v723 6986675 SM 4-10 (Full Permission) - Unprotected

Service Manual
V723 VersaHANDLER®
S/N A8HL11001 & Above (with Cab)

S/N A8HP11001 & Above (with Cab and Frame Leveling)
Dealer Copy -- Not for Resale

S/N A8HK11001 & Above (with Canopy and Frame Leveling)
Michael Vance
500 county rd 37
maple lake, MN 55358
Email address:
swervedout@hotmail.com
Phone:
2819056730
6986675 (4-10) Printed in U.S.A. © Bobcat Company 2010
1 of 913
2 of 913
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
CORRECT
Safety Alert Symbol: This symbol with a warning statement,

means: “Warning, be alert! Your safety
is involved!” Carefully read the
message that follows.
P-90216
Never service the Bobcat
VersaHANDLER without instructions.
CORRECT WRONG WRONG

B-16082 B-16080 B-16079
Cleaning and maintenance are Disconnecting or loosening any Never work on VersaHANDLER
required daily. hydraulic tubeline, hose, fitting, with boom up unless boom is
component or a part failure can held by an approved boom stop.
cause boom to drop. Do not go Replace if damaged.
under boom when raised unless Never modify equipment or add
supported by an approved boom attachments not approved by
stop. Replace if damaged. Bobcat Company.
WRONG WRONG WRONG
B-16081 B-16078 B-6589
Have good ventilation when Keep body, jewelry and clothing Lead-acid batteries produce
welding or grinding painted away from moving parts, flammable and explosive gases.
parts. electrical contact, hot parts and Keep arcs, sparks, flames and
Wear dust mask when grinding exhaust. lighted tobacco away from
painted parts. Toxic dust and gas Wear eye protection to guard batteries.
can be produced. from battery acid, compressed Batteries contain acid which
Avoid exhaust fume leaks which springs, fluids under pressure burns eyes or skin on contact.
can kill without warning. Exhaust and flying debris when engines Wear protective clothing. If acid
system must be tightly sealed. are running or tools are used. contacts body, flush well with
Use eye protection approved for water. For eye contact flush well
type of welding. and get immediate medical
attention.
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.
MSW12-0409
3 of 913 1-1 V723 Service Manual


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


FOREWORD
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Spark Arrestor Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

VersaHANDLER Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Other Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
BOBCAT VERSAHANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14


FOREWORD
This manual is for the Bobcat VersaHANDLER mechanic. It provides necessary servicing and
adjustment procedures for the Bobcat VersaHANDLER 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 VersaHANDLER has had service
or repair:
1. Check that ROPS/FOPS 8. The parking brake must
(including right side window) function correctly.
is in good condition and is not
modified.
2. Check that ROPS mounting 9. Enclosure door latches must

hardware is tightened and is open and close freely.
Bobcat approved.
3. The seat belt must be 10. Attachment locking pins must

correctly installed, functional function correctly and be in

and in good condition. good condition. Bob-Tach
wedges and linkages (if
equipped) must function
correctly and be in good
condition.
4. Check boom stop, replace if 11. Safety treads must be in good
damaged. condition.
5. Machine signs (decals) must 12. Check for correct function of

be legible and in the correct indicator lamps and gauges.
location.
6. Joystick control lever and foot 13. Check hydraulic fluid level,
pedals must return to neutral. engine oil level and fuel
supply.
7. Check for correct function of 14. Inspect for fuel, oil or

the work lights. hydraulic fluid leaks.
FW VH-0308 SM

15. Lubricate the VersaHANDLER. 20. Check for any field
modification not completed.
16. Check the condition of the 20. Operate the machine and
battery and cables. check all functions.
17. Inspect the air cleaner for 21. Check for correct function of
damage or leaks. Check the the Lateral Operator Restraint
condition of the element. System (LORS) if equipped.
18. Check the electrical charging 22. Check function or condition of

system. all equipped options and
accessories (examples: back-

up alarm, fire extinguisher,
rotating beacon, front
stabilizers, etc.).
19. Check tires for wear and 23. Recommend to the owner
pressure. Use only approved that all necessary corrections
tires. be made before the machine
is returned to service.
20. Inspect for loose or broken

parts or connections.
CALIFORNIA
PROPOSITION 65 WARNING
Diesel engine exhaust and some of its
constituents are known to the state of California
to cause cancer, birth defects and other
reproductive harm.
FW VH-0308 SM

SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or service.
Untrained operators and failure to follow instructions • An Operator’s Handbook fastened to the operator
can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0807

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 Telescopic Handler 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 Telescopic Handler.
manuals indicates a hazardous situation which, if not
avoided, will result in death or serious injury. • The Telescopic Handler Safety Video is available from
D-1002-1107 your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
The dealer and owner / operator review the

recommended uses of the product when delivered. If the
WARNING owner / operator will be using the machine for a different
application(s) he or she must ask the dealer for
The signal word WARNING on the machine and in the recommendations on the new use.
manuals indicates a potentially hazardous situation
which, if not avoided, could result in death or serious
injury.
W-2044-1107
SI VH EMEA-0409 SM

SAFETY INSTRUCTIONS (CONT’D) FIRE PREVENTION
Maintenance
The machine and some attachments have components

that are at high temperatures under normal operating
Cutting or drilling concrete containing sand or rock conditions. The primary source of high temperatures is
containing quartz may result in exposure to silica dust. the engine and exhaust system. The electrical system, if
Use a respirator, water spray or other means to control damaged or incorrectly maintained, can be a source of
dust. arcs or sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
can cause a fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential fire hazard.
The operator’s area, engine compartment and engine

cooling system must be inspected every day and cleaned
if necessary to prevent fire hazards and overheating.
All fuels, most lubricants and some coolants mixtures are

flammable. Flammable fluids that are leaking or spilled
onto hot surfaces or onto electrical components can
cause a fire.
Operation
Do not use the machine where exhaust, arcs, sparks or

hot components can contact flammable material,
explosive dust or gases.
Electrical
Check all electrical wiring and connections for damage.

Keep the battery terminals clean and tight. Repair or
replace any damaged part or wires that are loose or
frayed.
Battery gas can explode and cause serious injury. Use

the procedure in the Operation & Maintenance Manual
for connecting the battery and for jump starting. Do not
jump start or charge a frozen or damaged battery. Keep
any open flames or sparks away from batteries. Do not
smoke in battery charging area.
SI VH EMEA-0409 SM

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

the battery, and disconnect the wiring from the Bobcat
Check hydraulic tubes, hoses and fittings for damage controllers before welding. Cover rubber hoses, battery
and leakage. Never use open flame or bare skin to check and all other flammable parts. Keep a fire extinguisher
for leaks. Hydraulic tubes and hoses must be properly near the machine when welding.
routed and have adequate support and secure clamps.
Tighten or replace any parts that show leakage. Have good ventilation when grinding or welding painted
parts. Wear dust mask when grinding painted parts.
Always clean fluid spills. Do not use gasoline or diesel Toxic dust or gas can be produced.
fuel for cleaning parts. Use commercial nonflammable
solvents. Dust generated from repairing nonmetallic parts such as
hoods, fenders or covers can be flammable or explosive.
Fueling Repair such components in a well ventilated area away
from open flames or sparks.
Fire Extinguishers
Stop the engine and let it cool before adding fuel. No

smoking! Do not refuel a machine near open flames or

sparks. Fill the fuel tank outdoors.
Starting
Do not use ether or starting fluids on any engine that has

glow plugs. These starting aids can cause explosion and Know where fire extinguishers and first aid kits are
injure you or bystanders. located and how to use them. Inspect the fire
extinguisher and service the fire extinguisher regularly.
Use the procedure in the Operation & Maintenance Obey the recommendations on the instructions plate.
Manual for connecting the battery and for jump starting.
Spark Arrestor Exhaust System
The spark arrestor exhaust system is designed to control

the emission of hot particles from the engine and exhaust
system, but the muffler and the exhaust gases are still
hot.
Check the spark arrestor exhaust system regularly to

make sure it is maintained and working properly. Use the
procedure in the Operation & Maintenance Manual for
cleaning the spark arrestor muffler (if equipped).
SI VH EMEA-0409 SM

SERIAL NUMBER LOCATION Engine Serial Number
Always use the serial number of the VersaHANDLER Figure 2

when requesting service information or when ordering
parts.
VersaHANDLER Serial Number
Figure 1
S6813
P-24121
P-24121

The front, on the right side of the chassis [Figure 1].
S6801
The engine serial number can be found on the water

pump [Figure 2] in front of you when opening the engine
cover. Always use the full number when ordering
replacement parts.
Other Serial Numbers
Some components may also have serial numbers.

Always use these serial numbers when requesting parts.

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
VersaHANDLER is delivered. An explanation of the form
must be given to the owner. Make sure it is filled out

completely [Figure 3].

BOBCAT VERSAHANDLER IDENTIFICATION
BOOM MIRROR OPERATOR HANDBOOK AND

BOOM ANGLE LOAD CAPACITY CHARTS
TELESCOPING INDICATOR
INDICATOR RESTRAINT BAR
BOOM (CANOPY MODELS
TELESCOPING ONLY)
BOOM
OPERATORS CAB
(ROPS/FOPS)
BOOM
STOP
SEAT
BELT

SAFETY TREAD TIRES
(under boom, (use only approved tires
on top of frame) at correct pressure)
BUCKET
ATTACHMENT
LIGHTS
MIRROR
LIGHT
ENGINE
COVER
S6922
S6923

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE VERSAHANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
OPERATOR CAB / CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1

Cab Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Cab Door Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2
TRANSPORTING THE VERSAHANDLER ON A TRAILER . . . . . . . . . . . . . . . . . . . . . 10-30-1

Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
TOWING THE VERSAHANDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Engine Oil Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1
Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-2
HYDRAULIC / HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1

Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Replacing Hydraulic / Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
Replacing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-2
AXLES (FRONT AND REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1

Checking Oil Level (Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Draining Oil (Differential) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Checking Oil Level (Front Axle Drop Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Draining Oil (Front Axle Drop Box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-1
Checking Oil Level (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-2
Draining Oil (Planetary Carrier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-110-2

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1

Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
Rotating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
APPROVED BOOM STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Installing The Approved Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Removing The Approved Boom Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Opening And Closing The Engine Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
LATERAL OPERATOR RESTRAINT SYSTEM (LORS) . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-2

VERSAHANDLER STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . 10-180-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1
STOPPING THE ENGINE AND LEAVING THE VERSAHANDLER . . . . . . . . . . . . . . 10-190-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1
EMERGENCY EXIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-200-1

LIFTING AND BLOCKING THE VERSAHANDLER Figure 10-10-2
Procedure
Always park the machine on a level surface.
WARNING
The seat bar system must deactivate the lift, and tilt
control functions when the seat bar is up. Service the
system if joysticks do not deactivate.
W-2461-0603
S7423
Figure 10-10-1
Put the floor jack under the center of the rear axle. Lift the
VersaHANDLER and install jackstands [Figure 10-10-2].

P-23829
STOP the engine. Put the floor jack under the center of
the front axle. Lift the VersaHANDLER and install
jackstands [Figure 10-10-1].
19 of 913 10-10-1 V723 Service Manual


OPERATOR CAB / CANOPY Cab Door
Figure 10-20-1 Figure 10-20-2
1
1
S3527 P-47350
The VersaHANDLER has an operator cab or canopy Figure 10-20-3

(ROPS and FOPS) (Item 1) [Figure 10-20-1] to protect
the operator from rollover and falling objects. Check with
your dealer if the operator cab or canopy has been

damaged. Never operate without right window. The seat
belt must be worn for roll over protection.
ROPS/FOPS - Roll Over Protective Structure per SAE

J1040 and ISO 3471, and Falling Object Protective
Structure per SAE J1043 and ISO 3449 (FOPS Level II).
1
WARNING
P-47201
Never modify operator cab or canopy by welding,
grinding, drilling holes or adding attachments unless
instructed to do so by Bobcat. Do not operate The cab door can be opened from the outside of the cab
without right window. Changes to the cab or canopy using the latch (Item 1) [Figure 10-20-2] and open from
can cause loss of operator protection from rollover the inside of the cab when you squeeze the latch (Item 1)
and falling objects, and result in serious injury or [Figure 10-20-3] (as shown).
death.
W-2396-1202 The cab door can be locked (Item 2) [Figure 10-20-2]
with the start key.

OPERATOR CAB / CANOPY (CONT’D)
Cab Door Window
Figure 10-20-4
P-47202
Turn the handle (Item 1) [Figure 10-20-4] (as shown).

Push open the window fully until it latches against the

cab.
Figure 10-20-5
P-47203
Pull the lever (Item 1) [Figure 10-20-5] inside the cab to

disengage the latch and close the window.

TRANSPORTING THE VERSAHANDLER ON A Fastening
TRAILER
Figure 10-30-2
Loading And Unloading
Figure 10-30-1
3
2
4
1 1
S3519
1
P-97038 Fasten the VersaHANDLER to the transport vehicle to
prevent if from moving during sudden stops or when
going up or down slopes.
The VersaHANDLER must be loaded backward on the
trailer.

