 0.3134 - 0.3140 in.
(7,96 - 7,98 mm)
Clearance Between 0.0016 - 0.0028 in.
Turn the crankshaft until the piston exceeds T.D.C.
Valve Stem and Guide (0,04 - 0,07 mm)
Remove the cylinder head.
Allowable Limit 0.004 in.
Remove the solder wire (Item 3) [Figure 70-80-25] and (0,1 mm)
measure it.
If the measurement exceeds the specifications, check the

oil clearance of the crank pin journal or the piston pin.
Top Clearance 0.0236 - 0.0276 in. (0,6-0,7 mm)

760 of 888
CYLINDER HEAD (CONT'D) Reconditioning The Valve And Valve Seat
Valve Guide-Checking (Cont’d) Figure 70-80-29
Figure 70-80-27
8.86” (225 mm)
0.787” 2.76” (70mm) 1.77”

(20 mm) (45 mm)
0.460-0.468”
(11,7-11,9 mm) 0.256-0.259”
(6,5-6,6 mm)
0.2” 0.350-0.358” 0.787”
(5,0 mm) (8.9-9.1 mm) (20,0 mm)
0.263-0.275” 0.98” PI-9993

0.490-0.50”
(6,7-7 mm) (25,0 mm) (12.5-12.8 mm)
MC-1364
Grind the valve face to the correct angle using a valve re-
facer [Figure 70-80-29].
To remove and replace the valve guide, make the driver
tool as shown in figure [Figure 70-80-27]. Clean the valve seat and combustion chamber.

Figure 70-80-28 Figure 70-80-30
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 70-80-28]. recessing or protrusion with a depth gauge [Figure 70-
80-30].
Put oil on the outside diameter of the new valve guide.
Press the new valve guide into the cylinder head from the
top side. Use the special driver tools (Items 1 & 2)
[Figure 70-80-28], press the new guide until the tool
contacts the cylinder head.
Ream the valve guide to the correct specifications.

761 of 888
Reconditioning The Valve And Valve Seat (Cont’d) 1 2

15° Exhaust
Figure 70-80-31 30° Intake
1. Cylinder Head
Surface PI-9995
2. Recessing
3. Protrusion
Check the seat surface and valve face (Item 1) [Figure
PI-9990 70-80-33].
If the measurement exceeds the allowable limit, replace (a) identical dimensions above and below the valve seat
the valve or cylinder head [Figure 70-80-31].
If the seat surface (b) is too wide, use a 30 degree cutter

(Item 2) on the intake, and a 15 degree cutter on the
Protrusion 0.002 in. (0,5 mm)
exhaust to get the correct width (Item 3) [Figure 70-80-
Recessing 0.006 in. (0,15 mm) 33].
Allowable Limit (Recessing) 0.016 in. (0,4 mm)
Valve Seat Width
Figure 70-80-32
Intake 0.0835 in. (2,12 mm)
Exhaust 0.0835 in. (2,12 mm)
Valve Seat & Face Angle
Intake 60°
Exhaust 45°
45° Exhaust
15° Exhaust 60° Intake
30° Intake
PI-9994
Grind the valve seat surface in the cylinder head to the

correct angle [Figure 70-80-32].

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Valve Spring
Figure 70-80-34
A-2759
Put the spring on a tester and compress to specified

B-3680 length [Figure 70-80-35].
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 70-80-34].
Setting Length 1.378 in. (35,0 mm)
Free Length 1.6417 - 1.6614 in. (41,7 - 42,2 mm) Setting Load 26.4 lb. (117,6 N)
Allowable Limit 1.622 in. (41,2 mm) Allowable Limit 22.5 lb. (100,0 N)
Put the spring on a flat surface, place a square on the

side of the spring [Figure 70-80-34].
Rotate the spring and measure the maximum tilt. If the

measurement exceeds the allowable limit, replace the
spring.
Tilt Allowable Limit 0.039 in. (1,0 mm)

763 of 888
CYLINDER HEAD (CONT'D) Rocker Arm And Shaft Checking
Valve Tappets Figure 70-80-38
Figure 70-80-36
1
2
B-3697
P-47267
Measure the rocker arm I.D. (Item 1) [Figure 70-80-38]
with an inside micrometer.
Remove the valve tappets (Item 1) [Figure 70-80-36].
Measure the rocker arm shaft O.D. (Item 2) [Figure 70-

Figure 70-80-37 80-38] with an outside micrometer.

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 0.0006 - 0.0018 in.
(0,016 - 0,045 mm)
(0,10 mm)
Rocker Arm Shaft O.D. 0.5501 - 0.5506 in.
(13,973 - 13,984 mm)
P-47268 Rocker Arm I.D. 0.5512 - 0.5519 in.
(14,0 - 14,02 mm)
Measure the O.D. of the tappet [Figure 70-80-37].
Measure the ID of the tappet bore [Figure 70-80-37].

tappets.
Tappet OD 0.9433 - 0.9441 in. (23,96 - 23,98mm)

Tappet Bore ID 0.9449 - 0.9457 in. (24 - 24,02 mm)
Clearance
Between Tappet
and Tappet Bore 0.0008 - 0.0024 in. (0,02 - 0,06 mm)
Allowable limit 0.0028 in. (0,07 mm)

764 of 888
CYLINDER HEAD (CONT'D)
Push Rod Alignment - Checking
Figure 70-80-39
P-76926
Place the push rod on V blocks [Figure 70-80-39].

Measure the push rod alignment [Figure 70-80-39].
If the push rod exceeds the allowable limit, replace the

push rod.
Push rod Allowable 0.0098 in. (0,25 mm)

alignment limit

765 of 888

766 of 888
CRANKSHAFT AND PISTONS Figure 70-90-2
Piston And Connecting Rod Removal And

Installation
Remove the cylinder head. (See Cylinder Head Removal

Remove the top edge from the cylinder bore with a ridge
reamer.
Remove the oil pan.
Figure 70-90-1
1
P-51633
1
Remove the rod cap and bearing [Figure 70-90-2].
Use a hammer handle and push the piston/connecting

2 rod assembly out of the cylinder bore [Figure 70-90-2].
NOTE: Make sure the pistons are marked so they will

be returned to the same cylinder bore.
Installation: Do not damage the piston skirt (Item 1)

[Figure 70-90-2] when installing piston assembly.
P-47269
Figure 70-90-3
Remove the oil pump strainer (Item 1) and O-ring (Item

2) [Figure 70-90-1] by tapping the edge of the strainer
with a soft faced hammer.
Turn the flywheel and put a pair of connecting rods at

bottom dead center.
Remove the connecting rod bolts.

1
Installation: Tighten the connecting rod bolts to 33 - 36
A-2903
Installation: Make sure the marks on the connecting rod

and bearing are aligned when installing the bearing cap
(Item 1) [Figure 70-90-3].
Repeat the procedure to remove the other piston/

connecting rod assemblies from the engine block.

767 of 888
CRANKSHAFT AND PISTONS (CONT'D) Figure 70-90-6
Piston And Connecting Rod Removal And

Installation (Cont’d) 3
1
Figure 70-90-4 2
4
1 3
5
2 4
1
P-47271
Installation: When reassembling, align the marks (Item

1) on the connecting rod and piston (Item 2). Heat the
P-47270 piston in clean engine oil to 176° F (80° C) and tap the
piston pin into position. Place the piston rings so that
there are gaps every 120 degrees (Items 3, 4 & 5)
Remove the piston rings [Figure 70-90-4]. [Figure 70-90-6] with no gap facing the piston pin in the

cylinder.
Remove the snap ring (Item 1) and piston pin (Item 2)
[Figure 70-90-4]. Piston And Connecting Rod - Servicing
Separate the piston (Item 3) from the connecting rod Figure 70-90-7
(Item 4) [Figure 70-90-4].
Figure 70-90-5
1
P-47272
3
PI-10015 Measure the I.D. of the piston pin bore in both horizontal
and vertical directions [Figure 70-90-7].
Installation: When installing new rings, assemble the If the measurement exceeds the allowable limit, replace
ring so the mark (Item 1) near the gap faces the top of the the piston.
piston. When installing the oil ring, place the expander
joint (Item 2) on the opposite side of the oil ring gap (Item Piston Bore I.D. 0.9843 - 0.9848 in.
3) [Figure 70-90-5].
(25,0 - 25,013 mm)
(25,05 mm)

768 of 888
Piston And Connecting Rod - Servicing (Cont’d) 1.38” (35 mm)

1.063” (27 mm)
Figure 70-90-8
6.38” (162 mm)
1 1.378”
(35 mm)
2
1.098-1.1004”
(27,9-27,95 mm)
0.984-0.985”
(25,0-25,01 mm)
MC-1366
To replace the connecting rod small end bushing, make a

P-47273 driver tool as shown in figure [Figure 70-90-9].
Figure 70-90-10
Measure the O.D. of the piston pin (Item 1) [Figure 70-
90-8].

Measure the I.D. of the connecting rod small end (Item 2)
[Figure 70-90-8].
Calculate the oil clearance. If the clearance exceeds the

allowable limit, replace the bushing. If it still exceeds the
specifications, replace the piston pin.
Piston Pin O.D. 0.9843 - 0.9847 in.

(25,0 - 25,011 mm)
Bushing I.D. 0.9852 - 0.9858 in.
(25,03 - 25,04 mm)
PI-10016
Oil Clearance Between Piston Pin
& Bushing 0.0006 - 0.0015 in.
(0,014 - 0,038 mm) Use a press and special driver tool to remove the small
end bushing [Figure 70-90-10].
(0,15 mm) Installation: Clean the small end bushing and bore. Put
oil on the bushing and press into the connecting rod until
it is flush [Figure 70-90-10].

769 of 888
Piston And Connecting Rod - Servicing (Cont’d)
Figure 70-90-11
P-51630
Remove the carbon from the ring grooves. Measure the

B-3622 clearance between the ring and groove with a feeler
gauge [Figure 70-90-12].
Install a piston ring into the lower part of the cylinder If the clearance exceeds the allowable limit, replace the
bore. Measure the ring gap with a feeler gauge [Figure ring. If the clearance still exceeds the allowable limit,

70-90-11]. replace the piston.
If the gap exceeds the allowable limit, replace the ring. Second Ring 0.0037 - 0.0050 in.
(0,093 - 0,128 mm)
Top Ring Gap 0.0079 - 0.0138 in. Allowable Limit 0.0079 in. (0,2 mm)
(0,2-0,35 mm) Oil Ring 0.0008 - 0.0024 in. (0,02
Oil Ring Gap 0.0098 - 0.0177 in. - 0,06 mm)
(0,25 - 0,45 mm) Allowable Limit 0.0059 in. (0,15 mm)
(1,25 mm)
Second Ring Gap 0.016 - 0.022 in.
(0.40 - 0,55 mm)

770 of 888
CRANKSHAFT AND PISTONS (CONT'D) Connecting Rod Alignment
Cylinder Bore - Checking NOTE: The small end bushing is the basis of this
check, check the bushing for wear before
Figure 70-90-13 doing this check.
Install the piston pin into the connecting rod.
Install the connecting rod on an alignment tool.
Put the gauge over the piston pin and move it against the
face plate.
Figure 70-90-15
B-4066
Use a gauge to check the inside measurement of the

cylinder bore [Figure 70-90-13].

Figure 70-90-14
B-4067
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 0.002 in. (0,05 mm)

A-2717
Measure the six points as shown in figure [Figure 70-90-

14] to find the maximum wear.
The factory specifications are:
3.4252 - 3.4261 in. (87,000 - 87,022 mm).
The wear limit is +0.0059 in. (+0,15 mm).
If the cylinder bore is not within specifications, re-bore the

cylinder for oversize piston.

771 of 888
CRANKSHAFT AND PISTONS (CONT'D) Crankshaft And Bearings Removal And Installation
Crankshaft Gear Removal And Installation Remove the piston and connecting rod assemblies. See
Piston And Connecting Rod Removal And Installation on
Remove the timing gearcase cover.(See Timing Page 70-90-1.
100-1.) Figure 70-90-17
Remove the idler gear. (See Idler Gear And Camshaft

2 5
Figure 70-90-16
4
P-47274

Mark and remove the inside screws (Item 1) first, then
remove the outside screws (Item 2) [Figure 70-90-17].
B-3686
NOTE: The inside bolts are different length than the
outside bolts.
Remove the crankshaft gear with a puller [Figure 70-90-
16]. Install two screws in the bearing case cover and remove
the cover (Item 3) [Figure 70-90-17].
Remove the crankshaft key.
Remove the two gaskets (Item 4) and oil seal (Item 5)
[Figure 70-90-17] from the cover.
Figure 70-90-18
P-47275
Installation: Install the gaskets (Item 1) & (Item 2)

[Figure 70-90-18] as shown.

772 of 888
Crankshaft And Bearings Removal And Installation

(Cont’d)
Figure 70-90-19
1
1
P-47278
Remove the main bearing case bolt (Item 1) [Figure 70-

90-21].
P-47276
Installation: Align the bearing case hole (Item 2) [Figure
Install the bearing case cover (Item 1) with the casting 70-90-21] with the hole in the block. Put oil on the bolt
mark (Item 2) [Figure 70-90-19] in the upward position. threads and tighten to 51 - 54 ft.-lb. (69 - 73 N•m) torque.

Tighten the bolts to 17 - 20 ft.-lb. (23.5 - 27.5 N•m)
torque. Figure 70-90-22
Figure 70-90-20
P-47279
P-47277
Remove the crankshaft/main bearing assembly from the
engine block [Figure 70-90-22].
Before removing the crankshaft/main bearings, check the
end play. Install a dial indicator. Move the crankshaft NOTE: Turn the crankshaft as needed to allow the
[Figure 70-90-20] to the flywheel side, zero the dial crank pin journals to pass through the cut out
indicator. Measure the end play by pulling the crankshaft (Item 1) [Figure 70-90-22] of the engine block.
toward the gear case side.
Mark the bearing case halves for correct installation.
If the measurement exceeds the allowable limit, replace
the thrust washers [Figure 70-90-20].
End Play 0.0059 - 0.0138 in.

(0,15 - 0,35 mm)
(0,5 mm)

773 of 888
CRANKSHAFT AND PISTONS (CONT'D) Crankshaft And Bearings - Servicing
Crankshaft And Bearings Removal And Installation Figure 70-90-25

(Cont’d)
Figure 70-90-23
A-2763
B-4092 Put the crankshaft on V-blocks. Install a dial indicator on

the center journal [Figure 70-90-25].
Remove the two bearing case bolts [Figure 70-90-23]. Turn the crankshaft at a slow rate to obtain the

misalignment (one half of the alignment measurement).
Remove the bearing case and bearing.
If the misalignment exceeds the allowable limit, replace
Installation: Tighten the bearing case bolts to 34 - 38 ft.- the crankshaft.
Alignment 0.0008 in. (0,02 mm)
Figure 70-90-24
Tighten the connecting rod bolts to 33 - 36 ft.-lb. (45 - 49
N•m) torque.
Figure 70-90-26
120
PI-10021
Installation: When installing the main bearing case

assemblies, face the mark FLYWHEEL to the flywheel
A-2727
side of the engine block [Figure 70-90-24]. The thrust
washers oil grooves must face outward.
Measure the crankpin bearing I.D. [Figure 70-90-26].

774 of 888
Crankshaft And Bearings - Servicing (Cont’d) 1
Figure 70-90-27
PI-10022
Check the wear on the crankshaft sleeve (Item 1) [Figure

A-2716 70-90-28].
If the wear exceeds the allowable limit or the seal leaks

Measure the crankpin O.D. [Figure 70-90-27]. oil, replace the sleeve.

Calculate the oil clearance. Wear of Sleeve 0.0039 in. (0,1 mm)
Crankpin Bearing I.D. 1.8504 - 1.8522 in.

The special tool set will be needed to replace the
(47,0 - 47,05 mm) crankshaft sleeve.
Crankpin O.D. 1.8488 - 1.8494 in.
(46,96 - 46,98 mm) Remove the sleeve.
Oil Clearance 0.0010 - 0.0034 in.
(0,025 - 0,087 mm)
Allowable limit 0.008 in. (0,2 mm)

775 of 888
Crankshaft And Bearings - Servicing (Cont’d)
Figure 70-90-29
2 2
1 3
B-3618
Measure the O.D. of the crankshaft journal [Figure 70-

PI-10023 90-31].
Calculate the oil clearance.

Install the sleeve guide (Item 1) and stop (Item 2) [Figure
70-90-29]. If the clearance exceeds the allowable limit, replace the

No. 1 crankshaft bearing.
Heat the sleeve to approximately 300° F (150° C). Install
the sleeve on the crankshaft using the special driver tool Bearing 1:
(Item 3) [Figure 70-90-29].
Bearing I.D. 2.3614 - 2.3637 in. (59,98 - 60,04 mm)
NOTE: The sleeve is installed with the larger
Journal O.D. 2.3591 - 2.3598 in. (59,92 - 59,94 mm)
chamfered surface to the front of the
Oil Clearance 0.0016 - 0.0046 in. (0,04 - 0,12 mm)
crankshaft (Item 1) [Figure 70-90-28 on Page
9]. Allowable Limit 0.0079 in. (0,2 mm)
Figure 70-90-30
B-3631
Measure the I.D. of the No. 1 crankshaft bearing [Figure

70-90-30].

776 of 888

1. Seam 4
Figure 70-90-32 2. Bearing
3. Engine Block
Removal Tool 4. Bearing Recession
3
5.31” (135 mm)
0.8”
(20 mm)
2.354-2.358”
(59,80-59.90 mm)
2.83”
(72 mm) 2 1 2
P-48778
0.8” (20 mm)
2.551-2.555
1.57” 0.4” (64,80-64,90 mm) Remove the front bearing with the special removal tool
(40 mm) (10 mm) MC-1367 [Figure 70-90-32].
Installation: Clean the new bearing (Item 2) and bore,

To remove the front bearing make the tool as shown in apply oil to the bearing and bore. Install the new bearing
figure [Figure 70-90-32]. with the seam (Item 1) [Figure 70-90-34] towards the

exhaust manifold side, using the installation driver tool.
Figure 70-90-33
Check the depth (Item 4) of the bearing (Item 2) from the
Installation Tool face of the engine block (Item 3) [Figure 70-90-34]. This
5.12” (130 mm) will ensure proper bearing alignment with the crankshaft.
0.8”
(20 mm) Bearing Number 1 0.1654 - 0.1772 in.
0.16”
(4 mm) Recession (4,2 - 4,5 mm)
2.551-2.555”
2.83” (64,80-64.90 mm) Clean the crankshaft journal and bearing. Put a strip of
(72 mm) press gauge on the center journal.
2.68”
(68 mm) Install the main bearing case halves and tighten the bolts.
Remove the bearing case halves.
0.8” (20 mm)
1.57” 2.354-2.358” NOTE: DO NOT turn the crankshaft with the press
0.4” (59,80-59,90 mm) gauge installed. Incorrect measurements will
(40 mm) (9mm) MC-1365 be obtained.
To install the front bearing make the tool as shown in

figure [Figure 70-90-33].

777 of 888
CRANKSHAFT AND PISTONS (CONT'D)
Figure 70-90-35
PI-10025
Measure the flattened press gauge [Figure 70-90-35].

No. 2 crankshaft bearing.
Bearing No. 2
Journal O.D. 2.3591 - 2.3598 in. (59,92 - 59,94 mm)

Bearing I.D. 2.3614 - 2.3632 in. (59,98 - 60,02 mm)
Oil Clearance 0.0016 - 0.0041 in. (0,04 - 0,12 mm)
Allowable Limit 0.0079 in. (0,2 mm)

778 of 888
CAMSHAFT AND TIMING GEARS Figure 70-100-3
Timing Gearcase Cover Removal And Installation
Figure 70-100-1
7.87” (200 mm)
P-47256
Remove the speed control plate (Item 1) [Figure 70-100-

P-47254 3].
Figure 70-100-4
Bend a hook on the end of a 7.87 in. (200 mm) long,
0.050 in. (1.2 mm) diameter hard wire [Figure 70-100-1].

Figure 70-100-2
P-47257
Remove the wire (Item 1) [Figure 70-100-4] from the

P-47255 springs.
Installation: Do not drop the governor springs into the

Disconnect the two governor springs (Item 1) [Figure 70- gear case.
100-2].
Remove the crankshaft pulley nut.

N•m) torque.

779 of 888
CAMSHAFT AND TIMING GEARS (CONT'D) Figure 70-100-7
Timing Gearcase Cover Removal And Installation

(Cont'd)
Figure 70-100-5
P-47259
Remove the timing gearcase cover [Figure 70-100-7].
P-47258 Figure 70-100-8
Use a puller and remove the crankshaft pulley. [Figure

70-100-5].
3
2
Figure 70-100-6
1
2
B-14340
Remove the crankshaft collar (Item 1), O-ring (Item 2)

and oil slinger (Item 3) [Figure 70-100-8].
B-14339
Remove the crankshaft pulley (Item 1) and key (Item 2)

[Figure 70-100-6].
Remove the bolts from the timing gearcase cover.

N•m) torque.

780 of 888
CAMSHAFT AND TIMING GEARS (CONT'D) Timing Gears Backlash-Checking
Timing Gearcase Cover Removal And Installation When the gears are installed, check the backlash of the
(Cont'd) gears.
Figure 70-100-9 Figure 70-100-10
Oil Seal O-Rings
B-3617B P-47264
Installation: Install new O-rings and oil seal into the Install a dial indicator [Figure 70-100-10].

timing gearcase cover [Figure 70-100-9].
Hold one gear while turning the other gear [Figure 70-
100-10].
If the backlash exceeds the allowable limit, check the oil

clearance of the shaft and gear. If the oil clearance is
correct, replace the gear.
Crank Gear & Idler Gear 0.0016 - 0.0044 in.

(0,042 - 0,112 mm)
(0,15 mm)
Cam Gear & Idler Gear 0.0016 - 0.0045 in.
(0,042 - 0,115 mm)
(0,15 mm)
Injection Pump Gear & Idler Gear
0.0016 - 0.0045 in.
(0,042 - 0,115 mm)
(0,15 mm)
Oil Pump Gear & Crankgear 0.0016 - 0.0043 in.
(0,042 - 0,109 mm)
(0,15 mm)

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CAMSHAFT AND TIMING GEARS (CONT'D) Installation: Check the idler gear end play. If the
clearance exceeds the allowable limit, replace the gear
Idler Gear And Camshaft Removal And Installation collar.
Remove the timing gearcase cover. (See Timing Idler Gear End Play 0.0047 - 0.0189 in.
Gearcase Cover Removal And Installation on Page 70- (0.12 - 0.48mm)
100-1.) Allowable Limit 0.0354 in. (0,9 mm)
Figure 70-100-11 Figure 70-100-13
2 2
1
P-47260 P-47262

Remove the snap ring (Item 1) and collar from the idler Align the holes (Item 1) on the camshaft gear with the
gear shaft (Item 2) [Figure 70-100-11]. camshaft retainer plate bolts (Item 2) [Figure 70-100-13].
Remove the bolts.
Installation: Make sure the timing marks are in correct
alignment when installing the timing gears [Figure 70- Installation: Tighten the camshaft retainer bolts to 18 -
100-11]. 20 ft.-lb. (24 - 27 N•m) torque.
Figure 70-100-12 Remove the camshaft from the engine block.
Figure 70-100-14
B-3699
PI-10002B
Installation: Check the camshaft end play. If clearance
exceeds the allowable limit, replace the camshaft retainer
plate [Figure 70-100-14].
Camshaft End Play 0.0028 - 0.0087 in.