• Block the wheels (Item 1) [Figure 10-30-2].
The rear of the trailer must be blocked or supported (Item • Fasten the machine frame to the transport vehicle
1) [Figure 10-30-1] when loading or unloading the (Items 2 and 3) [Figure 10-30-2].
VersaHANDLER to prevent the front end of the trailer
from raising up. • Attach the forks or bucket attachment to the transport
vehicle (Item 4) [Figure 10-30-2].
Be sure the transport and towing vehicles are of
adequate size and capacity. For the weight of
VersaHANDLER (See Performance on Page SPEC-10-
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.
W-2058-0807


TOWING THE VERSAHANDLER Figure 10-40-2
Procedure DEACTIVATE - ACTIVATE
The VersaHANDLER can be towed a short distance such

as removing it from mud or loading onto a transport
vehicle.
1
WARNING
UNEXPECTED MACHINE MOVEMENT CAN CAUSE
S1394
SERIOUS INJURY OR DEATH
• Block wheels to prevent roll away before
adjusting screws to bypass the park brake At each end of the central part of the front axle are two
system. bolts (see (Item 1) [Figure 10-40-1] and (Item 1) [Figure
• Return adjustment screws to the operating 10-40-2]). When screwed in, these bolts will remove the
position before operating the machine. spring pressure that engages the brake disks.
W-2808-0909
[Figure 10-40-2] shows the function of such a bolt inside
the axle.
Block the wheels to prevent the machine from rolling.
The work will first be carried out on the two bolts on one

side of the front axle then the two bolts on the other side:
Releasing The Park Brake
Loosen the locking nuts (Item 2) [Figure 10-40-1] of the
The brakes are engaged by spring pressure and released
bolts and create some clearance for the bolts.
by hydraulic pressure. The park brake must be released
manually before towing. Only the front axle has brakes.
Turn the two bolts (Item 1) [Figure 10-40-1] IN, 1/4 turn
at a time, alternating between the two bolts until the bolts
The following procedure describes how to release the
are firmly seated.
brakes:
Repeat this on the two opposite side bolts on the front
Figure 10-40-1
axle.
2
2 The brakes are now released for towing the vehicle.
Please note that the vehicle will not be able to brake until
the bolts are returned to their original position.
1
1
S2722

TOWING THE VERSAHANDLER (CONT’D) Engaging Brake Disks:
Procedure (Cont’d)
Figure 10-40-3
WARNING
UNEXPECTED MACHINE MOVEMENT CAN CAUSE
1 SERIOUS INJURY OR DEATH
Operating
Position • Block wheels to prevent roll away before
adjusting screws to bypass the park brake
system.
• Return adjustment screws to the operating
position before operating the machine.
W-2808-0909
Towing
Position
Block the wheels to prevent the machine from rolling.
S6802
After towing is completed, turn the tow valve (Item 1)
[Figure 10-40-3] clockwise 90× to the OPERATING
POSITION.
Raise the engine cover.
Figure 10-40-4

Turn the tow valve counterclockwise 90× (Item 1) [Figure
10-40-3] to TOWING POSITION. 2
2
Tow the VersaHANDLER at a slow speed.
1
1
S2722
To reactivate the park brake, release the 4 bolts (see

(Item 1) on the front axle to their original position (turn
the two bolts out, 1/4 turn at a time, until no resistance
can be felt. Repeat this procedure for the opposite side
two bolts).
Make sure that all 4 bolts have been turned out until they
can easily be loosened by hand.
Tighten the locking nuts (Item 2) [Figure 10-40-4].
This will allow the park brake piston to be active again.

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 VersaHANDLER.
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
WARNING making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
SERVICE SCHEDULE HOURS

[5]
ITEM SERVICE REQUIRED 10 50 100 250 500 1000
Engine Oil Check the oil level and add oil as needed.
Hydraulic Fluid Check fluid level and add as needed.
Articulation Pins Lubricate with multipurpose lithium based grease.
Safety Signs, Safety Tread and Check for damaged signs (decals), safety tread and mirrors. Replace if
Mirrors damaged or worn.
Fuel Filter Clean the sediment bowl/water trap.
Nuts and Bolts Check for loose nuts and bolts. Tighten as needed.
Seat Belt Check the condition of the seat belt.
Brakes Check for function. Service as necessary.
Back-up Alarm (if equipped) Check for function. Replace as necessary.
Tires Check for wear or damage. Inflate to correct pressure. Be sure all tires are

inflated to the same pressure. Use only approved tires.
Engine Air Filter And Air System Check condition indicator, replace element when required and empty dust
cup as needed. Check air system for leaks.
Engine Cooling System Clean debris from oil cooler, radiator and air conditioner condenser. check
coolant level cold in reservoir. Add premixed coolant as needed. (See
ENGINE COOLING SYSTEM.) Check cooling system for leaks.
King Pins, Axle Oscillation (Front/ Lubricate with multipurpose lithium based grease.
Rear), Attach. Frame Pivot(s), Tilt/
Lift Cyl., Boom Pivot, Levelling
Cyl (if equipped).
Telescopic Boom Slide Lubricate with multipurpose lithium based grease. Check wear blocks for
adjustment or replacement.
Hydraulic Hoses, Tubelines and Check condition of hoses, tubelines and connectors. Repair or replace as
Connections needed.
Battery Check electrolyte level. Add distilled water as needed.
Wheel Nuts Check wheel nut torque. Tighten as needed [266 ft.-lb. (360 N•m)]. [1]
Alt. & Air Cond. Belt (if equipped) Check belt tension and adjust as needed. [2]
Door hinges Lubricate door hinges with multipurpose lithium based grease.
Engine Oil and Filter Replace the engine oil and filter. See SPECIFICATIONS for correct
capacity. Use a genuine Bobcat filter. [2]
Engine Air Filter Replace the outer filter element. Use a genuine Bobcat filter. [2]
Fuel Filter, secondary Replace the secondary fuel filter element. Use a genuine Bobcat filter. [2]
Fuel Filter, primary Replace the primary fuel filter (pre-filter) element. Use a genuine Bobcat filter. [2]
Hydraulic Fluid Filter Replace the hydraulic filter element. Use a genuine Bobcat filter. [2]
Hydraulic Tank Breather Replace the hydraulic tank breather.
Hydraulic Fluid and Filter Replace the hydraulic fluid and filter element. See SPECIFICATIONS.
Front and Rear Axle Fluid Replace the axle fluid. See SPECIFICATIONS. [3] [4]
Telescopic Boom Wear Blocks Check for wear and adjust as needed. Replace as necessary.
Pivot Pins and Bushings Check for wear on the pivot pins and bushings.
Engine valve lash Check and adjust as needed.
Engine Coolant Check freeze protection of antifreeze -34°F (-30°C). Flush cooling system
and replace with premixed coolant Every 2 years
[1] Check wheel nut torque every 8 hours for the first 24 hours.
[2] Perform service first time, then as indicated in chart.
[3] Check level.
[4] Replace fluid first time, then as indicated in chart.
[5] Or every 12 months.


AIR CLEANER SERVICE Release the fastener and remove the cover (Item 2)
[Figure 10-60-1].
Replacing Filter Element
Figure 10-60-2
Outer Filter
Figure 30-30-1
1 S6804
S3571 Pull the element straight out [Figure 10-60-2].
NOTE: Make sure all sealing surfaces are free of dirt

Replace the large (outer) filter element only when the red and debris.
ring shows in the window of the condition indicator (Item
1) [Figure 30-30-1]. Install a new outer element.
NOTE: Before replacing the filter element, push the Install the dust cover and fasten [Figure 10-60-1].
button on the condition indicator (Item 2)
[Figure 30-30-1]. Start the engine. If the red Connect the filter housing clamps.
ring does not show, do not replace the filter
element.
Replace the inner filter every third time the outer filter is
replaced or when the red ring still shows in the indicator
window after the outer filter has been replaced.
Figure 10-60-1
2 1 S6803
Loosen the filter housing clamps (Item 1) [Figure 10-60-

1].

AIR CLEANER SERVICE (CONT’D)
Replacing Filter Element (Cont’d)
Inner Filter
Remove the outer element.
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Figure 10-60-3

S6805
Remove the inner filter (Item 1) [Figure 10-60-3] and

install a new element.
Install the outer element.
Install the dust cover and fasten [Figure 10-60-1].
Connect the filter housing clamp (Item 1) [Figure 10-60-

1].

ENGINE COOLING SYSTEM Checking The Coolant Level
Check the cooling system every day to prevent over- Open the engine cover.
heating, loss of performance or engine damage.
Check the coolant level in the coolant reservoir.
Figure 10-70-3
WARNING
AVOID INJURY OR DEATH
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running. 1
• Tools are being used. MAX
W-2019-0907
MIN
Cleaning The Cooling System
Figure 10-70-1 S3528

The coolant level must be between the MIN and MAX
marks (Item 1) [Figure 10-70-3] on the coolant reservoir
when the engine is cold.
1
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
S3527
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine
Open the engine cover (Item 1) [Figure 10-70-1]. damage.
Figure 10-70-2 Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.
Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
S6815
Use low air pressure or water pressure to clean the

radiator, oil cooler and intercooler [Figure 10-70-2].

ENGINE COOLING SYSTEM (CONT’D) Figure 10-70-5
Replacing The Coolant
WARNING
AVOID BURNS
Do not remove radiator cap when the engine is hot.
You can be seriously burned. 1
W-2070-1203
Open the engine cover. 2

S6817
Figure 10-70-4
Remove the engine block drain plug (Item 1) [Figure 10-

1 70-5].
Open the drain valve (Item 2) [Figure 10-70-5] and drain

all of the coolant into a container. Dispose of used
coolant in an environmentally safe manner.

2 Close the drain valve.
MAX
MIN Mix the coolant in a separate container.
NOTE: The VersaHANDLER is factory filled with

ethylene glycol coolant.
S3528
Add premixed coolant, 50% water and 50% ethylene
glycol to the reservoir if the coolant level is low.
Remove the cap (Item 1) [Figure 10-70-4] from the
coolant reservoir. One gallon (3,8 L) of ethylene glycol mixed with one
gallon (3,8 L) of water is the correct mixture of coolant to
Remove the fan shield. provide a -34 °F (-37 °C) freeze protection.
Use a refractometer to check the condition of ethylene

glycol in your cooling system.
Fill the radiator with the premixed coolant. Install the

radiator cap.
Add coolant to the reservoir. The coolant level must be

between the MIN and MAX marks (Item 2) [Figure 10-
70-4] on the coolant reservoir.
Run the engine until it is at operating temperature.
Stop the engine.

ENGINE COOLING SYSTEM (CONT’D)
Replacing The Coolant (Cont’d)
Check the coolant level (COLD) in the reservoir when

cool.
Add coolant to the reservoir as needed.
IMPORTANT
AVOID ENGINE DAMAGE
Always use the correct ratio of water to antifreeze.
Too much antifreeze reduces cooling system

efficiency and may cause serious premature engine
damage.
Too little antifreeze reduces the additives which

protect the internal engine components; reduces the
boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength
concentrated coolant can cause serious premature
engine damage.
I-2124-0497


FUEL SYSTEM Fuel Filter
Fuel Specifications Figure 10-80-2
Use only clean, high quality diesel fuel, Grade No. 2 or

Grade No. 1.
The following is one suggested blending guideline which

should prevent fuel gelling problems in cold
temperatures:
TEMP. F° (C°) NO. 2 NO. 1 1

+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
S6806
Filling The Fuel Tank
For the service interval when to replace the fuel filter

(See SERVICE SCHEDULE on Page 10-50-1.)
WARNING Remove the filter element (Item 1) [Figure 10-80-2].

AVOID INJURY OR DEATH Clean the area around the filter housing.
Stop and cool the engine before adding fuel. NO
SMOKING! Failure to obey warnings can cause an Put oil on the seal of the new filter element.
explosion or fire.
W-2063-0807 Install the fuel filter, and hand tighten.
Figure 10-80-1
1 WARNING
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause
explosion or fire.
W-2103-0508
P-50821
Remove the fuel fill cap (Item 1) [Figure 10-80-1].
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
SMOKING!
Install and tighten the fuel fill cap [Figure 10-80-1].


ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking Engine Oil Figure 10-90-2
Check the engine oil level every day before starting the RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
engine for the work shift.
Figure 10-90-1
S6807

Open the engine cover and remove the dipstick (Item 1)
[Figure 10-90-1].
Keep the oil level between the marks on the dipstick

(Inset) [Figure 10-90-1].
Use a good quality motor oil that meets API Service

Classification of CD or better. (See Oil Chart, [Figure 10-
90-2].)

ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-90-4
Replacing Oil And Filter
For the service interval for replacing the engine oil and
filter (See SERVICE SCHEDULE on Page 10-50-1.)
Run the engine until it is at operating temperature. Stop

the engine.
1
Figure 10-90-3
S6814
Open the engine cover. (See Opening And Closing The

Engine Cover on Page 10-160-1.)
Remove the oil filter (Item 1) [Figure 10-90-4].
Clean the filter housing surface.