(0,07 - 0,22 mm)

782 of 888
Camshaft - Servicing
Figure 70-100-15
B-5001
Measure the cam lobes at their highest point [Figure 70-

P-47263 100-17].
If the measurement is less than the allowable limit,

Measure the cylinder block bore in the engine block replace the camshaft.
[Figure 70-100-15].

Cam Lobe Height 1.3346 in. (33,9 mm)
Figure 70-100-16
Figure 70-100-18
A-2761
Measure the camshaft journal [Figure 70-100-16]. A-2760
Calculate the oil clearance. If the clearance exceeds the

Put the camshaft in V-blocks. Install a dial indicator
allowable limit, replace the camshaft.
[Figure 70-100-18].
Cylinder Block Bore I.D. 1.5748 - 1.5758 in. Turn the camshaft at a slow rate. If the misalignment
(40,0 - 40,03 mm) exceeds the allowable limit, replace the camshaft.
Journal O.D. 1.5722 - 1.5728 in.
(39,93 - 39,95 mm) Camshaft Alignment Allowable Limit 0.0004 in.
Oil Clearance of Camshaft Journal (0,01 mm)
0.002 - 0.0036 in.
(0,05 - 0,091 mm)
(0,15 mm)

783 of 888
Idler Gear And Shaft Servicing

1.49” (38 mm)
Figure 70-100-19
6.89” (175 mm)
1.77” 1.575”
(45 mm) (40 mm)
1.650-1.652”
(41,9-41,95 mm)
1.494-1.495”
(37,95-37,97 mm)
MC-1366
To replace the idler gear bushing, make a driver tool as

PI-10003 shown in figure [Figure 70-100-20].
Figure 70-100-21
Measure the O.D. of the idler gear shaft [Figure 70-100-
19].

Measure the I.D. of the idler gear bushing [Figure 70-
100-19].

bushing.
Idler Gear Shaft O.D. 1.4945 - 1.4951 in.

(37,96 - 37,98 mm)
Idler Gear Bushing I.D. 1.4961 - 1.4970 in.
(38,0 - 38,03 mm)
Clearance Between Idler Shaft &
PI-10004
Gear Bushing 0.001 - 0.0026 in.
(0,025 - 0,07 mm)
Allowable Limit 0.0039 in. Use a press and special driver tool, to remove the old
(0,1 mm) bushing and install the new bushing [Figure 70-100-21].

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TURBOCHARGER Figure 70-110-2
Description
WARNING 1
Turbochargers, operate at high speed and high 2

temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
Figure 70-110-1 P-48783
The oil flows from the fitting (Item 1) on the front of the
engine to the turbocharger and returns to the engine
block through the fitting (Item 2) [Figure 70-110-2].
The turbocharger internal components are not

serviceable.

Testing
Inspect the turbine fins and the turbo housing for

1 damage.
Spin turbine by hand. Turbine should spin freely.

P-48893
If the turbine is damaged replace the turbocharger.
The turbocharger (Item 1) [Figure 70-110-1] is placed Check the oil tubelines for leaks.
between the exhaust and 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.

785 of 888
TURBOCHARGER (CONT'D) Figure 70-110-4
Remove the muffler. (See Removal And Installation on

Page 70-30-1.) 1
Figure 70-110-3
2 1
P-48598
Figure 70-110-5
1
P-48599

Remove the compressor outlet hose (Item 1) [Figure 70- 2
110-3] from the turbo.
Remove the air cleaner hose (Item 2) [Figure 70-110-3]

from the turbocharger.
P16230
Remove the oil supply line fitting (Item 1) [Figure 70-110-

4] and [Figure 70-110-5] and the brass washer(s) (Item
2) [Figure 70-110-5] from the turbocharger.
Installation: Tighten to 12 - 15 ft.-lb. (16,0 - 20,3 N•m)

torque.

786 of 888
Figure 70-110-6
1 1 P-48780

P-48597 from the exhaust muffler flange.

Figure 70-110-7 torque.

Figure 70-110-9
1
1
2
P-48785
P-48781
Remove the mounting bolts (Item 1) [Figure 70-110-6] &
[Figure 70-110-7] from the oil return line (Item 2) [Figure
70-110-7]. Remove the mounting bolt (Item 1) [Figure 70-110-9]
from the exhaust muffler flange.
Installation: Tighten to 84 - 132 in.-lb. (9,5 - 15,0 N•m)
torque. Installation: Tighten to 17 - 20 ft.-lb. (23,0 - 27,0 N•m)
torque.

787 of 888

1
Figure 70-110-10
1
1
P16230
Remove the turbocharger assembly (Item 1) [Figure 70-

P-48601 110-11] from the engine.
Remove the mounting nut and washer (Item 1) [Figure

70-110-10] from the turbocharger.

torque.

788 of 888
FLYWHEEL AND HOUSING Ring Gear Removal And Installation
Flywheel Removal And Installation Figure 70-120-2
Remove the drive belt shield. (See Shield Removal And

Installation Page 30-50-1.)
Remove the drive belt. (See Belt Removal And

Remove the drive belt tension pulley. (See Tensioner

Pulley Assembly Page 30-50-7.)
Figure 70-120-1
1
P-4237
The ring gear (Item 1) [Figure 70-120-2] on the flywheel

is an interference fit. Heat the ring gear enough to
1 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.
2
P-48649 Clean the new ring gear and heat it to a temperature of
450° - 500° F (232° - 260° C).
Remove the six mounting bolts (Item 1) from the engine

Fit the ring on the flywheel and be sure the gear is seated
flywheel (Item 2) [Figure 70-120-1].
fully.
Installation: Apply engine oil to the threads and seats
before tightening. Tighten to 72 - 80 ft.-lb. (98 - 108 N•m)
torque.
Remove the flywheel from the engine.
Installation: Be sure to align the hole in the flywheel with

the pin located on the crankshaft.
Reverse the removal procedure to install the flywheel.

789 of 888
FLYWHEEL AND HOUSING (CONT’D) Figure 70-120-4
Remove the drive belt shield. (See Shield Removal And

Remove the engine/hydrostatic pump package from the

loader.(See Removal And Installation Page 70-10-8.)
Remove the drive belt. (See Belt Removal And

Remove the drive belt tension pulley. (See Tensioner

Pulley Removal And Installation Page 30-50-4.)
P-48651C
Remove the starter. (See Removal And Installation Page
60-40-2.)
Install a puller in the drive pulley and remove the pulley
Remove the flywheel. (See Flywheel Removal And from the hydrostatic pump shaft [Figure 70-120-4].
Installation: Install the pulley key in the shaft before
Figure 70-120-3 installing the drive pulley.

NOTE: DO NOT hit puller or end of shaft with a
hammer on the SJC equipped loaders. Pump
damage will result from a direct blow to the
shaft.
P-48651B
Remove the hydrostatic pump drive pulley mounting nut

(Item 1) [Figure 70-120-3] and washer.
Installation: Tighten the mounting nut to 175 - 200 ft.-lb.

(237 - 271 N•m) torque.

790 of 888
FLYWHEEL AND HOUSING (CONT’D) Figure 70-120-7
Housing Removal And Installation (Cont’d)
Figure 70-120-5
2
1
1 1 P-48648
1
Remove the seven mounting bolts (Item 1) [Figure 70-
P-48650 120-7] which fasten the housing on the engine.

Remove the two mounting bolts (Item 1) [Figure 70-120- (48 - 54 N•m) torque.
5] from the drive belt housing which mount the

hydrostatic pump to the housing. Remove the 2 bolts (Item 2) [Figure 70-120-7] which
fasten the housing on the engine.
(88 - 95 N•m) torque. Installation: Tighten the mounting bolts to 60 - 65 ft.-lb.
(82 - 88 N•m) torque.
Figure 70-120-6
Remove the housing.
Reverse the removal procedure to install the housing.

2
P-4231A

from engine coolant tubeline mounting bracket which is
attached to the flywheel housing.
Installation: Tighten the mounting bolt to 25 - 28 ft.-lb.

(34 - 38 N•m) torque.
Remove the blower fan drive belt tensioner assembly

(Item 2) [Figure 70-120-6] from the housing.

791 of 888

792 of 888
HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-10-2

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-4 SAFETY &
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2 MAINTENANCE
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-7
BLOWER FAN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

Connector Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-4
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-130-2
DRIVE
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1 SYSTEM
Clutch Disassembly And Assembly . . . . . . . . . . . . . . . . . . 80-50-5
Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1

ELECTRICAL
SYSTEM &
EVAPORATOR COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1 ANALYSIS
EVAPORATOR / HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . 80-80-1 ENGINE

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1 SERVICE
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

HVAC
HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
Removal And Installation With A/C . . . . . . . . . . . . . . . . . 80-120-1
Removal And Installation Without A/C . . . . . . . . . . . . . . . 80-120-3
HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-140-2

793 of 888
HEATING, VENTILATION, AIR CONDITIONING (CONT’D)
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

Pressure Relief Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-2
Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-3
Receiver / Drier Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Schraeder Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-4
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1

Air Conditioning Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Air Conditioning Service Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-3
Compressor Drive Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-2
Compressor Drive Belt Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-20-2
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-20-2
Evaporator / Heater Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-20-4
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-20-1
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Charging With A Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-4
Reclamation And Charging With Recovery / Charging Unit. . . . . . . . . . . . . . . . . 80-40-2
Refrigerant Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Blower Motor Operates Normally, But Air Flow Is Insufficient . . . . . . . . . . . . . . . 80-30-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-11
Engine Coolant Bypassing The Heater Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-19
Gauge Pressure Related Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-2
HVAC Repair And Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-10
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-20
Insufficient Cooling Although Air Flow And Compressor Operation Are Normal . 80-30-1
Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-9
The Compressor Does Not Operate At All, Or Operates Improperly . . . . . . . . . . 80-30-1
Temperature / Pressure Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-8
Troubleshooting Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-4
TIGHTEN ALL HARDWARE PER SIZE TO GRADE 5 TORQUE (SEE STANDARD TORQUE
SPECIFICATIONS FOR BOLTS, SECTION SPEC-01) UNLESS OTHERWISE SPECIFIED.
SPECIFICATIONS SUBJECT TO CHANGE WITHOUT NOTICE AND STANDARD ITEMS MAY VARY.

794 of 888

795 of 888
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 80-10-3. takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) See Chart on Page 80-10-3.
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver/drier (Item 3) See Chart on Page 80-10-3. 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 80-10-3.
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) See Chart on Page 80-10-3. As the
refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) See Chart on Page 80-10-3. Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and

drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.

796 of 888
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

797 of 888
AIR CONDITIONING SYSTEM FLOW (CONT'D) Figure 80-10-3
Components
Figure 80-10-1 2
1
1
P-24219
Receiver/Drier: The receiver/drier (Item 1) [Figure 80-10-

P-24288 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 535 PSI.
P-48011
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.

798 of 888
Components (Cont'd)
Figure 80-10-5
N-22087
1
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-
P-24227 10-7] cools and dehumidifies the air before it enters the
cab.
Heater/Evaporator Unit: The heater/evaporator unit (Item Thermostat: The thermostat (Item 2) [Figure 80-10-7]
1) [Figure 80-10-5] is located behind the loader cab. The controls the temperature of the evaporator coil.

unit delivers the cold air for the A/C and warm air for heat
into the cab. The unit contains the blower, heat & A/C Heater Coil: The heater coil (Item 3) [Figure 80-10-7]
coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-10-6
Figure 80-10-8
P-21902
N-22100
Expansion Valve: The expansion valve (Item 1) [Figure

80-10-6] controls the amount of refrigerant entering the Heater/Evaporator Blower: The blower (Item 1) [Figure
evaporator coil. 80-10-8] is used to push air through the heater and
evaporator coils and into the cab.

799 of 888
Components (Cont'd)
1
Figure 80-10-9
2
3 4
P-24229
Pressure Switch: The pressure switch (Item 1) [Figure

N-22261 80-10-11] will disengage the compressor clutch at high
pressure readings over 384 PSI. (2647 bar) on the high
side, or at very low pressure of 28 PSI (193 bar) or less
Control Panel: The panel (Item 1) [Figure 80-10-9] has on the high side, which indicates loss of refrigerant.
three separate components.

Fan Switch: This is a four position rotary switch (Item 2)
[Figure 80-10-9]. 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 80-10-9]

will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure 80-

10-9] 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 80-10-10
P-66919
Heater Valve: The heater valve (Item 1) [Figure 80-10-

10] is used to control the amount of engine coolant that
flows to the heater coil.

800 of 888
AIR CONDITIONING SYSTEM FLOW (CONT'D) In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
Safety Equipment contact with a flame, R134a refrigerant gives a toxic
gas.
Figure 80-10-12 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 21.6 F DEGREES
“INSTANTLY”. If it spills on your skin or in your eyes you
should flood the area with cool water and SEEK
MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-10-13] to prevent frost bite if you
should get refrigerant on your hands.
P16398
WARNING
HFC 134A refrigerant can be dangerous if not
Figure 80-10-13 properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious

frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
W-2373-0500
P16399
In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-
10-12] 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.
WARNING

801 of 888

802 of 888
REGULAR MAINTENANCE
Filters
Figure 80-20-1
P-48012
The Fresh Air Filter (Item 1) [Figure 80-20-1] is located

below the rear window outside the cab. Remove the
clamping knobs, filter cover and filter.
Shake the filter or use low pressure air to remove dirt.

This can be done several times before replacement is

required. Install the filter, filter cover and clamping knobs.
Figure 80-20-2
1 P-48005
The Recirculation Filter (Item 2) [Figure 80-20-2] is

located in front of the rear window inside the cab.
Remove the clamping knobs, filter cover, and filter.
Shake the filter or use a vacuum to clean. This can be

done several times before replacement is required. Install
the filter with the arrows pointing forward (Inset) [Figure
80-20-2], install the filter cover and clamping knobs.

803 of 888
REGULAR MAINTENANCE (CONT’D) Compressor Drive Belt Replacement
Compressor Drive Belt Adjustment Stop the engine and open the rear door.
Stop the engine and open the rear door. Loosen the mounting and adjustment bolts (Item 1)
[Figure 80-20-3] and move the compressor as far as it
Figure 80-20-3 will go toward the front of the loader.
Remove old belt and install a new belt.
Perform the belt adjustment procedure above.

1 Run the machine for several hours and readjust as
necessary.
Condenser
3 (See ENGINE COOLING SYSTEM on Page 10-90-1.)

2
Air Conditioning Lubrication
P-19519 P19518 Run the air conditioning for about five minutes every
week to lubricate the internal components.

Loosen the mounting and adjustment bolts (Item 1)
[Figure 80-20-3].
Rotate the compressor toward the back of the machine

(Item 2) [Figure 80-20-3] to increase tension on the belt.
NOTE: The drive belt cover (Item 2) [Figure 80-20-3]

must be removed to check the air conditioner
belt tension (Item 3).
Tighten the mounting and adjustment bolts. Check

regularly for belt wear.
Run the air conditioner for about 5 minutes every week to

lubricate the internal components.
Troubleshooting - If the fan does not run, or the air

conditioning does not turn on, Check the fuse. (See
ELECTRICAL SYSTEM INFORMATION on Page 60-10-
1.) If the air conditioning system circulates warm air, the
refrigerant may need to be recharged.

804 of 888
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:

805 of 888
REGULAR MAINTENANCE (CONT’D)
Evaporator / Heater Coil

Figure PM-4
P-76565
Remove the cover screws (Item 1) [Figure PM-4] and

remove the cover.

Figure PM-5
2
P-76201
Use low pressure air or water to remove debris from the

evaporator (Item 1) and heater coil (Item 2) [Figure PM-
5].
Install the cover and lower the operator cab. (See

Lowering on Page 10-30-3.)

806 of 888
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 Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
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 hoses are properly hooked Repair of adjust.
to Louvers, and air ducts.
3. Defective thermo. switch Check thermostat using a circuit tester. Replace thermostat.

(frozen evaporator).
4. Plugged cab filters Check cab filter condition. 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
correct refrigerant level.
The Compressor Does Not Operate At All, Or Operates Improperly

1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compressor The compressor is locked up and the belt slips. Replace compressor.
malfunction.
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 Test the conductance of the pressure switch, Check operation.
components. thermostat, Relay, etc.

807 of 888
TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210-265 PSI
Low pressure side pressure: 15-33 PSI
As a rule of thumb, the high side pressure will be around eight times greater than the low side pressure.

Low pressure side The low pressure side pressure normally becomes too
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 The high and low pressure side gauge pressures Replace compressor.
compressor. equalize when the compressor 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.
High pressure side
Too high.
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the
performance. Operating. fan.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the
correct refrigerant level.
3. Excessive oil charge. The high pressure side will be high. Evacuate system. Remove oil
from condenser and
compressor. Measure oil from
compressor and add correct oil
charge back into compressor.
Flush system with nitrogen.
Replace drier.
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 will be low. replacing defective parts.
pressure line.
High 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.

808 of 888
Gauge Pressure Related Troubleshooting (Cont'd)

System pressures equal
1. Clutch not operating. See magnetic clutch related topics above.
2. Compressor not Equal high and low pressures. Replace compressor.
pumping.

809 of 888
Troubleshooting Tree
B-21491

810 of 888
Troubleshooting Tree (Cont’d)
B-21491A

811 of 888
B-21492

812 of 888
B-21493

813 of 888
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
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 8-10 degrees F. to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F. to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient Temperature=90 degrees F.

90 degrees F.
+40 degrees F.
130 degrees F. condenser temperature=200 psig
Conditions and pressures will vary from system to system.

814 of 888
TROUBLESHOOTING (CONT'D) Check the belt tension on the A/C compressor. (See
Compressor Drive Belt Adjustment on Page 80-20-2.)
Poor A/C Performance
Check the A/C condenser for dirt or mud, and clean if
Figure 80-30-1 necessary. (See Condenser on Page 80-20-2.)
Check the A/C evaporator coil for dirt or mud, and clean if
necessary. (See Air Conditioning Service Chart on Page
80-20-3.)
Inspect the sight glass located on the receiver/drier for air

bubbles. (See Receiver / Drier Removal And Installation
1 on Page 80-70-1.)
Check the engine coolant to see if it is bypassing the

heater valve. (See Engine Coolant Bypassing The Heater
Valve on Page 80-30-19.)
N-22273
WARNING
Figure 80-30-2

W-2059-0598
N-22411
Start the loader, engage the parking brake. Engage the

A/C system with the blower fan on high. Run the loader at
full RPM for approximately 15 minutes, with the loader
cab door closed.
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 36° - 53° F

(2,2° - 11,6° C) depending on the amount of humidity in
the air.
If louver temperature is too high, (See Troubleshooting

Tree on Page 80-30-4.)
Check the blower fan for proper operation or noise, and

replace if necessary. (See BLOWER FAN on Page 80-
130-1.)

815 of 888
HVAC Repair And Leaks
Figure 80-30-3
P-24219
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.

816 of 888
TROUBLESHOOTING (CONT'D) Figure 80-30-6
Electrical System
Figure 80-30-4
1
2 1 P-24300
N-22284 device. (See Installing on Page 10-20-1.)

Check to see if the compressor clutch is engaging.
Disconnect the loader harness (Item 1) [Figure 80-30-6]
With an operator in the loader seat and the cab door

open, turn the loader key switch to RUN (Standard Panel) from the compressor clutch wire.
OR press the RUN/ENTER Button (Deluxe Panel),
without starting the loader. Figure 80-30-7
Push the A/C switch (Item 1) to the ON position. Turn the

blower fan switch (Item 2) [Figure 80-30-4] to the first On
position.
The compressor clutch should make a click sound, which

indicates the clutch is engaging.
Figure 80-30-5 1
P-24314
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. (See Clutch Disassembly And Assembly on Page
P-21912 80-50-5.)
If the compressor clutch does not engage, check the

loader fuse (Item 1) [Figure 80-30-5] located on the
control panel in the loader cab.
Replace the fuse if burned out.
NOTE: The decal inside the fuse cover, refers to the

fuse as HEATER. This fuse controls the power
for both the Heater and the A/C systems.

817 of 888
Electrical System (Cont'd)
Figure 80-30-8
1
1
P-24315
Using a multi meter check the loader wiring harness

P-24314 (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
2
1
P-24315
1
If there is voltage at the harness, check the resistance at
the pressure switch (Item 1) [Figure 80-30-11].
If there is no resistance value, check for low refrigerant

P-24299 level. (See Refrigerant Identification on Page 80-40-1.)
If a resistance value is observed, the pressure switch is

Disconnect the loader harness (Item 1) from the pressure good.
switch (Item 2) [Figure 80-30-9].
Reconnect the loader harness to the pressure switch.

818 of 888
Figure 80-30-12
1 1
P-68448
Check the loader harness (Item 1) [Figure 80-30-14] for

P-66829 voltage. The voltage should be 12 volts.
If there is no voltage at the wiring harness, check the

Remove the access cover (Item 1) [Figure 80-30-12] harness for broken wires.
from the loader.

If there is voltage at the wiring harness, check the
Figure 80-30-13 thermostat (Item 2) [Figure 80-30-14] for resistance.
The resistance value of the thermostat should be 10

Ohms at 68° F (20° C).
If there is no resistance value, replace the thermostat.

If there is a resistance value, check the blower fan.
P-68118
Disconnect the thermostat wiring connector (Item 1)

[Figure 80-30-13] from the loader wiring harness.

819 of 888
Figure 80-30-15 2
P-68444

P-68118 voltage. The voltage should be 12 volts.

Disconnect the blower fan wiring connector (Item 1) harness for broken wires.

If there is voltage at the wiring harness, check the
resistance to the blower fan at the blower fan wiring
connector (Item 2) [Figure 80-30-16].
If there is no resistance value replace the blower fan.

If there is a resistance value check the climate controls at

the control panel inside the loader cab.
Figure 80-30-17
N-22261
Remove the three mount screws (Item 1) [Figure 80-30-

17] from the cab control panel.

820 of 888
Figure 80-30-18
H C
M B
N-22288
If there is voltage at the wiring harness, check the blower

N-22262 switch [Figure 80-30-20] for resistance.
With the switch in the OFF position, there should be zero

Remove the control panel and wiring harness from the resistance between all terminals.
cab [Figure 80-30-18].

With the switch in the 1 position, there should be
Figure 80-30-19 resistance between C terminal and the B terminal,
between the C terminal and the L terminal, and also
between the B terminal and the L terminal frame [Figure
80-30-20].

resistance between C terminal and the B terminal,
1 between the C terminal and the M terminal, and also
between the B terminal and the M terminal frame [Figure
80-30-20].

resistance between C terminal and the B terminal,
between the C terminal and the H terminal, and also
between the B terminal and the H terminal frame [Figure
N-22265 80-30-20].
If any of the above resistance tests fail, replace the

Disconnect the loader wiring harness (Item 1) [Figure blower switch.
80-30-19] from the blower switch.
If the above resistance tests are good, check the A/C
Check the loader harness for voltage. The voltage should switch.
be 12 volts.