S6926 Put clean oil on the new oil filter gasket. Install the filter
and hand tighten.
Remove the access panel at the rear of the engine Figure 10-90-5
compartment. Route the hose (Item 1) [Figure 10-90-3]
out through the access hole. Remove the cap.
Drain the oil into a container and recycle or dispose of

used oil in an environmentally safe manner. 1
2
Install cap and put the drain hose into the engine
compartment, install the access cover.
WARNING
S6809
Always clean up spilled fuel or oil. Keep heat, flames,
sparks or lighted tobacco away from fuel and oil. Remove the filler cap (Item 1) [Figure 10-90-5].
Failure to use care around combustibles can cause
explosion or fire. Put oil in the engine. (See Capacities on Page SPEC-10-
W-2103-0508
4.) (See Engine Oil Chart on Page 10-90-1.)
Install fill cap, start the engine and let it run for several
minutes.
Stop the engine, and check for leaks at the oil filter.
Remove the dipstick (Item 2) [Figure 10-90-5] and check

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

HYDRAULIC / HYDROSTATIC SYSTEM Replacing Hydraulic / Hydrostatic Filter
Checking And Adding Fluid For the correct service intervals (See SERVICE
SCHEDULE on Page 10-50-1.)
Use only recommended fluid in the hydraulic system.
(See Specifications on Page SPEC-60-1.) Figure 10-100-3
Stop the machine on a level surface. Lower the boom all

the way. 1
Stop the engine.
Figure 10-100-1
S6811
1
Open the engine cover and remove the fill cap (Item 1)

[Figure 10-100-3].
Figure 10-100-4
S6811
Check the fluid level at the sight gauge (Item 1) [Figure

10-100-1].
Figure 10-100-2
1
S6819
Remove the filter element (Item 1) [Figure 10-100-4].
Clean the surface of the filter housing where the seal

contacts the housing.
S6812 Put clean oil on the seal of the new filter element.
Install and hand tighten the filter element.

Remove the fill/breather cap (Item 1) [Figure 10-100-2]
and add hydraulic fluid.

HYDRAULIC / HYDROSTATIC SYSTEM (CONT’D) Figure 10-100-6
Replacing Hydraulic Fluid
WARNING
Diesel fuel or hydraulic fluid under pressure can
penetrate skin or eyes, causing serious injury or
death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
not use your bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention P-52179
from a physician familiar with this injury.
W-2072-0807
Remove the reservoir drain plug (Item 1) [Figure 10-100-
6] behind the right front wheel and drain the fluid into a
container. Recycle or dispose of the fluid in an
WARNING environmentally safe manner. Reinstall the drain plug

and tighten.

AVOID INJURY OR DEATH Add fluid until it is at the center of the sight gauge (Item 1)
Always clean up spilled fuel or oil. Keep heat, flames, [Figure 10-100-1].
sparks or lighted tobacco away from fuel and oil.
Failure to use care around combustibles can cause Install the fill cap.
explosion or fire.
W-2103-0508
Figure 10-100-5
S6812
Remove the fill/breather cap (Item 1) [Figure 10-100-5].

AXLES (FRONT AND REAR) Checking Oil Level (Front Axle Drop Box)
Checking Oil Level (Differential) Figure 10-110-2
Figure 10-110-1
1
2
2 S1851
S1843
With the machine on a level surface, remove the plug
(Item 1) [Figure 10-110-2]. The oil level should be at the
Put the machine on a level surface. bottom edge of the plug hole.

Remove the plug (Item 1) [Figure 10-110-1]. The oil level Add oil through the hole if the oil level is below the hole.
should be at the bottom edge of the plug hole. (See Capacities on Page SPEC-10-4.) for capacity and
type. Install and tighten the plug.
Add oil through the hole if the oil level is below the hole.
(See Capacities on Page SPEC-10-4.) for capacity and Draining Oil (Front Axle Drop Box)
type. Install and tighten the plug.
(See SERVICE SCHEDULE on Page 10-50-1.) for the
Draining Oil (Differential) correct service interval.
(See SERVICE SCHEDULE on Page 10-50-1.) for the With the machine on a level surface, remove the plug
correct service interval. (Item 2) [Figure 10-110-2] and drain into a container.
Recycle or dispose of the used lubricant in an
With the machine on a level surface, remove the plug environmentally safe manner. Reinstall the drain plug.
(Item 2) [Figure 10-110-1] and drain into a container.
Recycle or dispose of the used lubricant in an Remove the plug (Item 1) [Figure 10-110-2]. Add oil until
environmentally safe manner. Reinstall the drain plug. the oil level is at the bottom edge of the plug hole.
Reinstall the plug.
Remove the plug (Item 1) [Figure 10-110-1]. Add oil until
the oil level is at the bottom edge of the plug hole.
Reinstall the plug.

AXLES (FRONT AND REAR) (CONT’D) Draining Oil (Planetary Carrier)
Checking Oil Level (Planetary Carrier) For the correct service interval (See SERVICE
SCHEDULE on Page 10-50-1.)
Figure 10-110-3
Figure 10-110-4
S1954
S1954
Put the machine on a level surface with the plugs (Item 1)

[Figure 10-110-3] positioned as shown. Put the machine on a level surface with the plug (Item 1)

[Figure 10-110-4] positioned as shown.
Remove the plugs (Item 1) [Figure 10-110-3]. the oil
level should be at the bottom edge of the plug hole. Remove the plug (Item 1) [Figure 10-110-4] and drain
into a container. Recycle or dispose of the used lubricant
Add gear lube through the hole if the oil level is below the in an environmentally safe manner.
hole. For capacity and type (See Capacities on Page
SPEC-10-4.) Reposition the plug hole and add gear lube until the lube
level is at the bottom edge of the plug hole (Item 1)
Install and tighten the plug. [Figure 10-110-3]. For capacity and type (See Capacities
on Page SPEC-10-4.)
Repeat the procedure for the other side.
Install and tighten the plug.
Repeat the procedure for the other side.

LUBRICATION Figure 10-120-3
Procedure
Lubricate as specified in the “SERVICE SCHEDULE” on

page 10-50-1 for the best performance of the machine.
Record the operating hours each time you lubricate so 1 1

that it is performed at the correct interval.
Always use a good quality lithium based multi-purpose

grease. Apply lubricant until extra grease shows.
Lubricate the following locations on the VersaHANDLER:
Figure 10-120-1 P-25919 P-25918
Axle Oscillation - Rear Axle (Item 1) [Figure 10-120-3].
Figure 10-120-4

1
P-24167
Axle Pivots - Top and bottom (Item 1) [Figure 10-120-1]

1
all four wheels.
P-34461A
Figure 10-120-2
FRONT REAR Axle Oscillation - Front Axle (Item 1) [Figure 10-120-4].
(V723 Model With Frame Leveling Only).
1
1
P-52025
Universal Joints - Front and Rear (Item 1) [Figure 10-

120-2].

LUBRICATION (CONT’D) Figure 10-120-7
Figure 10-120-5
S7484
NOTE: Raise the boom and install the approved

P-25917 Boom Stop (See Installing The Approved
Boom Stop on Page 10-150-1.) before
lubricating the Boom and Slave Cylinders.
Attachment Frame Pivot (Item 1) [Figure 10-120-5] (Both
Sides). Lift Cylinder Base End, Slave Cylinder Base End (Item 1)

[Figure 10-120-7].
Figure 10-120-6
Figure 10-120-8
1
2
P-29721
P-29315A
Lower Pivot Attachment Frame Link (Items 1 and 2)

[Figure 10-120-6]. Lift Cylinder Rod End, Slave Cylinder Rod End (Item 1)
[Figure 10-120-8].

LUBRICATION (CONT’D) Figure 10-120-11
Figure 10-120-9 1
1
1
1
P-52182
Cab Door Hinges (Item 1) [Figure 10-120-11] (Lower).

P-24168
Figure 10-120-12
Boom Pivot (Item 1) [Figure 10-120-9] (Four Places).

Figure 10-120-10
P-24117
1
Boom Slide [Figure 10-120-12] (Four Places).

P-52183
Cab Door Hinges (Item 1) [Figure 10-120-10] (Upper).

LUBRICATION (CONT’D)
Figure 10-120-13
P-34455
Frame Level Cylinder (Item 1) [Figure 10-120-13]. (V723

Model With Frame Leveling Only)

TIRE MAINTENANCE Rotating
Wheel Nuts Check the tires regularly for wear, damage and pressure.
(See Tires on Page SPEC-10-3.) for the correct tire
Figure 10-130-1 pressure.
Rear tires usually wear faster than front tires. To keep the
wear even, move the front tires to the rear and rear tires
to the front.
It is important to keep the same size tires on each side of

the VersaHANDLER. If different sizes are used, each tire
will be turning at a different rate and cause excessive
wear. the tread bars of all the tires must face the same
direction.
Recommended tire pressure must be maintained to avoid

excessive tire wear and loss of stability and handling
capacity. Check for the correct pressure before operating
P-23838 the VersaHANDLER.

service interval to check the wheel nuts. The correct

torque is 266 ft.-lb. (360 N•m) torque [Figure 10-130-1].
Mounting
WARNING
When the engine is running during service, the
Travel Direction Lever must be in neutral and the
parking brake engaged. Failure to do so can cause
injury or death.
W-2397-0301
Tires are to be repaired only by an authorized person

using the correct procedures and type of equipment.
Tires and rims must always be checked for correct size

before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
bead and rim flange must be lubricated with a rubber
lubricant before mounting the tire.
Avoid excessive pressure which can rupture the tire and

cause serious injury or death.
During inflation of the tire, check the tire pressure

frequently to avoid over inflation.


SPARK ARRESTOR MUFFLER
Cleaning

IMPORTANT
service interval for cleaning the spark arrester muffler.
This VersaHANDLER is factory equipped with a
Do not operate the machine with a defective exhaust U.S.D.A. Forestry Service approved spark arrestor
system. muffler. It is necessary to do maintenance on this
spark arrestor muffler to keep it in working condition.
Stop the engine. The spark arrestor muffler must be serviced by
dumping the spark chamber every 100 hours of
Figure 10-140-1 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
be in violation of California State Law, Section 4442
PRC.
Make reference to local laws and regulations for

spark arrestor requirements
I-2271-0208

1
S3529
Remove the plug (Item 1) [Figure 10-140-1] from the

bottom of the muffler.
WARNING
When the engine is running during service, the
Travel Direction Lever must be in neutral and the
parking brake engaged. Failure to do so can cause
injury or death.
W-2397-0301
Start the engine and run for about 10 seconds while a

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

hole.
Stop the engine.
Install and tighten the plug.


APPROVED BOOM STOP Figure 10-150-2
If the boom is raised for service or maintenance, use the

following procedure to install and remove the boom stop.
Installing The Approved Boom Stop
• Put the VersaHANDLER on a flat, solid and level

surface.
• With the operator in the seat, the restraint bar

lowered, (if equipped) seat belt fastened, Travel
Direction Control in neutral and the parking brake
engaged, start the engine and raise the boom. Stop
the engine.
P-29315A
Figure 10-150-1
• Install the boom stop over the rod of the boom

cylinder [Figure 10-150-2].
• Install the pins and secure the fasteners

[Figure 10-150-2].

1 • Start the engine and lower the boom slowly [Figure
10-150-2] so that the boom stop is held securely.
Removing The Approved Boom Stop
• Start the engine lower the restraint bar (if equipped)

and raise the boom. Stop the engine.
P-58126
• Remove the fasteners, pins and boom stop.
• Have a second person remove the boom stop (Item 1) • Put the boom stop in the storage position and secure
[Figure 10-150-1] from the storage position. with pins and fasteners.
• Start the engine lower the restraint bar (if equipped)

and lower the boom


ENGINE COVER
WARNING
Never service or adjust the machine when the engine
is running unless instructed to do so in the manual.
W-2012-0497
Opening And Closing The Engine Cover
Figure 10-160-1

P-47356
Pull up on the latch handle (Item 1) [Figure 10-160-1]

and rotate counterclockwise to release latch.


LATERAL OPERATOR RESTRAINT SYSTEM (LORS) Figure 10-170-2
System Inspection
1
Figure 10-170-1
B-15831
Lower the restraint bar, disengage the parking brake, and

P-39865 put the Travel Direction Lever (F-N-R) in Forward (F)
position. Move the machine forward slowly and raise the
restraint bar. The machine must stop when the restraint
With the engine off, raise and lower the restraint bar bar is raised. The light (Item 1) [Figure 10-170-2] will
(Item 1) [Figure 10-170-1]. Make sure the restraint bar come ON when the bar is raised. Repeat this procedure

moves freely and that there are no damaged or loose for the Reverse (R) position.
parts.
The restraint bar has an over-center spring that is used to

keep the bar in either the up or down position. Check the
spring and guides for damage and make sure the
restraint bar remains in the full up position when it is
raised.
Sit in the seat and fasten the seat belt. Engage the
parking brake and lower the restraint bar. Start the engine
and raise the boom. While the boom is raising, raise the
restraint bar. The boom must stop when the restraint bar
is raised.
Repeat this procedure for boom down, tilt out, tilt back,
boom extend, boom retract and auxiliary hydraulics.
Each time the respective functions must deactivate.