821 of 888
TROUBLESHOOTING (CONT'D) If a resistance value is found, check the potentiometer.
Electrical System (Cont'd) Figure 80-30-23
Figure 80-30-21
1 1
N-22262
N-22264
The potentiometer will effect the A/C system and also
effect the operation of the heater.
At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-30-21] from the A/C switch. If heater valve does not open, or close, or the A/C does
not work, check the potentiometer.

Check the harness for voltage. The voltage should be 12
volts. At the loader cab, disconnect the loader harness (Item 1)
[Figure 80-30-23] from the potentiometer.
Figure 80-30-24
Figure 80-30-22
1 1
2
N-22263
N-22289

If there is voltage at the wiring harness, check the A/C voltage. The voltage should be 12 volts.
switch [Figure 80-30-22] for resistance.
With the switch in the OFF position there should be no harness for broken wires.
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 80-30-22].
If no resistance value is found, replace the A/C switch.

822 of 888
Figure 80-30-25
C 1
A
N-22175
B
To check the resistance of the white wire, turn the
N-22290 potentiometer control (Item 1) to the full A/C position
[Figure 80-30-27].
If there is voltage at the wiring harness, check the Figure 80-30-28

potentiometer [Figure 80-30-25] for resistance.

The resistance should be 10 K Ohm's between wire
terminal A and wire terminal C frame [Figure 80-30-25].
If no resistance is found, replace the potentiometer.

C
Figure 80-30-26 A
N-22290
The resistance between the wire terminal A and wire

1 terminal B frame [Figure 80-30-28] should be
approximately 49 K Ohm's.
Check the resistance between the wire terminal C and

N-22201 wire terminal B frame [Figure 80-30-28] should be
The white wire B, (Item 1) [Figure 80-30-26], on the

potentiometer, is a resistor wire.

823 of 888
Figure 80-30-29
N-22175
To check the resistance of the white wire, turn the

potentiometer control (Item 1) [Figure 80-30-29] to the

full Heater position.
Figure 80-30-30
C
A
N-22290
Check the resistance between the wire terminal A and

wire terminal B frame [Figure 80-30-30] should be
Check the resistance between the wire terminal C and

wire terminal B frame [Figure 80-30-30] should be
If the resistance is not found, replace the potentiometer.

824 of 888
Engine Coolant Bypassing The Heater Valve
Figure 80-30-31
2 3
1 P-68119

N-22284
Raise the lift arms and install an approved lift arm support 1.)
device.(See Installing on Page 10-20-1.)

Start the loader and run at high idle, for ten minutes.
Push the A/C switch (Item 1) to the OFF position. Turn
the fan switch (Item 2) to the High Speed position. Turn Check the heater hose (Item 1) [Figure 80-30-32] for
the temperature control (Item 3) [Figure 80-30-31] to the temperature.
High A/C position, with the loader ignition switch OFF.
If the hose is hot, the heater valve is leaking by, and

825 of 888
Heater Valve Not Opening Or Closing
Figure 80-30-33
2 3
1 P-68117
Place the remote start tool on the left fender of the loader,
N-22284 so the heater valve can be clearly seen. Watch the valve
shaft (Item 1) [Figure 80-30-34], as the key of the remote
start is turned to the ON position without starting the
Raise the lift arms and install an approved lift arm support loader. The heater valve should rotate.

If it does not rotate, check the potentiometer (See
Push the A/C switch (Item 1) to the OFF position. Turn Electrical System on Page 80-30-11.) for proper function.
the fan switch (Item 2) to position 1. Turn the temperature
control (Item 3) [Figure 80-30-33] to the High A/C Replace the heater valve. (See Removal And Installation
position, with the loader ignition switch OFF. on Page 80-140-1.)

1.)
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 80-30-34], as the key of the remote
start tool is turned to the ON position without starting the
loader. The heater valve should rotate. Place a mark on
the loader shaft.
Turn the key of the remote start tool to the OFF position
and remove the remote start tool from fender.
Lower operator cab.
Turn the temperature control (Item 3) [Figure 80-30-33]

to the High Heater position, with the loader ignition switch
OFF.
Raise the operator cab.

826 of 888
SYSTEM CHARGING AND RECLAMATION Figure 80-40-2
Refrigerant Identification
1
WARNING
In the event of a leak, wear safety goggles. Escaping
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500
Figure 80-40-1 P-24316
1 Raise the lift arms and install an approved lift arm support
Connect the Refrigerant Identifier to the low pressure

hose (Item 1) [Figure 80-40-2].
Connect the Refrigerant Identifier to its power source.
Follow the steps displayed on the refrigerant identifier

screen.
N-23024
Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
NOTE: It is recommended to identify the type of sound if potentially flammable hydrocarbons are present
refrigerant that is in the A/C system and if it is and will also indicate on the visual display.
pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-40-1] Disconnect the refrigerant identifier from the loader A/C.
will determine, the kind of refrigerant and any
possible harmful or dangerous substances If the refrigerant is dangerous or flammable, it must be
that may be present in the system. Thus evacuated from the A/C system into a separate container
preventing mixing of dangerous material with and properly and safely disposed of.
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems If R134a is found, evacuate the system.
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.

827 of 888
SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-40-5
Reclamation And Charging With Recovery / Charging

Unit
Figure 80-40-3
2
N-22291
IMPORTANT: Only A/C trained technicians should

perform the reclaiming and recharging.
P-24208
Open the rear door and locate the low pressure port
WARNING

(Item 1), and high pressure port (Item 2) [Figure 80-40-
3].
Figure 80-40-4 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.
1 Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
W-2373-0500
P-24230
Use an approved recovery/charging unit [Figure 80-40-
5] to evacuate the system.
NOTE: Do not use this port (Item 1) [Figure 80-40-4]
for testing or charging.
WARNING
gas.
W-2371-0500

828 of 888

Unit (Cont'd)
Figure 80-40-6
N-22381
NOTE: The reclaimer unit, has a complete step by

step set of instructions [Figure 80-40-8] to
P-24317 follow for reclimation and recharging of the A/
C system. A trained technician should follow
these instructions as they may very slightly
Connect the reclaimer to the loader A/C charge ports. depending on the model and brand of

reclaimer used.
Connect the Red hose (Item 1) [Figure 80-40-6] to the
high pressure port and open the valve.
Connect the Blue hose (Item 2) [Figure 80-40-6] to the

low pressure port and open the valve.
Figure 80-40-7
N-22292
Turn the reclaimer unit [Figure 80-40-7] to the ON

position and follow the on screen instructions.

829 of 888
Charging With A Manifold Gauge Set
WARNING
1
gas. 2
W-2371-0500
Figure 80-40-9 P-24319
Connect the gauges to the loader A/C charge ports.
Connect the Red hose (Item 1) [Figure 80-40-10] to the

high pressure port and open the valve.
Connect the Blue hose (Item 2) [Figure 80-40-10] to the

low pressure port and open the valve.
Figure 80-40-11
1
P-24318
Open the rear door. 1
Check to see that the hand valves (Item 1) [Figure 80-

40-9] are closed on the manifold gauge set.
If there is any refrigerant in the A/C system, it must be

recovered by an approved A/C reclamation procedure.
(See Reclamation And Charging With Recovery /
Charging Unit on Page 80-40-2.) P-24320
Connect the Yellow hose (Item 1) [Figure 80-40-11] to

the vacuum pump.

830 of 888
Charging With A Manifold Gauge Set (Cont’d)
Figure 80-40-12
1
1 P-24322
A thermistor vacuum gauge (Item 1) [Figure 80-40-14]

P-24321 can be used to determine the critical vacuum level during
evacuation. It is a solid state instrument that constantly
monitors and visually indicates the vacuum level.
Start the vacuum pump and open ISO-valve (Item 1)
[Figure 80-40-12] on the vacuum pump. The thermistor vacuum gauge is used with the vacuum

pump [Figure 80-40-14].
Run the vacuum pump for at least 5-10 minutes to insure
that a vacuum has been pulled on the system. Start the vacuum pump and open ISO-valve on the
vacuum pump.
Close the ISO-valve (Item 1) [Figure 80-40-12] (which
isolates the vacuum pump from the A/C system) and turn Be sure that both hand valves, and both charge port
OFF the vacuum pump. valves are open.
Figure 80-40-13 Run the vacuum pump for at least 45 minutes to insure
that all the moisture is boiled out of the system.
Stop the vacuum pump and close the ISO-valve on the

vacuum pump.
Close both hand valves on the manifold gauge set and

remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
Remove the vacuum pump and thermistor vacuum

1 gauge.
P-24319
NOTE: Vacuum pressure indicated on the low

pressure (Blue) gauge (Item 1) [Figure 80-40-
13]. Let stand for 5-10 min. and recheck the
pressure for changes.
If the pressure drops, this may be an indication of a leak

in the A/C system.
Determine the problem with the A/C system and repair it.

831 of 888
Charging With A Manifold Gauge Set (Cont’d)
Figure 80-40-15
1
2
3 1
N-22284
2
P-24323 REMOTE START TOOL KIT-MEL1563 on Page 10-60-
1.)
Place a refrigerant container with R134a (Item 1) on a Press the A/C (Item 1) [Figure 80-40-17] switch to ON
charging scale (Item 2) [Figure 80-40-15] and zero out position.

the scale.
Turn fan switch (Item 2) [Figure 80-40-17] to HIGH
Connect the yellow hose (Item 3) [Figure 80-40-15] from position.
the manifold gauge set to the valve on the refrigerant
tank. Start loader engine, with the remote start switch, and run
at medium speed.
Figure 80-40-16
Watch the scale and run system until the predetermined
amount of refrigerant is added to the A/C system.
The A/C system holds 2.0 lb. (0,91 kg) of refrigerant.
Turn OFF the valve on the refrigerant container, and

hand valves on the manifold gauge set.
2
Turn OFF the engine, and remove the A/C charging
1 equipment from the loader.
P-24324
Open the valve on the refrigerant container (Item 1) and

open the low pressure hand valve (Blue) (Item 2) [Figure
80-40-16] on the manifold gauge set. Allow the vacuum
to pull in the refrigerant until the pressure stabilizes.

832 of 888
COMPRESSOR

WARNING
Figure 80-50-18
gas.
W-2371-0500
Remove the compressor hoses (Item 3) [Figure 80-50-

1 19] from the compressor.
2
Installation: Tighten the compressor hoses to 22 ft.-lb.
(29,8 N•m) torque.
Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.
P-24325
Figure 80-50-20
Remove drive belt guard.

Remove A/C belt guard (Item 1), by removing the
mounting bolt and nut (Item 2) [Figure 80-50-18].
Evacuate the A/C system. (See SYSTEM CHARGING

AND RECLAMATION on Page 80-40-1.)
1
Figure 80-50-19
P-24327
Remove the compressor mount bolt (Item 1) [Figure 80-

50-20].
3
1 Remove the compressor from the loader.
2
P-24326
Remove the compressor adjustment bolt (Item 1) [Figure

80-50-19].
Installation: Tighten the compressor adjustment bolt to

34 ft.-lb. (46 N•m) torque.
Remove the compressor belt (Item 2) [Figure 80-50-19].
Mark the compressor hoses for proper installation.

833 of 888
COMPRESSOR (CONT'D) Whenever the refrigerant has leaked from the system.
Oil Whenever the refrigerant is suddenly released from the

cooling cycle.
Figure 80-50-21
Whenever any oil-related problems occur in the cooling
cycle.
When one of the components (the evaporator, condenser

1 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.
N-22243
The compressor (Item 1) [Figure 80-50-21] 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.