LATERAL OPERATOR RESTRAINT SYSTEM (LORS)
(CONT’D)
System Maintenance
See the SERVICE SCHEDULE on the VersaHANDLER

for correct service interval and in this manual (See
“SERVICE SCHEDULE” on Page 10-50-1.)
Use compressed air to clean any debris or dirt from the

restraint bar pivot area. Do not lubricate the main pivot.
Figure 10-170-3

1
P-39863
The spring guide pivot (Item 1) [Figure 10-170-3] must

be lubricated every 250 hours or as required with multi-
purpose lithium based grease.
If the Lateral Operator Restraint System (LORS) does

not function correctly, check all wiring and connections.
Replace parts that are worn or damaged. Use only
genuine Bobcat replacement parts.
See your Bobcat dealer for parts and service

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

• Put grease on any exposed cylinder rods. • Start the engine and let run for a few minutes while
observing the instrument panels and systems for
• Put fuel stabilizer in the fuel tank and run the engine correct operation.
a few minutes to circulate the stabilizer to the pump
and fuel injectors. • Operate machine, check for correct function.
If biodiesel blend fuel has been used, perform the • Stop the engine and check for leaks. Repair as
following: needed.
Drain the fuel tank, refill with 100% petroleum diesel

fuel, add fuel stabilizer and run the engine for at least
30 minutes.
• Drain and flush the cooling system. Refill with

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

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

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

condition.


STOPPING THE ENGINE AND LEAVING THE
VERSAHANDLER
Procedure
• Stop the engine on solid, flat and level ground.
• Put the Travel Direction Control Lever and Joystick in

neutral.
• Engage the parking brake.
Figure 10-190-1

S3518
• Retract and lower the boom and attachment flat on

the ground [Figure 10-190-1].
• Turn the key switch to STOP, unfasten the seat belt

and raise the restraint bar (if equipped).
• Use grab handles, safety tread and steps when

getting off.
DO NOT JUMP
WARNING
Before you leave the operator’s position:
• Put the travel Direction Control Lever and the
Joystick in neutral.
• Engage the parking brake.
• Retract and lower the boom and attachment flat
on the ground.
• Stop the engine. Raise the restraint bar (if
equipped).
SEE THE MACHINE OPERATION & MAINTENANCE
MANUAL FOR MORE INFORMATION.
W-2637-0607


EMERGENCY EXIT
Rear Window
Figure 10-200-1
S3520
Turn the handle (Inset) [Figure 10-200-1] and push the

rear window open. (Models with enclosed cab only.) Exit

through the rear window opening.


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

Glossary Of Hydraulic / Hydrostatic Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-4
Tightening Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-5
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-11
BUCKET POSITIONING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-9
EXTENSION CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Cylinder Group Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Upper Tubeline Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3
Upper Tubeline Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4
Extension Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
Tubeline Tray Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-8
Tubeline Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-11
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-14
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-15
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-20
TILT CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-3
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-7
STEERING CYLINDER (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-7
STEERING CYLINDER (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-5
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-7

DRIVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-9
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-2
QUICK-TACH CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-4
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-7
FRAME LEVELING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-4

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-9
STEERING MODE VALVE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-1
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-3
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-4
Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-6
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-110-6
BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-2
GEAR PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-130-1

FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-140-1

HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-150-1


STEERING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-3
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-160-10
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1

Troubleshooting Chart (Controllers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-1
Telescoping Valve Section Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-2
Auxiliary Valve Section Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-6
Troubleshooting Chart (Control Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-10
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-170-11
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-15
Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-16
End Housing Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-170-17
Lifting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-170-18
Tilting Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-170-23
Telescoping Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-170-28
Auxiliary / Frame Leveling Valve Section Disassembly And Assembly . . . . . . . . 20-170-40
Inlet-Outlet Valve Section Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . 20-170-50

PORT RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-180-1
FLOW CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-190-1

JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-200-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1

Pressure Switch Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-1
Pressure Switch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-3
Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-4
Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-210-5
PRESSURE REDUCING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-220-1
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-230-1
TOW VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-240-1



HYDRAULIC/HYDROSTATIC SCHEMATIC
Without Frame Leveling
V723 (S/N A8HL11001 AND ABOVE)
(Printed February 2008)
V-1035legend
LEGEND
1 RESERVOIR: 17 HYDRAULIC PUMP - Gear Type 34 BRAKE VALVE 363 PSI (25 Bar)
System Capacity 88 Qts. (83 L) 4.2 GPM (16 L/min.) @ High Engine Idle
35 RELIEF VALVE 2320 PSI (160 Bar)
2 FILTER - Hydraulic 18 PRIORITY VALVE
36 RELIEF VALVE (2) 3553 PSI (245 Bar)
3 SPRING LOADED FILTER BYPASS 19 LOAD CHECK
VALVE: 36 PSI (2,5 Bar) 37 SHUTTLE VALVE - Drive Pressure
20 ANTICAVITATION/WORK PORT RELIEF
4 CHECK VALVE 38
VALVE 3988 PSI (275 Bar) MOTOR DISPLACEMENT CONTROL
SPOOL - 2610 PSI (140 Bar)
5 CHECK VALVE - With 7 PSI (0,5 Bar) 21 ANTICAVITATION/WORK PORT RELIEF
39 SHUTTLE VALVE - Drain
Spring VALVE 3045 PSI (210 Bar)
22 ANTICAVITATION/WORK PORT RELIEF 40 VARIABLE CAPACITY DISPLACEMENT

6 BOOM CYLINDER LOCK VALVE - Lock VALVE 3625 PSI (250 Bar) BIDIRECTIONAL HYDROSTATIC MOTOR
Pressure - 5438 PSI (375 Bar)
23 ANTICAVITATION/WORK PORT RELIEF 41 SERVO PISTON - Swash Plate
7 ORIFICE VALVE 3625 PSI (250 Bar)
24 COMPENSATOR 42 RELIEF VALVE - 392 PSI (27 Bar)

8 TILT CYLINDER LOCK VALVE
3552 PSI (245 Bar) 43 TOW VALVE
25 RELIEF VALVE
9 SOLENOID - Reverse Drive 218 PSI (15 Bar) 44 TELESCOPIC CYLINDER LOCK
26 RELIEF VALVE VALVE - 2030 PSI (140 Bar)
10 SOLENOID - Forward Drive 3408 PSI (235 Bar) 45 AUXILIARY PRESSURE RELEASE
VALVE
27 LOAD SENSE RELIEF CARTRIDGE
11 RELIEF VALVE - Charge 46 ACCUMULATOR - 217 PSI (15 Bar)
435 PSI (30 Bar)
28 BUCKET POSITIONING CYLINDER
12 RELIEF/REPLENISHING VALVE - LOCK VALVE - 3625 PSI (250 Bar) 47 CHECK VALVE - With 43 PSI (3,0 Bar)
HIGH PRESSURE (2) - 6527 PSI (450 Spring
29 LOAD SENSE ACTIVATION VALVE
Bar)
13 VARIABLE CAPACITY DISPLACEMENT 48 RELIEF VALVE
BIDIRECTIONAL HYDROSTATIC PUMP 30 ACCUMULATOR - 3625 PSI (250 Bar)
49 CHECK VALVE - Anti-cavitation
14 CHARGE PUMP
4.5 GPM (17 L/min.) @ 2200 RPM 31 RELIEF VALVE - 392 PSI (27 Bar)
15 SERVO PISTON - Swash Plate
32 PRESSURE SWITCH 232 PSI (16 Bar)
16 HYDRAULIC PUMP - Gear type
24.0 GPM (91 L/min.) @ High Engine Idle 33 DIRECTIONAL CONTROL VALVE
NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V1035Hle (2-1-08)

67 of 913
HYDRAULIC SCHEMATIC
Without Frame Leveling 8
BOOM
CYLINDER
(PRINTED FEBRUARY 2008)
V-1035 7 SPOOL VALVE BLOCK
3/1
C2
V2
SECONDARY AUX. 24
VALVE (OPTIONAL)
EV51 TILT CYLINDER C2
4/1
AC
6
C
C4
pil
C3 C2
C1
A1
28
C1
V1
V2
COOLING MOTOR 20
B1
OIL COOLER
CYLINDER
B
SPOOL
A
BOOM
74.5 kW @ 2200 RPM
412 Nm @ 1400 RPM
PERKINS 1104C-44T
QUICK
MAX 2400 RPM

48
MIN 800 PRM

COUPLERS
T
19
a
SELF LEVELLING CYLINDER
24
B C 21
T
49
BUCKET PINS
A2
A
M2 M1 HYDROSTATIC PUMP
HYDRAULIC FILTER 22
B2
2
CYLINDER
SPOOL
A
TILT
b
T
19
a
3 M4
15 44 24
B1
13
L1 23
T
B2
5 10
A3
3/1
A
4
3/1
M5
TELESCOPIC
B3
CYLINDER
T
SPOOL
RESERVOIR
1
14 19
S
9 TELESCOPIC 44
CYLINDER 24
47 M3
A4
11
B4
AUXILIARY
SPOOL
L2
19
Y
pst
26
T1
43
FRONT AXLE HYDROSTATIC
BY-PASS
M
VALVE B A 27
HYDROSTATIC MOTOR
18 12
M2 L1 B
38 16 30 25
M5 XB
CF
IN
EF
17
LS
T
P
IN
41
40
;
39
37
OUT LS
MAX. GEAR PUMP
DISP.
42
n
XA
A
N M1 M3 M4 L2
JOYSTICK
A1 A2 2
REAR AXLE
Prop. 1
Prop. 2
32 ACCUMULATOR
CHARGING
STEERING VALVE
VALVE
STEERING UNIT A
AUXILIARY CONTROL VALVE
L R LS T P PRESSURE
36 34 33 MS RELEASE VALVE B1 B2 4
C7 C6
P
45
C
MA
A P T P 1
T
C5 A B P T
C1 C2 C3 C4
C10
T
C9
U
31 C8 C7 C6 C5 ENCLOSURE
MA
X C1 C2 C3 C4
PASSIVE BRAKE AND DRAIN PUMP SUPPLY
46 1
BLOCK
35 SERVICE BRAKE PASSIVE BRAKE VALVE
WORKING CIRCUITS
36 ACCUMULATOR
B 29 PILOT PRESSURE
SYSTEM RETURN LINES
DIRECT TANK RETURN
LOAD SENSE
INTERSECTION OF HYDRAULIC LINES

INDICATED BY JUNCTION DOT
68 of 913 V-1035 (2-1-08)

HYDRAULIC/HYDROSTATIC SCHEMATIC
With Frame Leveling
V723 (S/N A8HP11001 AND ABOVE)
(S/N A8HK11001 AND ABOVE)
V-1036legend
LEGEND
1 RESERVOIR: 17 HYDRAULIC PUMP - Gear Type 34 BRAKE VALVE 363 PSI (25 Bar) 52 SHUTTLE VALVE - Priority
System Capacity 88 Qts. (83 L) 4.2 GPM (16 L/min.) @ High Engine Idle
35 RELIEF VALVE 2320 PSI (160 Bar) 53 LOCK VALVES - 3045 PSI (210 Bar)
2 FILTER - Hydraulic 18 PRIORITY VALVE
36 RELIEF VALVE (2) 3553 PSI (245 Bar) 54 RELIEF VALVE
3 SPRING LOADED FILTER BYPASS 19 LOAD CHECK
VALVE: 36 PSI (2,5 Bar) 37 SHUTTLE VALVE - Drive Pressure 55 CHECK VALVE - Anti-cavitation
20 ANTICAVITATION/WORK PORT RELIEF
4 CHECK VALVE 38
VALVE 3988 PSI (275 Bar) MOTOR DISPLACEMENT CONTROL
SPOOL - 2610 PSI (140 Bar)
5 CHECK VALVE - With 7 PSI (0,5 Bar) 21 ANTICAVITATION/WORK PORT RELIEF
39 SHUTTLE VALVE - Drain
Spring VALVE 3045 PSI (210 Bar)
22 ANTICAVITATION/WORK PORT RELIEF 40 VARIABLE CAPACITY DISPLACEMENT

6 BOOM CYLINDER LOCK VALVE - Lock VALVE 3625 PSI (250 Bar) BIDIRECTIONAL HYDROSTATIC MOTOR
Pressure - 5438 PSI (375 Bar)
23 ANTICAVITATION/WORK PORT RELIEF 41 SERVO PISTON - Swash Plate
7 ORIFICE VALVE 3625 PSI (250 Bar)
24 COMPENSATOR 42 RELIEF VALVE - 392 PSI (27 Bar)

8 TILT CYLINDER LOCK VALVE
3552 PSI (245 Bar) 43 TOW VALVE
25 RELIEF VALVE
9 SOLENOID - Reverse Drive 218 PSI (15 Bar) 44 TELESCOPIC CYLINDER LOCK
26 RELIEF VALVE VALVE - 2030 PSI (140 Bar)
10 SOLENOID - Forward Drive 3408 PSI (235 Bar) 45 AUXILIARY PRESSURE RELEASE
VALVE
27 LOAD SENSE RELIEF CARTRIDGE
11 RELIEF VALVE - Charge 46 ACCUMULATOR - 217 PSI (15 Bar)
435 PSI (30 Bar)
28 BUCKET POSITIONING CYLINDER
12 RELIEF/REPLENISHING VALVE - LOCK VALVE - 3625 PSI (250 Bar) 47 CHECK VALVE - With 43 PSI (3,0 Bar)
HIGH PRESSURE (2) - 6527 PSI (450 Spring
29 LOAD SENSE ACTIVATION VALVE
Bar) 48 PRIORITY VALVE - 58 PSI (4,0 Bar)
13 VARIABLE CAPACITY DISPLACEMENT
BIDIRECTIONAL HYDROSTATIC PUMP 30 ACCUMULATOR - 3625 PSI (250 Bar)
49 RELIEF VALVE - 2900 PSI (200 Bar)
14 CHARGE PUMP
4.5 GPM (17 L/min.) @ 2200 RPM 31 RELIEF VALVE - 392 PSI (27 Bar) 50 SOLENOID ACTIVATED DIRECTIONAL
15 SERVO PISTON - Swash Plate CONTROL VALVE - FRAME LEVEL -
32 PRESSURE SWITCH 232 PSI (16 Bar) REDUCED SPEED
16 HYDRAULIC PUMP - Gear type 51 SOLENOID ACTIVATED DIRECTIONAL
24.0 GPM (91 L/min.) @ High Engine Idle 33 DIRECTIONAL CONTROL VALVE CONTROL VALVE - FRAME LEVEL -
LEFT/RIGHT DIRECTION CONTROL NOTE: Unless otherwise specified
springs have NO significant
pressure value.
Printed in U.S.A. V1036Hle (2-1-08)

69 of 913
HYDRAULIC SCHEMATIC
With Frame Leveling 8
BOOM
V723 (S/N A8HP11001 AND ABOVE) CYLINDER
(S/N A8HK11001 AND ABOVE)
(PRINTED FEBRUARY 2008) 7 SPOOL VALVE BLOCK
V-1036 3/1
C2
V2
SECONDARY AUX. 24
VALVE (OPTIONAL)
EV51 TILT CYLINDER C2
4/1
AC
6
C
C4
pil
C3 C2
C1
A1
28
C1
V1
V2
COOLING MOTOR 20
B1
OIL COOLER
CYLINDER
B
SPOOL
A
BOOM
74.5 kW @ 2200 RPM
412 Nm @ 1400 RPM
PERKINS 1104C-44T
QUICK
MAX 2400 RPM

54
MIN 800 PRM

COUPLERS
T
19
a
SELF LEVELLING CYLINDER
24
B C 21
T
55
BUCKET PINS
A2
A
FRAME LEVELLING CYLINDER HYDROSTATIC PUMP
M2 M1
HYDRAULIC FILTER 22
B2
2
CYLINDER
SPOOL
A
TILT
b
T
53 19
a
53 M4
3
15 44 24
B1
13
L1 23
T
B B2
A
5 10
A3
3/1
A B
A
4
FRAME LEVELLING HYDRAULIC BLOCK
3/1
M5
TELESCOPIC
B3
CYLINDER
52 T
SPOOL
RESERVOIR
A B 51 1
14 19
a 0 b
P T S
9 TELESCOPIC 44
CYLINDER 24
49
47 M3
48
A4
11
50
B4
AUXILIARY
SPOOL
P T V
L2
19
Y
pst
26
HYDROSTATIC
T1
43 BY-PASS
FRONT AXLE VALVE
M
B A 27
HYDROSTATIC MOTOR
18 12
M2 L1 B
38 16 30 25
M5 XB
CF
IN
EF
17
LS
T
P
IN
41
40
;
39
37
OUT LS
MAX. GEAR PUMP
DISP.
42
n
XA
A
N M1 M3 M4 L2
JOYSTICK
A1 A2 2
REAR AXLE
Prop. 1
Prop. 2
32 ACCUMULATOR
CHARGING
STEERING VALVE
VALVE
STEERING UNIT A
AUXILIARY CONTROL VALVE
L R LS T P PRESSURE
36 33 MS C6 RELEASE VALVE B1 B2 4
34 C7
P
MA 45
C
A P T P 1
T
C5 A B P T
C1 C2 C3 C4
C10
31 T
C9
U C8 C7 C6 C5 ENCLOSURE
MA C1 C2 C3 C4
X PUMP SUPPLY
PASSIVE BRAKE AND 1 DRAIN
46 BLOCK
35 SERVICE BRAKE PASSIVE BRAKE VALVE
ACCUMULATOR WORKING CIRCUITS
36 B 29 PILOT PRESSURE
SYSTEM RETURN LINES
DIRECT TANK RETURN
LOAD SENSE
INTERSECTION OF HYDRAULIC LINES

INDICATED BY JUNCTION DOT
70 of 913 V-1036 (2-1-08)

HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
mc-2340

HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
mc-2340-2

Glossary Of Hydraulic / Hydrostatic Symbols (Cont’d)
mc-2340-3

Troubleshooting Chart
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, 6
The hydraulic oil temperature warning light comes ON when hydraulics are operating. 1, 2
Slow hydraulic system action. 1, 2, 4, 8
Hydraulic action is not smooth. 1, 3, 4, 5
Boom goes up slowly at full engine RPM. 1, 2, 4, 5, 6, 7
The boom comes down with the lever in neutral position. 7, 8, 9
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.

2. The hydraulic pump has damage.
3. Relief valve is not at the correct pressure.
4. Suction leak on the inlet side of the hydraulic pump.
5. Fluid is cold. Wrong viscosity fluid. ((See “Capacities” on Page SPEC-10-4.) for type of fluids.)
6. Using the machine for more than its rated capacity.
7. Internal leak in the lift cylinder.
8. External leak from the cylinder(s).
9. Damaged lift spool.

Tightening Procedures
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
To tighten the hydraulic fittings, tubelines etc. (See

“HYDRAULIC CONNECTION SPECIFICATIONS” on
Page SPEC-50-1.) for the correct procedure and torque.
WARNING

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


LIFT CYLINDER Figure 20-20-3
Removal And Installation
Figure 20-20-1
P-29765
Place a wood block (Item 1) [Figure 20-20-3] under the

P-29763 lift cylinder.
Figure 20-20-4
Lower the boom onto adequate stands or blocks as
shown [Figure 20-20-1].

Figure 20-20-2
1 1
P-29764
Remove the pivot pin retainer bolt (Item 1) [Figure 20-

S7421 20-4] from the rod end.
Remove the rear cover (Item 1) [Figure 20-20-2] from

the machine.

LIFT CYLINDER (CONT'D) Figure 20-20-7
Removal And Installation (Cont'd)
Figure 20-20-5
1
2
P-29766A
1 2. The side window (Item 1) and frame opening (Item 2)

P-29768A [Figure 20-20-7] must be protected from sparks.
Figure 20-20-8
Remove the upper pivot pin using a pin removal tool
(Item 1) [Figure 20-20-5].

NOTE: If a nut must be welded onto the pin for
removal the following three steps must be
performed.
Figure 20-20-6
1
P-29767A
3. The cylinder rod must be wrapped with a damp

welding blanket (Item 1) [Figure 20-20-8] to prevent
damage.
P-29253
1. Rotate the battery disconnect switch (Item 1) [Figure

20-20-6] to the right to disconnect the power supply
from the battery.

LIFT CYLINDER (CONT'D)

IMPORTANT
Figure 20-20-9
damage the system.
I-2003-0888
Figure 20-20-11
1
P-29778
After the upper pivot pin has been removed, the rod end
of the cylinder should be lowered onto the center frame

with a pipe (Item 1) [Figure 20-20-9] positioned as
shown.
Figure 20-20-10
P-50974
Remove the base end pivot pin snap ring (Item 1)

1
[Figure 20-20-11].
Figure 20-20-12
P-29774
Remove the two hoses (Item 1) [Figure 20-20-10] from

the lift lock on the lift cylinder.
NOTE: Mark all hoses for correct installation. 2

P-50973
Remove the bolt (Item 1) (both sides) and remove the

cross brace (Item 2) [Figure 20-20-12].
Installation: Tighten the bolt to 255 ft.-lb. (345 N•m)

torque.

Figure 20-20-13
P-29779A
Lift and remove the cylinder [Figure 20-20-15].

P-50975
Lift and support the base end of the cylinder [Figure 20-
20-13].

Figure 20-20-14
P-29776
Remove the base end pivot pin (Item 1) [Figure 20-20-

14].

Parts Identification
1. Housing
2. Bushing
3. Spacer
4. Grease Fitting
5. Wiper
6. Wear Ring
7. Seal
8. O-ring
9. Rod
10. Head
11. Piston
12. Lock Washer
13. Nut
B-19851

Disassembly
Figure 20-20-16
P-29905
Carefully peen the lock ring from the head gland [Figure
P-29903 20-20-18].
Figure 20-20-19
Use the following tools to disassemble the cylinders:

MEL1354-Spanner Wrench
MEL1076-Cylinder Wrench
Put the cylinder in a vise [Figure 20-20-16].
Figure 20-20-17
1
2
P-29906
Use a spanner wrench to loosen the head gland [Figure

20-20-19].
P-29904
Remove the four bolts (Item 1) and remove the lift lock
(Item 2) [Figure 20-20-17].

Disassembly (Cont'd)
Figure 20-20-20
P-29910
Support the cylinder rod on a wood block [Figure 20-20-

P-29907 22].
Figure 20-20-23
Remove the rod assembly (Item 1) [Figure 20-20-20]
from the housing.

Figure 20-20-21
P-29923
Carefully peen the lock ring tab (Item 1) [Figure 20-20-

P-29909 23] up and out of the lock nut groove.
Put the rod end of the cylinder in a vise [Figure 20-20-

21].

Figure 20-20-24
1
P-29914
Remove the piston (Item 1) [Figure 20-20-26] from the

P-29912 rod.
Figure 20-20-27
Remove the lock nut from the cylinder rod [Figure 20-20-
24] using a cylinder wrench. 1

Figure 20-20-25
2
P-29915
Remove the two wear rings (Item 1) and seal (Item 2)

P-29913 [Figure 20-20-27] from the piston.
Remove the lock ring (Item 1) [Figure 20-20-25].

Figure 20-20-28 1
P-29918
1
Remove the head gland (Item 1) [Figure 20-20-30] from
P-29916 the rod.
Figure 20-20-31
Remove the expander O-ring (Item 1) [Figure 20-20-28].

Figure 20-20-29
P-29919
P-29917 Remove the two O-rings (Item 1) [Figure 20-20-31] from

the head gland.
Remove the O-ring (Item 1) [Figure 20-20-29] from the

piston.

Figure 20-20-32
P-29920
Remove the wear ring (Item 1) [Figure 20-20-32].

Figure 20-20-33
P-29921
Remove seal (Item 1) wear ring (Item 2) and wiper (Item

3) [Figure 20-20-33] from the head gland.

Assembly
Use the following tools to assemble the cylinders:
MEL1354-Spanner Wrench 1
MEL1033-Rod Seal Installation Tool
Wash the cylinder parts in solvent and dry with

compressed air.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
P-29885
Lubricate all O-rings and seals with hydraulic oil during
installation. Always use new O-rings and seals.
Install the center seal (Item 1) [Figure 20-20-36].
Figure 20-20-34
NOTE: The groove in the seal must point away from
the wiper seal (Item 1) [Figure 20-20-34].
1
Figure 20-20-37

1
2
P-29884
Install the wiper (Item 1) and wear ring (Item 2) [Figure

20-20-34] in the head gland. P-29919
Figure 20-20-35
Install the two O-rings (Item 1) [Figure 20-20-37].
P-29883
Install the wear ring (Item 1) [Figure 20-20-35].

Assembly (Cont'd)
Figure 20-20-38
1
P-29916
Install the expander O-ring (Item 1) [Figure 20-20-40] on

P-29918 the piston.
Figure 20-20-41
Install the head gland (Item 1) [Figure 20-20-38] onto the
rod.
1

Figure 20-20-39
2
P-29915
Install the two wear rings (Item 1) and seal (Item 2)

P-29917 [Figure 20-20-41] onto the piston.
Install the O-ring (Item 1) [Figure 20-20-39] in the piston.

Assembly (Cont'd)
Figure 20-20-42
P-29913
Install the lock ring (Item 1) [Figure 20-20-44].

P-32047
Figure 20-20-45
Clean off any old residue, and apply Loctite® 242 or

equivalent to the threads on the rod [Figure 20-20-42].

Figure 20-20-43
1
1
P-29922
Use the cylinder wrench to install the lock nut (Item 1)

[Figure 20-20-45] and tighten.
P-29914
Install the piston (Item 1) [Figure 20-20-43] on the rod.

Assembly (Cont'd)
Figure 20-20-46
P-29925
Use the spanner wrench to tighten the head gland

P-29924 [Figure 20-20-48].
Figure 20-20-49
Peen the lock ring tab (Item 1) [Figure 20-20-46] into the
groove in the lock nut.

Figure 20-20-47
P-29926
Peen the lock ring into the groove in the head gland
P-29907 [Figure 20-20-49].
Install the rod assembly (Item 1) [Figure 20-20-47] into

the housing.

Assembly (Cont'd)
Figure 20-20-50
1
1
P-29904
Install the lift lock (Item 1) onto the cylinder and tighten
the four bolts (Item 2) [Figure 20-20-50].


BUCKET POSITIONING CYLINDER Figure 20-30-3
Figure 20-30-1
3
2
1
P-58090
Remove the upper hose (Item 1), tubeline (Item 2) and

P-29315A fitting (Item 3) [Figure 20-30-3] from the cylinder.
NOTE: Mark all hoses for correct installation.