834 of 888
COMPRESSOR (CONT'D) Figure 80-50-23
Oil Check
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
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See SYSTEM CHARGING AND P-16534A
RECLAMATION on Page 80-40-1.)
Open the cab door and windows. Remove the oil drain plug (Item 1) [Figure 80-50-22] and
drain the oil through the connectors and the oil drain hole
Run the blower at maximum speed. [Figure 80-50-23].
Run the compressor for at least 20 minutes at 800-1200 Installation: Tighten the oil drain plug to 9.4 - 10.8 ft.-lb.
RPM. (13 - 15 N•m) torque.

Remove the compressor from the loader. (See Removal Figure 80-50-24
Figure 80-50-22
1 1
N-22246
N-22245
NOTE: After draining the oil through the drain hole
and the connectors, extract the remaining oil
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-50-
24] 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.

835 of 888
COMPRESSOR (CONT'D)
Oil Check (Cont'd)
Figure 80-50-25
N-22245
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 S and is the larger port on the
compressor.

836 of 888
Clutch Disassembly And Assembly
Figure 80-50-26
1.32”
1.32”
1.32”
2
1
1
N-22275
The armature plate puller, (Item 1) can be constructed by

N-22244 drilling three 10 mm holes in a flat circular plate, located
1.32 in. apart [Figure 80-50-28].
Remove the center armature bolt (Item 1) [Figure 80-50- Attach the puller to the armature plate using three 8 mm
26]. bolts (Item 2) [Figure 80-50-28].

Installation: Tighten the armature bolt to 8 - 10 ft.-lb. (12 Figure 80-50-29
- 14 N•m) torque.
Figure 80-50-27
N-22278
N-22277 Turn the bolts into the three 8 mm holes (Item 2) [Figure
80-50-27] on the armature plate as shown in [Figure 80-
50-29].
To remove the armature plate (Item 1) [Figure 80-50-27]
from the clutch face, you must make an armature plate
puller.

837 of 888
Clutch Disassembly And Assembly (Cont'd)
Figure 80-50-30
1
1 N-22283

N-22279 the pulley assembly.
Figure 80-50-33
Attach a slide hammer puller (Item 1) [Figure 80-50-30]
to the armature puller disk.

Remove the armature plate from the compressor clutch.
Figure 80-50-31
1
N-22369
Install the pulley puller tool MEL 1595 on the compressor

pulley [Figure 80-50-33].
N-22280
Remove the shims (Item 1) [Figure 80-50-31] from either

the armature shaft or armature plate.
Installation: Insure that the clutch has the correct

clearance by adding the shims (Item 1) [Figure 80-50-
31].
The specified clearance for the clutch is 0.01-0.02 in.

(0.3-0.6 mm). Adjusting shims are available in the
following thicknesses:
0.0039 in. (0.1 mm)
0.0118 in. (0.3 mm)
0.0197 in. (0.5 mm)

838 of 888
Figure 80-50-34
N-22373
Slide the wire grommet (Item 1) [Figure 80-50-36] from

N-22370 the wire holder.
Figure 80-50-37
Remove the pulley from the compressor [Figure 80-50-
34].

Figure 80-50-35
N-22374
Remove the coil lead wire (Item 1) [Figure 80-50-37]

N-22371 from the wire holder on the compressor.
The pulley assembly and bearing [Figure 80-50-35] must

be replaced as a complete unit.

839 of 888
COMPRESSOR (CONT'D)
Figure 80-50-38
1 1
N-22372
Remove the three coil mount bolts (Item 1) [Figure 80-

50-38] from the compressor.

Installation: Tighten the mount bolts to 2.9 - 4.3 ft.-lb. (4
- 6 N•m) torque.
Remove the coil from the compressor.
Figure 80-50-39
N-22375
The compressor [Figure 80-50-39] must be replaced as

a complete unit.

840 of 888
CONDENSER Figure 80-60-2
Figure 80-60-1
LIFT HERE
P-48011
Lift the rear of the condenser [Figure 80-60-2], and pull

P-48011 toward the rear of the loader until the front tabs (Item 1)
[Figure 80-60-4] slide out of bracket (Item 2) [Figure 80-
60-4]
Remove the refrigerant from the A/C system. (See
Reclamation And Charging With Recovery / Charging Figure 80-60-3

Unit on Page 80-40-2.)
Open the rear grill on the loader.
Mark the two A/C hoses (Item 1) [Figure 80-60-1] for

proper installation.
WARNING
In the event of a leak, wear safety goggles. Escaping P-48010
gas. Remove the condenser from the loader [Figure 80-60-3].
W-2371-0500
Disconnect the two hoses from the condenser (Item 1)

[Figure 80-60-1].
Cap and plug the hoses and the condenser fittings with
the proper A/C caps and plugs.

841 of 888
CONDENSER (CONT’D)
Figure 80-60-4
P-24303
Installation: Make sure to insert tabs (Item 1), into the

mounts (Item 2) [Figure 80-60-4], evenly for ease of

installation.

842 of 888
RECEIVER / DRIER Figure 80-70-2
Receiver / Drier Removal And Installation
WARNING 2

W-2059-0598
P-24298
Figure 80-70-1
Note the flow direction on the drier (Item 1) [Figure 80-

70-2] for proper installation.
1
WARNING

gas.
W-2371-0500
P-24299
Remove the two A/C hoses (Item 2) [Figure 80-70-2]

Raise the loader lift arms and install an approved lift arm from the receiver/drier.
Cap and plug the hoses and the receiver/drier fittings
Raise the operator cab. (See Raising on Page 10-30-2.) with the proper A/C caps and plugs.
Remove the refrigerant from the A/C system.(See Loosen the hose clamps (Item 3) [Figure 80-70-2] that
Reclamation And Charging With Recovery / Charging holds the receiver/drier to the mount.
Remove the receiver/drier from the loader.
Mark the A/C hoses (Item 1) [Figure 80-70-1] for proper
installation. NOTE: When replacing a receiver/drier in an A/C
system 1 fl. oz. (30 cc) of PAG 100 oil must be
Both fittings on the drier are the same size, so the hoses added to the system when recharging.
can be hooked up incorrectly.

843 of 888
RECEIVER / DRIER (CONT’D) Pressure Relief Valve Removal And Installation
Receiver / Drier Removal And Installation (Cont’d) Figure 80-70-4
Figure 80-70-3
1
N-22205
P-24295
The pressure relief valve (Item 1) [Figure 80-70-4] is
located on the receiver drier assembly.
from the receiver/drier mount bracket. Figure 80-70-5

N-22206
The pressure relief valve [Figure 80-70-5] is designed to

open and release the A/C charge if the pressure reaches
535 PSI (3689 bar).
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 384 PSI (2648 bar).
NOTE: If a Pressure Relief Valve is found open, check

the A/C system for problems. Replace the
complete receiver/drier unit.

844 of 888
RECEIVER / DRIER (CONT’D) Figure 80-70-7
Pressure Switch Removal And Installation
Figure 80-70-6
1
P-24298
Remove the pressure switch (Item 1) [Figure 80-70-7]

P-24299 from the A/C high pressure hose.
Remove the pressure switch from the loader.


Disconnect the loader wire harness (Item 1) [Figure 80-

70-6] from the pressure switch wire harness.
NOTE: The pressure switch can be changed without

evacuating the A/C system.
WARNING
gas.
W-2371-0500

845 of 888
RECEIVER / DRIER (CONT’D)
Schraeder Valve Removal And Installation
Figure 80-70-8
N-22166
The schraeder valve (Item 1) [Figure 80-70-8] is located

in the A/C high pressure hose and is located under the

pressure switch.
Remove the refrigerant from the A/C system. (See

Remove the pressure switch.
With a tire valve core removal tool, remove the valve core
from the hose.
Replace with a new core.

846 of 888
EVAPORATOR / HEATER UNIT Figure 80-80-2
Evacuate the A/C system. (See Reclamation And 1

Charging With Recovery / Charging Unit on Page 80-40-
2.)
Figure 80-80-1
N-22119
3 Remove the two mounting nuts (Item 1) [Figure 80-80-

2].
1 Figure 80-80-3

2
P-66918 1
At the rear of the cab, disconnect the heater valve wiring

Disconnect the blower fan wiring connector (Item 2)

N-22120
Disconnect the thermostat connector (Item 3) [Figure 80-
80-1] from the loader wiring harness.
Remove the two mounting nuts (Item 1) [Figure 80-80-
3].

847 of 888
EVAPORATOR / HEATER UNIT (CONT’D) Figure 80-80-5
Figure 80-80-4
1 1
1
P-66921
Remove the heater hoses (Item 1) [Figure 80-80-5] from

N-22126 the heater coil.
Installation: Tighten the Heater hoses to 22 ft.-lb. (29,8

Remove the Evaporator/Heater Unit from the rear of the N•m) torque.
cab and place it on the fenders of the loader supported

by 2 X 4's [Figure 80-80-4]. Remove the evaporator/heater unit from the loader.
NOTE: Mark the tubelines for correct installation.

from the expansion valve.
Installation: Tighten the A/C hoses to 22 ft.-lb. (29,8

N•m) torque.
Cap and plug the hoses and the expansion valve fittings

848 of 888
THERMOSTAT Figure 80-90-3
Figure 80-90-1
N-22072
Remove the thermostat from the unit [Figure 80-90-3].

N-22069
Figure 80-90-4
NOTE: The thermostat can be changed without A

evacuating the A/C system, or removing the

evaporator/heater unit from the loader. B
Remove the rear cover from the evaporator/heater unit.

(See Evaporator / Heater Coil on Page 80-20-4.) C
Remove the two thermostat mount bolts (Item 1), and

1
remove the wiring harness and grommet (Item 2) [Figure
80-90-1] from the evaporator/heater housing.
Figure 80-90-2
N-22072
The wire connector (Item 1) [Figure 80-90-4] can be

changed. The wiring position and color in the connector
is:
1 A Blue
B White
C Black
N-22071
Remove the thermostat probe (Item 1) [Figure 80-90-2]

from the A/C evaporator coil.

849 of 888

850 of 888
EXPANSION VALVE Figure 80-100-2
Figure 80-100-1
N-22073
Remove the two evaporator fittings (Item 1) [Figure 80-

N-22150 100-2] from the expansion valve.
Installation: Tighten the two evaporator fittings to 22 ft.-

NOTE: The expansion valve can be changed without lb. (29,8 N•m) torque.
removing the evaporator/heater unit from the

loader. Remove the two mount bolts (Item 2) [Figure 80-100-2].
Raise the lift arms and install an approved lift arm support Remove the expansion valve from the loader.
Figure 80-100-3
Evacuate the A/C system. (See Reclamation And

2.)
WARNING
gas. N-22074
W-2371-0500
Cap and plug the evaporator tubelines (Item 1) [Figure

80-100-3] and the expansion valve fittings with the
from the expansion valve.
proper A/C caps and plugs.
Installation: Tighten the two A/C hose fittings to 22 ft.-lb.
(29,8 N•m) torque.
Cap and plug the hoses and the expansion valve fittings

851 of 888
EXPANSION VALVE (CONT'D)
Figure 80-100-4
1
1
N-22074

from the expansion valve mount.

Remove the expansion valve mount from the unit.
Figure 80-100-5
N-22085
The expansion valve [Figure 80-100-5] is replaced as a

complete unit.