Raise the boom and install the boom stop (Item 1)
[Figure 20-30-1].

Figure 20-30-2
IMPORTANT
1 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
Figure 20-30-4
S7421
Remove the rear cover (Item 1) [Figure 20-30-2] from 2

the machine.
3
P-58091
Remove the lower hose (Item 1), tubeline (Item 2) and

load lock (Item 3) [Figure 20-30-4] from the cylinder.

BUCKET POSITIONING CYLINDER (CONT'D) Figure 20-30-7
Figure 20-30-5
P-29759
Remove the upper pivot pin using a pin removal tool

P-50977 [Figure 20-30-7].
NOTE: Secure the top of the cylinder from falling

Remove the nut (Item 1) [Figure 20-30-5] from the upper forward and causing damage to the cylinder
retainer bolt. rod when the pivot pin is removed.

P-29758
P-50978
Remove the upper retainer bolt (Item 1) [Figure 20-30-6] Remove the lower pivot pin snap ring (Item 1) [Figure
from the top pivot pin. 20-30-8].

Figure 20-30-9
P-29762A
Have an assistant tilt the cylinder forward while removing

P-29761
the cylinder out the back [Figure 20-30-10].
Remove the lower pivot pin (Item 1) [Figure 20-30-9].

BUCKET POSITIONING CYLINDER (CONT'D)
1. Bushing
2. Housing
3. Wear Ring
4. Seal
5. O-ring
6. Set Screw
7. Piston
8. Rod
9. Head Gland
10. Wiper
11. Grease Fitting
B-19852

Disassembly
Use the following tools to disassemble the cylinder:
Figure 20-30-11
P-29869
Use a spanner wrench to remove the head gland [Figure

20-30-13].
Figure 20-30-14
P-29871

1
Figure 20-30-12
P-29872

from the housing.
P-29868
20-30-12].

Figure 20-30-15 1
P-29874
Remove the piston assembly (Item 1) [Figure 20-30-17]

P-29873 from the rod.
Figure 20-30-18
15].

1
Figure 20-30-16
1
1
P-29877

Support the cylinder rod on a wood block and remove the

set screw (Item 1) [Figure 20-30-16] from the piston.

Figure 20-30-19
P-29881
1
P-29879 the rod.
Figure 20-30-22

Figure 20-30-20
P-29883
P-29880 Remove the center seal (Item 1) and outer wear ring
(Item 2) [Figure 20-30-22].

piston.

Figure 20-30-23
P-29878
Remove any residue from the threads on the cylinder rod

P-29884 [Figure 20-30-25].
Remove the outer wear ring (Item 1) and wiper (Item 2)

[Figure 20-30-23].

Figure 20-30-24
P-29882
Remove the two O-rings (Item 1) [Figure 20-30-24].

Assembly
Use the following tools to assemble the cylinder: 1

compressed air.

Lubricate all O-rings and seals with hydraulic oil during P-29883
installation.
Always use new O-rings and seals. Install the wear ring (Item 1) [Figure 20-30-28].
Figure 20-30-26 Figure 20-30-29

1
1
P-29882
P-29885
Install the two O-rings (Item 1) [Figure 20-30-26] onto

the head gland. Install the center seal (Item 1) [Figure 20-30-29].
Figure 20-30-27 NOTE: The groove in the seal must point away from
P-29884

20-30-27].

Assembly (Cont'd)
Figure 20-30-30
P-29879
Install the expander O-ring (Item 1) [Figure 20-30-32]

P-29881 onto the piston.
Figure 20-30-33
rod.

1
Figure 20-30-31
1
P-29877

P-29880 [Figure 20-30-33].

Assembly (Cont'd)
Figure 20-30-34
P-29888
Align the hole (Item 1) [Figure 20-30-36] in the piston

P-29886 with the hole in the end of the cylinder rod.
Figure 20-30-37
Apply Loctite® 242 or equivalent to the threads on the
rod [Figure 20-30-34].

Figure 20-30-35
P-29887
Apply Loctite® 242 or equivalent to the set screw (Item 1)

P-29874 [Figure 20-30-37].
Install the piston (Item 1) [Figure 20-30-35] onto the rod.

Assembly (Cont'd)
Figure 20-30-38
1
P-29869

P-29875 [Figure 20-30-40].
Figure 20-30-41
Install the set screw (Item 1) [Figure 20-30-38] into the
piston and tighten.

Figure 20-30-39
P-29868
Carefully peen the lock ring over and into the nut [Figure
P-29874 20-30-41].

the housing.

EXTENSION CYLINDER Figure 20-40-3
Cylinder Group Removal And Installation

1
1
Remove the inner boom. (See Removal on Page 50-50- 1
1.)
Remove the tilt cylinder. (See Removal And Installation

on Page 20-50-1.)
NOTE: The tilt cylinder may be removed from the

machine either before or after the inner boom
is removed.
Figure 20-40-1
P-32013
1 Remove any tie straps (Item 1) [Figure 20-40-3].
Figure 20-40-4

1
P-23869
Remove the electrical connector (Item 1) [Figure 20-40-

1] from the auxiliary valve.
Figure 20-40-2 P-32014
2
Remove the two tubelines (Item 1) [Figure 20-40-4] from
the bulkhead fittings.
1
P-23611
Remove the harness (Item 1) from the connector (Item 2)

[Figure 20-40-2].
NOTE: Mark the harness connector for correct

installation.

EXTENSION CYLINDER (CONT'D) Figure 20-40-7
Cylinder Group Removal And Installation (Cont'd)
Figure 20-40-5
1
1
1
1
P-23881
Remove the two bolts (Item 1) [Figure 20-40-7] from the

P-32015 top of the boom.
Installation: Tighten the bolts to 18 ft.-lb. (24 N•m)

Remove the two nuts (Item 1) [Figure 20-40-5] from the torque.
bulkhead fittings.

Figure 20-40-8
Figure 20-40-6
1
2
1
P-32017
P-32016
Remove the extension cylinder assembly from the boom

Pull the two bulkhead fittings (Item 1) and electrical [Figure 20-40-8].
harness (Item 2) [Figure 20-40-6] into the boom.
NOTE: Install caps and plugs after the bulkhead

fittings are pulled into the boom.

EXTENSION CYLINDER (CONT’D) Figure 20-40-11
Upper Tubeline Removal
Figure 20-40-9
1
1
1 1
P-47040
Remove the four hoses (Item 1) [Figure 20-40-11] from

P-47037 the tubelines.
NOTE: Mark the hoses for correct installation.

Remove all tie straps (Item 1) [Figure 20-40-9] securing
the electrical harness to the tubelines. Figure 20-40-12

Figure 20-40-10
1 1
P-47034
P-47038
Remove the bolt (Item 1) from the tubeline clamp bracket
(Item 2) [Figure 20-40-12].
Roll up the electrical harness (Item 1) [Figure 20-40-10]
and temporarily tie to the existing hoses. Lift and remove the tubeline assembly from the extension
cylinder.

Upper Tubeline Installation
Figure 20-40-13
1
1
P-47070
To move and adjust the tubeline clamps loosen the bolt

P-47034 (Item 1) [Figure 20-40-15]. (Both sides)
Figure 20-40-16
Set the tubeline assembly onto the extension cylinder
and install the bolt (Item 1) and tighten to secure the

tubeline clamp bracket (Item 2) [Figure 20-40-13] to the
rod end of the cylinder. 1
Figure 20-40-14
P-47039
Install the four hoses (Item 1) [Figure 20-40-16] to the

2
tubelines.
P-47069
Measure the distance from the tubeline clamp (Item 1) to

the tubeline flare (Item 2) [Figure 20-40-14] the correct
measurement must be 1.25 in. (31,75 mm) for all four
tubelines.

Upper Tubeline Installation (Cont’d)
Figure 20-40-17 2 3
1 3
3
1
1
3
P-47033
Route the electrical harness (Item 1) through the hole

P-47071 (Item 2) in the tubeline bracket and secure as shown
using tie straps (Item 3) [Figure 20-40-19].
Make sure the hoses (Item 1) [Figure 20-40-17] lean in

towards the cylinder after hoses are tight.

Figure 20-40-18
2
1 2
P-47036
Secure the electrical harness to the inner tubeline (Item

1) using tie straps (Item 2) [Figure 20-40-18]
approximately every 6 - 8 in. (152 - 203 mm).

Extension Cylinder Removal And Installation
Figure 20-40-20
P-47047
2
Install a hoist to lift and support the cylinder [Figure 20-
P-47043 40-22].
Remove the bolt and washer (Item 1) and remove the

bracket (Item 2) [Figure 20-40-20] from the bottom side

of the rod end of the cylinder.
Figure 20-40-21
P-47044
Disconnect the tubeline (Item 1) [Figure 20-40-21] from

the cylinder. (Both sides)

Extension Cylinder Removal And Installation

(Cont’d)
1
Figure 20-40-23
2
3
P-47048
1
Raise the cylinder (Item 1) slightly until the base end

(Item 2) drops away from the bracket (Item 3) [Figure 20-
P-47045 40-25].
Figure 20-40-26
Figure 20-40-24

1
P-47049
P-47046
Slide the extension cylinder through the tubelines

Remove the bolt and nut (Item 1) [Figure 20-40-23] and [Figure 20-40-26] and remove the cylinder.
[Figure 20-40-24] from the base end and rod end of the
cylinder. NOTE: It may be necessary to reposition the lifting
strap.

Tubeline Tray Disassembly
Figure 20-40-27 1
1
1
1
P-47057
Remove the four hoses (Item 1) [Figure 20-40-29] from

P-47054 the tubelines.
NOTE: Mark the hoses for correct assembly.

Remove all tie straps (Item 1) [Figure 20-40-27] securing
the electrical harness to the hoses. Figure 20-40-30

Figure 20-40-28
1
1
P-47059
P-47056
Straighten the two tabs (Item 1) [Figure 20-40-30] as
shown. (Both ends)
Temporarily roll up the electrical harness (Item 1) [Figure
20-40-28].

Tubeline Tray Disassembly (Cont’d)

1
Figure 20-40-31
P-47064
1 Remove the cover (Item 1) from the tubeline tray

P-47061 assembly (Item 2) [Figure 20-40-33].
Slide both clamp brackets (Item 1) [Figure 20-40-31]

from the tabs.

Figure 20-40-32
P-47063
Bend the eight tabs (Item 1) [Figure 20-40-32] up as

shown.

Tubeline Tray Disassembly (Cont’d)

1
Figure 20-40-34 1
1
P-47065
Remove the tubeline clamp mounting bolts (Item 1)

P-47066 [Figure 20-40-36] and clamps.
Remove the tubelines.

Figure 20-40-35

1
P-47067
For tubeline replacement, remove the two tubeline clamp

brackets (Item 1) [Figure 20-40-34] and [Figure 20-40-
35].

Tubeline Tray Assembly

1
Figure 20-40-37
P-47066
Install the inner tubeline clamp (Item 1) [Figure 20-40-

1 P-47065 39] over the tubelines.
Figure 20-40-40
Install the tubelines into tray, and install the bracket (Item
1) onto the tubelines using the clamps and bolts (Item 2)

[Figure 20-40-37]. 1
Figure 20-40-38
1
2
P-47064
Install the tubeline tray cover (Item 1) onto the tubeline

tray assembly (Item 2) [Figure 20-40-40].
P-47067
Install the outer tubeline clamp (Item 1) [Figure 20-40-

38] on the tubelines.

Tubeline Tray Assembly (Cont’d)
Figure 20-40-41
1
1
2
P-47060
Measure the distance from the tubeline clamp bracket

P-47063 (Item 1) to the tubeline flare (Item 2) [Figure 20-40-43].
The correct measurement must be 2.50 in. (64 mm) for
all four tubelines.
Using a hammer, bend the eight tabs (Item 1) [Figure 20-
40-41] over. Figure 20-40-44

Figure 20-40-42
P-47058
P-47059
Using a hammer, bend the two tabs (Item 1) [Figure 20-
40-44] over. (Both ends)
Slide the two tubeline clamp brackets (Item 1) over the
two tabs (Item 2) [Figure 20-40-42].

Tubeline Tray Assembly (Cont’d)
1 1
Figure 20-40-45
1
1 P-47054
Install new tie straps (Item 1) [Figure 20-40-46]

P-47057 approximately every 6 - 8 in. (152 - 203 mm) to secure
the electrical harness to the hose.
Install the four hoses (Item 1) [Figure 20-40-45] onto the

tubelines.

EXTENSION CYLINDER (CONT’D)
1. Housing
2. Cartridge
3. Bushing
4. Wiper Seal
5. Wear Ring
6. Seal
7. Head Gland
8. O-ring
9. Rod
10. Piston
11. Lock Ring
12. Nut
B-19853

Disassembly
Use the following tool to disassemble the cylinder:
MEL1075-Adjustable Gland Nut Wrench
Figure 20-40-47
P-25000
Carefully peen the lock ring from the groove in the head
gland [Figure 20-40-49].
Figure 20-40-50

P-23999
Figure 20-40-48
P-25001
Use the spanner wrench to loosen the head gland

1 [Figure 20-40-50].
P-25002
Remove the two fittings (Item 1) and relief cartridges

(Item 2) [Figure 20-40-48].