852 of 888
EVAPORATOR COIL Figure 80-110-3
Figure 80-110-1
N-22075
1 Remove the two mount bolts (Item 1) from the mount

N-22073 plate (Item 2) [Figure 80-110-3].
Remove the mount plate from the unit.

device. (See Installing on Page 10-20-1.) Figure 80-110-4

Evacuate the A/C system. (See Reclamation And

2.)
Remove the evaporator/heater unit from the back of the

cab. (See Removal And Installation on Page 80-80-1.)
Remove the expansion valve (Item 1) [Figure 80-110-1]

from the unit. (See Removal And Installation on Page 80-
100-1.)
1
Figure 80-110-2 N-22076
Remove the two retaining clips (Item 1) [Figure 80-110-

4] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil from the unit.
N-22074
Remove the expansion valve mount bracket (Item 1)

[Figure 80-110-2] from the unit.

853 of 888
EVAPORATOR COIL (CONT'D)
Figure 80-110-5
N-22078
Inspect the evaporator coil [Figure 80-110-5] for leaks,


Clean with low water or air pressure.

854 of 888
HEATER COIL Figure 80-120-2
Removal And Installation With A/C

1
Remove the heater unit from the back of the cab. (See
Figure 80-120-1
1
N-22086
1

from the heater coil at the expansion valve end of the
unit.
2 Figure 80-120-3
2

P-66921
Remove the heater valve (Item 1) [Figure 80-120-1].

Mark the heater hoses (Item 2) [Figure 80-120-1] for

1
Cap the hoses and the heater coil with hydraulic caps
and plugs to prevent oil loss from the system. N-22087
Remove the rear cover from the evaporator/heater unit.

(See Evaporator / Heater Coil on Page 80-20-4.) Remove the two retaining clips (Item 1) [Figure 80-120-
3] that connect the evaporator coil, to the heater coil.

855 of 888
HEATER COIL (CONT'D)
Removal And Installation With A/C (Cont'd)
Figure 80-120-4
1 1
N-22089
Remove the three mount bolts (Item 1) [Figure 80-120-4]

and remove the mount plate from the end of the unit.

Remove the heater coil from the unit.
Figure 80-120-5
N-22090
The heater coil [Figure 80-120-5] can be cleaned with

low air or water pressure.
If the heater coil needs replacement it must be replaced

as complete unit.

856 of 888
HEATER COIL (CONT'D) Figure 80-120-7
Removal And Installation Without A/C
Figure 80-120-6
1 1
2
2 N-22093
Remove the three mount bolts (Item 1) [Figure 80-120-7]

P-66921 and remove the mount plate from the end of the unit.
Figure 80-120-8

Remove the heater unit from the back of the cab. (See
Removal And Installation on Page 80-80-1.) 1
Remove the heater valve (Item 1) [Figure 80-120-6].
Mark the heater hoses (Item 2) [Figure 80-120-6] for

Cap the hoses and the heater coil with hydraulic caps N-22094
and plugs to prevent oil loss from the system.
Remove the rear cover from the evaporator/heater unit. Remove the two mount bolts (Item 1) [Figure 80-120-8]
(See Evaporator / Heater Coil on Page 80-20-4.) from the heater coil.
Remove the heater coil from the unit.

857 of 888

858 of 888
BLOWER FAN Figure 80-130-3
Raise the lift arms and install an approved lift arm support 1
NOTE: The blower fan assembly can be removed

from the evaporator/heater unit without
disconnecting the heater or A/C plumbing.
The unit is remove here for photo clarity.
Figure 80-130-1
P-39553
Remove the two flange mount bolts (Item 1) [Figure 80-

1
130-3] from the evaporator/heater unit.
Figure 80-130-4

P-39550
1
Remove the cover (Item 1) [Figure 80-130-1] from the
evaporator/heater unit.
Figure 80-130-2
P-39554
1 Remove the flange and attached foam (Item 1) [Figure

80-130-4] from the unit.
P-68120
Remove the two flange mount bolts (Item 1) [Figure 80-

130-2] from the evaporator/heater unit.

859 of 888
BLOWER FAN (CONT'D) Disassembly And Assembly
Figure 80-130-5
1 1
2 N-22102
P-68120A
Remove the eight mount bolts (Item 1) [Figure 80-130-7]
from the blower wheel cover.
Remove the blower fan wiring harness and grommet
(Item 1) [Figure 80-130-5] from the unit. Remove the blower wheel cover from the housings.

Figure 80-130-6 Remove the four mount bolts (Item 2) [Figure 80-130-7]
from the blower motor mount.
1
Remove the blower motor mount.
Remove the blower motor assembly from the housing.
Figure 80-130-8
P-39556
Remove the three mount bolts (Item 1) [Figure 80-130-6] 1

from the blower fan housing.
2
Remove the blower fan housing from the evaporator/
heater unit.
N-22107
Check the blower housing (Item 1) and blower motor

mount (Item 2) [Figure 80-130-8] for wear and replace
as needed.

860 of 888
BLOWER FAN (CONT'D) Figure 80-130-11
Figure 80-130-9
N-22110
2 Figure 80-130-12
N-22108
Remove the outside rings (Item 1) and blower wheel

covers (Item 2) [Figure 80-130-9] from the blower motor

and blower wheels.
Figure 80-130-10
N-22112
Remove the outside blower wheel clamp (Item 1) [Figure

80-130-11] & [Figure 80-130-12] from the blower wheel.
N-22109
Inspect the end rings and blower wheel covers for wear
and replace as needed [Figure 80-130-10].

861 of 888
BLOWER FAN (CONT'D) Connector Identification
Disassembly And Assembly (Cont'd) Figure 80-130-15
Figure 80-130-13
P-68118
N-22111
The wiring code for the blower fan connector (Item 1)
[Figure 80-130-15] is:
Remove the inside blower wheel clamp (Item 1) [Figure
80-130-13] from the blower wheel. Number on Connector Wire Color

A Orange
Figure 80-130-14
B Red
C Yellow
D Black
N-22116
Remove the blower wheel (Item 1) and inside ring (Item

2) [Figure 80-130-14] from the blower motor shaft.
Repeat the procedure for the other blower wheel.

862 of 888
HEATER VALVE Figure 80-140-2
Remove the Evaporator/Heater Unit from under the cab

and place it across the mainframe supported by blocks
Remove any tie-straps that hold the heater hoses. 1
Figure 80-140-1 P-66922
Disconnect the loader wiring harness (Item 1) [Figure

80-140-2] from the heater valve.

1
3
P-66921
Remove the mount bolts (Item 1) [Figure 80-140-1] from

the heater valve mount.
Remove the heater hose clamps (Item 2) & (Item 3)

[Figure 80-140-1].
Remove the heater hoses from the heater valve.
Cap the heater hoses and the heater valve with plugs to
prevent coolant loss from the system.

863 of 888
HEATER VALVE (CONT'D) Figure 80-140-5
Figure 80-140-3 1
P-66925
Remove the three mounting bolts (Item 1) [Figure 80-

P-66923 140-5] from the heater valve mount plate.
Remove the mount plate (Item 2) [Figure 80-140-5] from

Remove the three mount bolts (Item 1) [Figure 80-140-3] the heater valve bracket.
from the heater valve actuator.

Figure 80-140-6
Figure 80-140-4
1
1 1
2
2
P-66926
P-66924

Remove the actuator (Item 1) and the three mounting 6] from the heater valve.
spacers (Item 2) [Figure 80-140-4] from the heater valve
mount plate.

864 of 888
SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
Decimal And Millimeter Equivalents. . . . . . . . . . . . . . . . . . . SPEC-50-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . SPEC-50-1 SAFETY &
MAINTENANCE
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . SPEC-30-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . .SPEC-30-1

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-3
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-4 DRIVE
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2 SYSTEM
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-2
T190 LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4

ELECTRICAL
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3 SYSTEM &
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2 ANALYSIS
Ground Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-2 ENGINE
Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-4 SERVICE
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . SPEC-20-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . SPEC-20-2
Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1 SPECIFICATIONS

SPECIFICATIONS
SPECIFIED.

MAY VARY.
SPEC-01 T190 Service Manual

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SPEC-02 T190 Service Manual

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T190 LOADER SPECIFICATIONS
Dimensions
• Dimensions are given for loader equipped with standard tracks and 68 inch Construction & Industry bucket and may
vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in
millimeters enclosed by parentheses.
• Where applicable, specifications conform to SAE or ISO standards and are subject to change without notice.
68.0 in.
95° (1727 mm)
78.8 in.
(2001 mm)

152.1 in.
(3862 mm) 42°
118.2 in.
30.9 in. (3002 mm)
(784 mm)
76.3 in. 91.0 in.

(1938 mm) (2310 mm)
30°
25°
8.1 in. 55.2 in.

(205 mm) (1401 mm)
53.4 in.
101.9 in.
(1356 mm)
(2588 mm)
130.3 in. 66 in.
(3309 mm) (1676 mm)
B-20650D
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.
SPEC-10-1 T190 Service Manual

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T190 LOADER SPECIFICATIONS (CONT’D)
Performance
Rated Operating Capacity (ISO) 1900 lb. (862 kg)
Tipping Load (ISO Rating) 6851 lb. (3108 kg)
Operating Weight 7612 lb. (3453kg)
SAE Breakout Force - Lift 4700 lb. (2132 kg)
SAE Breakout Force - Tilt 4450 lb. (2018 kg)
Travel Speed 0 - 7.1 mph (0 - 11,4 km/hr.)
Push Force 4700 lb. (2132 kg)
Controls
Vehicle Steering Direction and speed controlled by two hand 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 Control (SJC)
- Front Auxiliary (Standard) 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 Quick couplers. Push couplers in, hold for 5 seconds.
Engine Hand lever speed control; key-type start switch 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
Secondary Brake One of the hydrostatic transmissions
Parking Brake (Standard) Mechanical disc, hand operated rocker switch on instrument panel
Engine
Make / Model Kubota V2403M-DI-T

Fuel / Cooling Diesel / Liquid
Horsepower (SAE Net) 61 HP (45,5 kW) @ 2700 RPM
Low Idle 1075 - 1225 RPM
High Idle 2760 - 2900 RPM
Torque (SAE Net) 155.6 lbf.-ft. (211 N•m) @ 1475 RPM
Number of Cylinders 4
Displacement 148.5 cu. in. (2.4 L)
Bore / Stroke 3.43 in. / 4.03 in. (87 mm / 102 mm)
Lubrication Gear Pump Pressure System with Filter
Crankcase Ventilation Open Breathing
Air Cleaner Dry replaceable paper cartridge with separate safety element
Ignition Diesel - Compression
Engine Coolant Propylene Glycol / Water Mixture
Starting Aid Glow Plugs - Automatically activated as needed in RUN position.

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Hydraulic System
Pump Type Engine driven, gear type
Pump Capacity - Standard 16.3 GPM (61,6 L/min.) @ 2830 Engine RPM @ 91% Efficiency
High Flow Option 25.5 GPM (96,4 L/min.) @ 2830 Engine RPM @ 91% Efficiency
System Relief at Quick Couplers 3250 - 3350 PSI (224 - 231 bar)
Filter (Hydraulic) Full flow replaceable, 3-micron synthetic media element
Hydraulic Cylinders Double-acting; tilt cylinders have cushioning feature on dump and rollback
Bore Diameter: Lift Cylinder (2) 2.50 in. (63,5 mm)
Tilt Cylinder (2) 2.75 in. (69,8 mm)
Rod Diameter: Lift Cylinder (2) 1.50 in. (38,1 mm)
Tilt Cylinder (2) 1.375 in. (34,9 mm)
Stroke: Lift Cylinder (2) 23.67 in. (601 mm)
Tilt Cylinder (2) 13.19 in. (335 mm)
Control Valve 3-Spool, open center type with spring detent for lift float and electrically
controlled auxiliary spool
Fluid Lines SAE Standard tubelines, hoses and fittings
Fluid Type Bobcat Fluid
6903117 - (2.5 Gal.)
6903118 - (5 Gal.)