Figure 20-40-51
P-29910

P-25003 53].
Figure 20-40-54
from the housing.

Figure 20-40-52
P-29923
Carefully peen the lock ring tab (Item 1) [Figure 20-40-

P-32036 54] up and out of the lock nut groove.

52].

Figure 20-40-55 1
P-29914
Use the adjustable gland nut wrench to remove the

P-29912 piston (Item 1) [Figure 20-40-57] from the rod.
Figure 20-40-58
Use the cylinder wrench to remove the lock nut from the
cylinder rod [Figure 20-40-55]. 1
1

Figure 20-40-56
2
P-29915


Figure 20-40-59 1
P-29918
1 Remove the head gland (Item 1) [Figure 20-40-61] from

P-29916 the rod.
Figure 20-40-62
1

Figure 20-40-60
P-29919
P-29917 Remove the two O-rings (Item 1) [Figure 20-40-62] from

the head gland.

piston.

3
Figure 20-40-63
2
1
1
P-29921
Remove seal (Item 1) wear ring (Item 2) and wiper (Item

P-29920 3) [Figure 20-40-64] from the head gland.
Remove the wear ring (Item 1) [Figure 20-40-63].

Assembly
Use the following tools to assemble the cylinder:

1
MEL-1075-Adjustable Gland Nut Wrench

compressed air.

damage. Replace any damaged parts. P-29885

installation. Always use new O-rings and seals. Install the center seal (Item 1) [Figure 20-40-67] using
the seal installation tool.
Figure 20-40-65
1

Figure 20-40-68
2 1
P-29884

20-40-65] in the head gland.
P-29919
Figure 20-40-66
P-29883

Assembly (Cont’d)
Figure 20-40-69
1
P-29916
Install the expander O-ring (Item 1) [Figure 20-40-71] on

P-29918 the piston.
Figure 20-40-72
rod. 1
1

Figure 20-40-70
2
P-29915

P-29917 [Figure 20-40-72] onto the piston.

Assembly (Cont'd)
Figure 20-40-73
1
P-29913

P-32047
Figure 20-40-76

equivalent to the threads on the rod [Figure 20-40-73].

Figure 20-40-74
P-29922
Use the cylinder wrench to install the lock nut (Item 1)

[Figure 20-40-76] and tighten.
P-29914
Install the piston (Item 1) [Figure 20-40-74] on the rod

and tighten.

Assembly (Cont'd)
Figure 20-40-77
P-29925

P-29923 [Figure 20-40-79].
Figure 20-40-80
Peen the lock ring tab (Item 1) [Figure 20-40-77] into the
groove in the lock nut.

Figure 20-40-78
P-29926
Peen the lock ring into the groove in the head gland
P-29907 [Figure 20-40-80].

the housing.

EXTENSION CYLINDER (CONT'D)
Assembly (Cont'd)
Figure 20-40-81
P-25002
Install the two fittings (Item 1) and two relief cartridges

(Item 2) [Figure 20-40-81].

TILT CYLINDER Figure 20-50-3

2
Figure 20-50-1
1
1
P-23866
1
Remove the bolt (Item 1) and bushing (Item 2) [Figure

P-32003 20-50-3] from each side of the boom.
Installation: Tighten the bolt to 188 - 210 ft.-lb. (255 -

Remove the four bolts [Figure 20-50-1]. Extend the inner 285 N•m) torque.
boom out approximately 36 in. (914 mm).

Figure 20-50-4
Remove the Pivot Link. (See Removal And Installation on
Page 50-130-1.)
Figure 20-50-2
P-32012
Remove the tilt cylinder from the end of the boom as

P-32011 shown [Figure 20-50-4].

the tubelines.

TILT CYLINDER (CONT’D)
1. Housing
2. Bushing
3. Cartridge
4. Grease Fitting
5. Rod
6. Wiper
7. Wear Ring
8. Seal
9. Head Gland
10. O-ring
11. Piston
12. Set Screw

7
B-19854

TILT CYLINDER (CONT'D) Figure 20-50-7
Disassembly
MEL1075-Adjustable Gland Wrench
Figure 20-50-5
P-32032
Remove the relief cartridge (Item 1) [Figure 20-50-7].
Figure 20-50-8
P-32030

1
Figure 20-50-6
P-32033
Remove the set screw (Item 1) [Figure 20-50-8].

1
1
P-32031

the cylinder.

Figure 20-50-9
P-32036

P-32034 11].
Figure 20-50-12
Use the adjustable gland wrench to loosen the head
gland [Figure 20-50-9].

Figure 20-50-10
P-32037

P-32035 12].
Remove the rod assembly (Item 1) [Figure 20-50-10].

1 1
Figure 20-50-13
1
2
P-32040

Figure 20-50-16

Figure 20-50-14
1
P-32041
P-32037 Remove the expander O-ring (Item 1) [Figure 20-50-16].
Remove the piston (Item 1) [Figure 20-50-14] from the

rod.

Figure 20-50-17
1
1
P-32044

P-32042 head.
Figure 20-50-20
inside of the piston. 3

Figure 20-50-18
1
2
P-32045
1
Remove the seal (Item 1) wear ring (Item 2) and wiper
P-32043 (Item 3) [Figure 20-50-20].

the rod.

Assembly

MEL1075-Adjustable Gland Nut Wrench

compressed air.
Inspect the cylinder parts for damage. Replace any

damaged parts.
Lubricate all O-rings and seals with hydraulic oil during 1

installation. Always use new O-rings and seals.
P-32043
Figure 20-50-21
3 Install the head gland (Item 1) [Figure 20-50-23] onto the

rod.
Figure 20-50-24

1
2
1
P-32045
Install the wiper (Item 1) wear ring (Item 2) and seal (Item
3) [Figure 20-50-21].
NOTE: The groove in the seal must point away from P-32042

Install the O-ring (Item 1) [Figure 20-50-24] on the inside
Figure 20-50-22 of the piston.
P-32044
Install the O-ring (Item 1) [Figure 20-50-22] on to the

head.

Assembly (Cont'd)
Figure 20-50-25
P-32047

P-32041 equivalent to the threads on the rod [Figure 20-50-27].
Figure 20-50-28
onto the piston.

Figure 20-50-26 1
1 1
P-32037
Install the piston (Item 1) [Figure 20-50-28] onto the rod

2
P-32040 and tighten.

[Figure 20-50-26].

Assembly (Cont'd)
Figure 20-50-29
P-32049
Use the adjustable gland wrench to tighten the head

P-32039 gland [Figure 20-50-31].
Figure 20-50-32

Figure 20-50-30
P-32050
P-32035 Apply Loctite® 242 or equivalent to the set screw (Item 1)

[Figure 20-50-32].
Install the piston/rod assembly (Item 1) [Figure 20-50-

30] into the housing.

Assembly (Cont'd)
Figure 20-50-33
1
1
P-32031
Install the two hoses (Item 1) [Figure 20-50-35].

P-32033
Install the set screw (Item 1) [Figure 20-50-33] and

tighten.

Figure 20-50-34
P-32032
Install the relief cartridge (Item 1) [Figure 20-50-34].

STEERING CYLINDER (FRONT) Figure 20-60-3
Removal
Figure 20-60-1 2
1
3 S2515
2
Remove the bolt (Item 1) for access for removing the nut
(Item 2) [Figure 20-60-3].
S2649
Figure 20-60-4
Remove the two bolts (Item 1) and remove the centering
sensor (Item 2) from the front steering cylinder (Item 3)
[Figure 20-60-1].

1
Figure 20-60-2
1
S2516
Remove the nut (Item 1) [Figure 20-60-4].
S2514
Remove the cotter pin (Item 1) [Figure 20-60-2].

STEERING CYLINDER (FRONT) (CONT’D) Figure 20-60-7
Removal (Cont’d)
Figure 20-60-5
2
S2651
Remove the securing screws (Item 1) from the steering

S2517 cylinder (Item 2) [Figure 20-60-7].
Figure 20-60-8
Remove the tie rod end (Item 1) [Figure 20-60-5] by
means of a puller.
Figure 20-60-6

1 2
S2652
Extract the cylinder (Item 1) [Figure 20-60-8] using a

S2650 plastic hammer.
NOTE: (See Disassembly on Page 20-60-5.) for

Disconnect the left and right steering bars (Item 1) from
cylinder disassembly.
the piston (Item 2) [Figure 20-60-6].

Installation
Figure 20-60-9
S2650
Apply Loctite® 242 to the thread and connect the

S2653
steering bars by screwing the terminals onto the piston
stem, apply a torque of 177 - 200 ft.-lb. (240 - 270 N•m)
[Figure 20-60-11].
Lubricate the seats of the seals and fit the steering
cylinder (Item 1) [Figure 20-60-9] into its seat. Figure 20-60-12
Figure 20-60-10

2
1
1
1
S2524
S2653
S2654
Insert the pins (Item 1) in the steering case (Item 2)
[Figure 20-60-12] and lock into position of 192 - 214 ft.-
Tighten the bolts (Item 1) [Figure 20-60-10] to 85 - 95 lb. (260 - 290 N•m) torque.
ft.-lb. (116 - 128 N•m) torque.
Find the position of the notching in relation to the hole of
the cotter pins and tighten the nut (Item 3) [Figure 20-
60-12] further.
NOTE: Check that the rubber guards [Figure 20-60-

12] are intact.

Installation (Cont’d)
Figure 20-60-13
1
2
S2526
1
Install the centering sensor (Item 1) for checking piston
S2525 centering and tighten the bolts (Item 2) [Figure 20-60-
14] to 3.7 - 4.4 ft.-lb. (5 - 6 N•m) torque.
Insert the cotter pins (Item 1) [Figure 20-60-13] and After the axle has been reinstalled on the machine,
bend the ends. perform the axle toe-in procedure (See AXLE TOE-IN on
Page 40-40-1.)

NOTE: Use new cotter pins.

Disassembly
Figure 20-60-15 2
1
S1518
With the help of a drift, apply pressure to the stop ring

S1516 (Item 1) that is placed inside the cylinder
(Item 2) [Figure 20-60-17] and extract the ring using a
screwdriver.
Remove the snap ring (Item 1) from the cylinder head
(Item 2) [Figure 20-60-15].
Figure 20-60-18

Figure 20-60-16
1
3
2
S1519
S1517
Hammer the piston (Item 1) on the rear of the head

With the help of a plastic hammer, push the head (Item 2) [Figure 20-60-18] using a plastic hammer.
(Item 1) inside the cylinder (Item 2) [Figure 20-60-16],
Continue hammering until the head (Item 2) is ejected
NOTE: The head should line up with the edge of the from the cylinder (Item 3) [Figure 20-60-18].
cylinder.

STEERING CYLINDER (FRONT) (CONT’D)
Disassembly (Cont’d)
Figure 20-60-19
2
1
A
S1520
Disassemble the cylinder unit (Item 1) by extracting first

the head (Item 2) then the piston (Item 3) [Figure 20-
60-19].

NOTE: Note down the assembly side of the piston
(Item 3) [Figure 20-60-19] bevelled part “A” of
the piston is oriented towards the head
(Item 2) [Figure 20-60-19].
Remove all seals, anti-extrusion rings and scraper rings

from head, cylinder and piston.
NOTE: 1) All seals must be replaced every time the

unit is disassembled.
2) Particular attention must be paid not to
damage the seats of both seals and piston
slide.

Assembly
1
Figure 20-60-20
1 2 3
S1523
Fit the seal (Item 1) [Figure 20-60-22] onto the outside

S1521 of the head (Item 2) [Figure 20-60-19].
NOTE: In order to facilitate assembly, apply grease to

After applying grease, install the sealing ring (Item 1) on the outer surface of the piston. Do not roll the
the shaft, the anti-extrusion ring (Item 2) and the scraper seal (Item 1) [Figure 20-60-22]
ring (Item 3) [Figure 20-60-20] inside the cylinder

(Item 3) [Figure 20-60-18]. Figure 20-60-23
NOTE: Thoroughly check that positioning of the anti-

extrusion ring (Item 2) [Figure 20-60-20] is 5 3 2
correct.
Figure 20-60-21 1
4
3 2 1
S1524
Prepare the piston (Item 1) by fitting it with the guide ring

(Item 2), the magnetic ring (Item 3), the O-ring (Item 4)
and the seal (Item 5) [Figure 20-60-23].
S1522
NOTE: In order to facilitate assembly, apply grease.
After applying grease, install the sealing ring (Item 1) on

the shaft, the anti-extrusion ring (Item 2) and the scraper
ring (Item 3) [Figure 20-60-21] in the head
(Item 2) [Figure 20-60-19].

extrusion ring (Item 2) [Figure 20-60-21] is
correct.

Assembly (Cont’d)
Figure 20-60-24
T18 1
T18
1
2
S1527
Remove tool T18 and apply it to the opposite side of the

S1525 piston (Item 1) [Figure 20-60-26]
Figure 20-60-27
Apply tool T18 to the shaft on the opposite side of the
head (Item 1) and centre it on the cylinder (Item 2)
[Figure 20-60-24] so that it fits into the piston.