6903119 - (55 Gal.)
Hydraulic Function Time:
Raise Lift Arms 3.7 Seconds
Lower Lift Arms 2.4 Seconds
Bucket Dump 2.4 Seconds
Bucket Rollback 1.9 Seconds
Electrical
Alternator Belt driven, 90 amps, open

Battery 12 volts, 600 cold cranking amps @ 0° F (-18° C)
115 Minute reserve capacity @ 25 amps
Starter 12 volts, gear type, 3.62 HP (2,7 kW)
Instrumentation Gauges: Engine Coolant Temperature, Fuel Level.
Warning lights: Fuel Level, Seat Belt, Engine Coolant Temperature, Engine
Malfunction, Hydraulic 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.
Other: Audible Alarm, Lights, Option / Accessory Switches.
Optional Deluxe Instrumentation Panel:
*Additional bar-type gauges for: Engine Oil Pressure, System Voltage,
Hydrostatic Charge Pressure and Hydraulic Oil Temperature.
*Additional Features Included: Keyless Start, Digital Clock, Job Clock,
Attachment Control Information, High-Flow / Two-Speed / Password Lockouts,
Multi-language Display, Help Screens, Diagnostic Capability and Engine /
Hydraulic Systems Shutdown Function.

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Drive System
Main Drive Fully hydrostatic, rubber track drive
Transmission Infinitely variable tandem hydrostatic piston pumps
Final Drive 2 fully reversing hydrostatic motors driving rubber tracks
Capacities
Fuel 28 Gal. (106 L)

Engine Lubrication & Filter 9.2 qt. (8,7 L)
Engine Cooling System w/o Heater 10.8 qt. (10,2 L)
Engine Cooling System w/ Heater 12 qt. (11,3 L)
Hydraulic/Hydrostatic Reservoir 19.2 qt. (18,2 L)
Hydraulic/Hydrostatic System 9 Gal. (34,1 L)
Tracks
Standard 12.6 in. (320 mm) Rubber, C-Pattern

Optional 16 in. (400 mm) Rubber, C-Pattern
Optional 12.6 in. (320 mm) Rubber, Winter Pattern

Ground Pressure
Standard track (12.6 in.) 4.9 PSI (0.338 bar)

Optional track (16 in.) 4.1 PSI (0.283 bar)

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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 Company that have zinc phosphate coating are specified by the letter H following the part number.
THREAD
SAE GRADE 5 SAE GRADE 8
SIZE
80 - 90 110 - 120
0.250
in-lb. (9,0 - 10,2) (12,4 - 13,6)
(N•m) 180 - 200 215 - 240
0.3125
(20,3 - 22,6) (24,2 - 27 - 1)
25 - 28 35 - 40
0.375
(34 - 38) (47 - 54)
40 - 45 60 - 65
0.4375
(54 - 61) (81 - 88)
65 - 70 90 - 100
0.500
(88 - 95) (122 - 136)
90 - 100 125 - 140
0.5625
(122 - 136) (170 - 190)
125 - 140 175 - 190
0.625
(170 - 190) (240 - 260)

220 - 245 300 - 330
0.750
(300 - 330) (410 - 450)
330 - 360 475 - 525
0.875
(450 - 490) (645 - 710)
475 - 525 725 - 800
1.000
ft.-lb. (645 - 710) (985 - 1085)
(N•m) 650 - 720 1050 - 1175
1.125
(880 - 975) (1425 - 1600)
900 - 1000 1475 - 1625
1.250
(1200 - 1360) (2000 - 2200)
1200 - 1350 2000 - 2200
1.375
(1630 - 1830) (2720 - 2980)
1500 - 1650 2600 - 2850
1.500
(2040 - 2240) (3530 - 3870)
2000 - 2800 3450 - 3800
1.625
(2720 - 2980) (4680 - 5150)
2500 - 2750 4300 - 4800
1.750
(3390 - 3730) (5830 - 6500)
3150 - 3500 5500 - 6100
1.875
(4270 - 4750) (7450 - 8300)
3800 - 4200 6500 - 7200
2.000
(5150 - 5700) (8800 - 9800)

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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
3 - 4 ft.-lb.
M 5 x 0.8
(4 - 5 N•m)
6 - 7 ft.-lb. 6 - 9 ft.-lb.
M 6 x 1.0
(8 - 9 N•m) (8 - 12 N•m)
6 - 9 ft.-lb. 11 - 16 ft.-lb. 18 - 25 ft.-lb.
M 8 x 1.25
(8 - 12 N•m) (15 - 22 N•m) (24 - 34 N•m)
13 - 18 ft.-lb. 22 - 30 ft.-lb. 36 - 50 ft.-lb.
M 10 x 1.25
(18 - 24 N•m) (30 - 41 N•m) (49 - 68 N•m)
22 - 30 ft.-lb. 40 - 54 ft.-lb. 69 - 87 ft.-lb.
M 12 x 1.25
(30 - 41 N•m) (54 - 73 N•m) (94 - 118 N•m)
36 - 50 ft.-lb. 58 - 80 ft.-lb. 116 - 137 ft.-lb.
M 14 x 1.25
(49 - 68 N•m) (79 - 108 N•m) (157 - 186 N•m)

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HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-2
O-ring Face Seal Connection O-ring Face Seal Tightening Torque

x x *
Tubeline x TORQUE
Outside x ft.-lb.
Diameter Thread Size (N•m)
IMPORTANT 1/4” 9/16” - 18 13 (18)
3/8” 11/16” - 16 22 (30)
1/2” 13/16” - 16 40 (54)
parts clean. Always use caps and plugs on hoses, 5/8” 1” - 14 60 (81)
tubelines and ports to keep dirt out. Dirt can quickly 3/4” 1-3/16” - 12 84 (114)
damage the system.
I-2003-0888
7/8” 1-3/16” - 12 98 (133)
1” 1-7/16” - 12 118 (160)
Figure SPEC-30-1 1-1/4” 1-11/16” - 12 154 (209)
1-1/2” 2” - 12 163 (221)

B-7575
When the fitting is tightened, you can feel when the fitting
is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-30-1].

873 of 888
HYDRAULIC CONNECTION SPECIFICATIONS Tubelines And Hoses
(CONT’D)
Replace any tubelines that are bent or flattened. They will
Straight Thread O-ring Fitting restrict flow, which will slow hydraulic action 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

Nut Nut hose or tubeline fittings.
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-
3].

874 of 888
HYDRAULIC CONNECTION SPECIFICATIONS
(CONT’D)
Flare Fitting
Figure SPEC-30-4
TS-1619
Use the following procedure to tighten the flare fitting:

Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-30-4]
Use the chart [Figure SPEC-30-5] to find the correct

tightness needed (Item 2) [Figure SPEC-30-4]. If the
fitting leaks after tightening, disconnect it and inspect the
seat area for damage.
Figure SPEC-30-5
Flare Fitting Tightening Torque
Tubeline x TORQUE
Outside x ft.-lb.
Diameter Thread Size (N•m)
1/4” 7/16” - 20 13 (18)
5/16” 1/2” - 20 17 (23)
3/8” 9/16” - 18 22 (30)
1/2” 3/4” - 16 40 (54)
5/8” 7/8” - 14 60 (81)
3/4” 1-1/16” - 12 84 (114)
7/8” 1-3/16” - 12 98 (133)
1” 1-5/16” - 12 118 (160)
1-1/4” 1-5/8” - 12 154 (209)
1-1/2” 1-7/8” - 12 163 (221)
2” 2-1/2” - 12 252 (342)

875 of 888
HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-30-7
(CONT'D)
Port Seal and O-ring Boss
Port Seal Fitting
Tightening Torque
Figure SPEC-30-6 x TORQUE
x ft.-lb.
Thread Size (N•m)
7/16” - 20 13 18)
9/16” - 18 22 (30)
3/4” -1 6 40 (54)
7/8” - 14 60 (81)
1-1/16” - 12 84 (114)
Nut Seals
To Fitting 1-3/16” - 12 98 (133)
1-5/16” - 12 118 (160)
1-7/16” - 12 154 (209)
Nut Seals
1-5/8” - 12 163 (221)
To Port
Use the following procedure to tighten the port seal

fitting:

Secondary O-ring Seal P-13008
Port seal and nut, washer and O-ring (O-ring Boss)
fittings use the same tightening torque valve chart.
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at If a torque wrench cannot be used, use the following
the connection [Figure SPEC-30-6]. method.
The hex portion of the nut does not contact the surface of Tighten the nut until it just makes metal to metal contact,
the component when the nut is tight. you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
guideline.
NOTE: Port seal fittings are not recommended in all

applications. Use O-ring boss fittings in these
applications.

876 of 888
HYDRAULIC / HYDROSTATIC FLUID During cold weather (32°F [0°C] and below), do not
SPECIFICATIONS operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
Specifications period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
Use Bobcat hydraulic/hydrostatic transmission fluid period.
(P/N 6903117 - 2, 2 1/2 Gal.), (P/N 6903118 - 5 Gal.),
(P/N 6903119 - 55 Gal.). 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

DO NOT use automatic transmission fluids in the loader
or permanent damage to the transmission will result.
WARNING
W-2072-0807
When temperatures below zero degree F (-18° C) 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.
WARNING

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CONVERSIONS
Decimal And Millimeter Equivalents

U.S. To Metric Conversion Chart

879 of 888

880 of 888
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: T190 - 1

Date: 7 May 2008
Product: Bobcat Loader
Model: T190
Manual No: 6987043 (5-08)
The following Sections are a revision to the above Service Manual.

Replace Manual dated 3-08 with Manual dated 5-08
Printed in U.S.A.
881 of 888
882 of 888
ROUTE TO
ATTENTION
PARTS MANAGER

Date: 10 October 2008
Model: T190
Manual No: 6987043 (10-08)

COVER
50-01
50-130
60-01
60-70
60-72
60-141
Printed in U.S.A.
883 of 888
884 of 888
ROUTE TO
ATTENTION
PARTS MANAGER

Date: 3 March 2009
Model: T190
Manual No: 6987043 (3-09)

COVER
FOREWORD
10-01
10-70
20-01
30-01
40-01
50-01
60-01
70-01
80-01
SPEC-01
Printed in U.S.A.
885 of 888
886 of 888
ROUTE TO
ATTENTION
PARTS MANAGER

Date: 1 August 2009
Model: T190
Manual No: 6987043 (8-09)

COVER
MAINTENANCE SAFETY
70-70
Printed in U.S.A.
887 of 888
888 of 888

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Service Manual

T190 Compact Track Loader

S/N 531660001 & Above

Dealer Copy -- Not for Resale

CORRECT CORRECT CORRECT

P-90216 B-15954 B-15956

Dealer Copy -- Not for Resale

B-15966 B-15951 B-6589

ACCESS PANEL (INSIDE) ..................................... 50-01

Dealer Copy -- Not for Resale

SEAT BAR ...............................................................50-01

Dealer Copy -- Not for Resale

WINDOW (FRONT DOOR) .................................... 50-01

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V HYDRAULIC

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XI DRIVE

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

Dealer Copy -- Not for Resale

HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . 80-01

SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01 HVAC

I T190 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.

II T190 Service Manual

Dealer Copy -- Not for Resale

22. Check for any field

III T190 Service Manual

IV T190 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

V T190 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

VI T190 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

VII T190 Service Manual

Welding And Grinding

Always clean the machine and attachment, disconnect

Have good ventilation when grinding or welding painted

Dust generated from repairing nonmetallic parts such as

Dealer Copy -- Not for Resale

VIII T190 Service Manual

Always use the serial number of the loader when Figure 2