1
NOTE: Apply a little grease to seals and cylinder.
Figure 20-60-25 T18
3
1
S1528
Apply grease to the head (Item 1) seals, fit the head onto
the piston and push it onto the cylinder (Item 3) [Figure
2 20-60-27].
S1526
Push the piston (Item 1) into the cylinder (Item 2) [Figure

20-60-25] for 100 MM. using a plastic hammer.

Assembly (Cont’d) 2
Figure 20-60-28
S1531
2 Fit the snap ring (Item 1) on the head (Item 2) [Figure

S1529 20-60-30].
NOTE: Make sure that the snap ring (Item 1) [Figure

Insert the stop ring (Item 1) ensuring that it fits into the 20-60-30] is securely fastened in its seat. If
seat of the cylinder (Item 2) [Figure 20-60-28]. necessary, force it into its seat using a drift
and a hammer.

Figure 20-60-29
S1530
Apply pressure to the head using two screwdrivers or

levers until the head is fastened onto the stop ring
(Item 1) [Figure 20-60-29].


STEERING CYLINDER (REAR) Figure 20-61-3
Removal
Figure 20-61-1 2
1
1 2
3
S2515
Remove the bolt (Item 1) for access for removing the nut
S2513
(Item 2) [Figure 20-61-3].
Figure 20-61-4
Remove the two bolts (Item 1) and remove the centering
sensor (Item 2) from the steering cylinder (Item
3) [Figure 20-61-1].

1
Figure 20-61-2
1 S2516
S2514
Remove the cotter pin (Item 1) [Figure 20-61-2].

STEERING CYLINDER (REAR) (CONT’D) Figure 20-61-7
Removal (Cont’d)
Figure 20-61-5 2
1
1
S2519
Remove the securing screws (Item 1) from the steering

Figure 20-61-8
Remove the tie rod end (Item 1) [Figure 20-61-5] by
means of a puller.

Figure 20-61-6 1
2
1
S2520
Extract the cylinder (Item 1) [Figure 20-61-8] using a

S2518 plastic hammer.
NOTE: (See Disassembly on Page 20-61-5.) for

Disconnect the left and right steering bars (Item 1) from cylinder disassembly.

Installation
Figure 20-61-9
S2523
Apply Loctite® 242 to the thread and connect the

S2521
steering bars by screwing the terminals onto the piston
stem, apply a torque of 170 - 200 ft.-lb. (240 - 270 N•m)
[Figure 20-61-11].
Lubricate the seats of the seals and fit the steering
cylinder (Item 1) [Figure 20-61-9] into its seat. Figure 20-61-12

Figure 20-61-10
2
1
1
S2524
S2522
Insert the pins (Item 1) in the steering case
(Item 2) [Figure 20-61-12] and lock into position of 192 -
Tighten the bolts (Item 1) [Figure 20-61-10] to 85 - 95 214 ft.-lb. (260 - 290 N•m) torque.
ft.-lb. (116 - 128 N•m) torque.
Find the position of the notching in relation to the hole of
the cotter pins and tighten the nut (Item 3) [Figure 20-
61-12] further.
NOTE: Check that the rubber guards [Figure 20-61-

12] are intact.

Figure 20-61-13
2 1
S2526
1
Install the centering sensor (Item 1) for checking piston
S2525 centering and tighten the bolts (Item 2) [Figure 20-61-
14] to 3.7 - 4.4 ft.-lb. (5 - 6 N•m) torque.
Insert the cotter pins (Item 1) [Figure 20-61-13] and After the axle has been reinstalled on the machine,
bend the ends. perform the axle toe-in procedure (See AXLE TOE-IN on
Page 40-40-1.)

NOTE: Use new cotter pins.

Disassembly
Figure 20-61-15 2
1 S1518
With the help of a drift, apply pressure to the stop ring

S1516 (Item 1) that is placed inside the cylinder
(Item 2) [Figure 20-61-17] and extract the ring using a
screwdriver.
Remove the snap ring (Item 1) from the cylinder head

Figure 20-61-16
1
1
3
2
S1519
S1517
Hammer the piston (Item 1) on the rear of the head
(Item 2) [Figure 20-61-18] using a plastic hammer.
With the help of a plastic hammer, push the head (Item 1)
inside the cylinder (Item 2) [Figure 20-61-16]. Continue hammering until the head (Item 2) is ejected
from the cylinder (Item 3) [Figure 20-61-18].
NOTE: The head should line up with the edge of the
cylinder.

STEERING CYLINDER (REAR) (CONT’D)
Figure 20-61-19
2
1
A
S1520
Disassemble the cylinder unit (Item 1) by extracting first

the head (Item 2) then the piston (Item 3) [Figure 20-
61-19].

NOTE: The bevelled part “A” (Item 3) of the piston is
oriented towards the head (Item 2) [Figure 20-
61-19].
Remove all seals, anti-extrusion rings and scraper rings

from head, cylinder and piston.
NOTE: 1) All seals must be replaced every time the

unit is disassembled.
2) Particular attention must be paid not to
damage the seats of both seals and piston
slide.

Assembly
1
Figure 20-61-20
1 2 3
S1523
Fit the seal (Item 1) [Figure 20-61-22] onto the outside

S1521 of the head (Item 2) [Figure 20-61-19].
NOTE: In order to facilitate assembly, apply grease to

After applying grease, install the sealing ring (Item 1) on the outer surface of the piston. Do not roll the
the shaft, the anti-extrusion ring (Item 2) and the scraper seal (Item 1) [Figure 20-61-22]
ring (Item 3) [Figure 20-61-20] inside the cylinder


extrusion ring (Item 2) [Figure 20-61-20] is 5 3 2
correct.
1
Figure 20-61-21
4
3 2 1
S1524
Prepare the piston (Item 1) by fitting it with the guide ring

(Item 2), the magnetic ring (Item 3), the O-ring
(Item 4) and the seal (Item 5) [Figure 20-61-23].
S1522
NOTE: In order to facilitate assembly, apply grease.
After applying grease, install the sealing ring (Item 1) on

the shaft, the anti-extrusion ring (Item 2) and the scraper
ring (Item 3) [Figure 20-61-21] in the head
(Item 2) [Figure 20-61-19].

extrusion ring (Item 2) [Figure 20-61-21] is
correct.

Assembly (Cont’d)
Figure 20-61-24 1
T18
T18
1
2
S1527
Remove tool T18 and apply it to the opposite side of the

S1525
piston (Item 1) [Figure 20-61-26]
Figure 20-61-27
Apply tool T18 to the shaft on the opposite side of the
head (Item 1) and centre it on the cylinder (Item 2) so
that it fits into the piston (Item 1) [Figure 20-61-24].

1
NOTE: Apply a little grease to seals and cylinder.
T18
Figure 20-61-25
3
1
S1528
Apply grease to the head (Item 1) seals, fit the head onto
the piston and push it onto the cylinder (Item 3) [Figure
2 20-61-27].
S1526
Push the piston (Item 1) into the cylinder (Item 2) [Figure

20-61-25] for 100 MM. using a plastic hammer.

Assembly (Cont’d) 2
Figure 20-61-28
S1531
2 Fit the snap ring (Item 1) on the head (Item 2) [Figure

S1529 20-61-30].
NOTE: Make sure that the snap ring (Item 1) [Figure

Insert the stop ring (Item 1) ensuring that it fits into the 20-61-30] is securely fastened in its seat. If
seat of the cylinder (Item 2) [Figure 20-61-28]. necessary, force it into its seat using a drift
and a hammer.
Figure 20-61-29

1
S1530
Apply pressure to the head using two screwdrivers or

levers until the head is fastened onto the stop ring
(Item 1) [Figure 20-61-29].


DRIVE BOX
Figure 20-70-1
5
1. Gear
4
2. Snap ring 3
3. Ball bearing 2
1
4. Snap ring
5. Vent
6. Ring nut 27
26
7. Bearing
9
8. Ring 8
9. Plug 7
6
10. Seal
11. Ball bearing
12. Gear

24 25
10
23
11
12
13
14 13. Snap ring
15 14. Ball bearing
22
15. Seal
16. Plug
17. Spring washer
18. Hexagon bolt
20 17 16
21 19. Magnet plug
19 18
20. Dowel
21. Plug
22. Flange
23. O-ring
24. Screw
25. Cover
26. Shim
27. Bearing
S2500

DRIVE BOX (CONT’D) Figure 20-70-4
Disassembly 1
Remove the front axle. (See Removal on Page 40-30-1.)
Remove the drive motor. (See Removal And Installation

on Page 30-30-1.)
Figure 20-70-2
S2463
Take off the drive side flange cover (Item 1) [Figure 20-
70-4] by alternatively forcing a screwdriver into the
appropriate slots.
1 NOTE: Look out not to damage the surfaces.
Figure 20-70-5
S2603

Loosen the securing bolts (Item 1) [Figure 20-70-2] only
so that later when you pry the drive side flange cover
loose, it does not fall.
Figure 20-70-3 1
S2463
1 Remove the securing bolts and lift off the cover (Item 1)
[Figure 20-70-5].
S2604
Loosen the drive side flange cover (Item 1) [Figure 20-

70-3] using a plastic hammer.

Figure 20-70-6
1
S2488
S2663 Using two levers, remove the flange sealing ring (Item 1)
[Figure 20-70-8].
To remove the drive side shaft (Item 1), hook off the snap Figure 20-70-9
ring (Item 2) [Figure 20-70-6].
Figure 20-70-7 1

1
S2432
S2463
Remove the snap ring (Item 1) [Figure 20-70-9].
Using two levers, remove the drive side shaft (Item 1)
[Figure 20-70-7].

1
Figure 20-70-10
S2490
1 Remove the secondary gear wheel (Item 1) [Figure 20-

70-12] using two levers.
S2433
With a puller, remove the bearing (Item 1) from the input

shaft (Item 2) [Figure 20-70-10].

Figure 20-70-11
1
S2489
With a puller, remove the bearing (Item 1) from the flange

shaft (Item 2) [Figure 20-70-11].

Figure 20-70-13
S2492
1
Remove the internal bearing (Item 1) [Figure 20-70-15].
S2435
Figure 20-70-16

Figure 20-70-14
S2493
1
Pull out the cup of the sealing ring (Item 1) by using drift
(Item 2) [Figure 20-70-16].
S2491
Remove the flange (Item 1) [Figure 20-70-14] by means

of a plastic hammer.

Assembly
Figure 20-70-17
S2494
T27
S2665
Fit the flange (Item 1) [Figure 20-70-19] and fasten it.
For keying the flange (Item 1) [Figure 20-70-19], use a

Insert the sealing ring using tool T27 [Figure 20-70-17]. plastic hammer if necessary.
NOTE: Bring the sealing ring just to the end stop, Figure 20-70-20
apply grease to the sealing lips.

Figure 20-70-18
1
S2495
S2436 Insert the bearing (Item 1) [Figure 20-70-20].
Insert the sealing ring (Item 1) [Figure 20-70-18] with a

normal tool.
NOTE: Bring the sealing ring just to the end stop,

apply grease to the sealing lips.

Assembly (Cont’d)
Figure 20-70-21
1 S2437 / S2438
Using a normal tool insert the bearing (Item 1) [Figure

20-70-23].
S2496
Figure 20-70-24
Using a normal tool insert the bearing (Item 1) [Figure
20-70-21] and snap ring.

Figure 20-70-22
2
1
S2439 / S2440
S2497 Insert the snap ring (Item 1) and using a normal tool
insert the bearing (Item 2) [Figure 20-70-24].
Install the secondary gear wheel (Item 1) [Figure 20-70-
22] with a plastic hammer.

Assembly (Cont’d)
Figure 20-70-25
1
1
S2606
Install drive side flange cover (Item 1) [Figure 20-70-27],

apply Loctite® 510 to the short screws.
S2441
Figure 20-70-28
Fix the bearing with the snap ring (Item 1) [Figure 20-70-
25].

Figure 20-70-26
S2666
Tighten the bolts [Figure 20-70-28] to 60 - 66 ft.-lb. (80-

90 N•m) torque.
S2498
Hold the drive side shaft (Item 1) [Figure 20-70-26] using

a plier and install the drive side shaft with a plastic
hammer.

DRIVE BOX (CONT’D)
Special Tools
TOOL IMAGE DESCRIPTION BOBCAT P/N

T27 Pinion tail seal 6912202


MAIN RELIEF VALVE Figure 20-80-3
Testing S/N A8HL12999 & BELOW, S/N A8HP12999 & BELOW,

S/N A8HK11001 & ABOVE
The following tool will be needed to do the following
procedure:
MEL10003-Hydraulic Tester
Figure 20-80-1
3
4

1 P-44328 2 1
Connect the inlet hose (Item 1) from the tester to the front S3507
coupler (Item 2) [Figure 20-80-1].
Connect the outlet hose (Item 3) from the tester to the Start the engine, lower the restraint bar (if equipped) and
rear coupler (Item 4) [Figure 20-80-1]. run at low idle RPM. Push the detent rocker switch (Item
1) and front auxiliary rocker switch (Item 2) [Figure 20-
80-2] and [Figure 20-80-3]. Make sure the tester is
connected correctly. If no flow is indicated on the tester,
IMPORTANT the hoses are connected wrong. with the hoses
connected correctly, increase the engine speed to 2200
RPM.
The hydraulic tester must be in the fully open
position before you start the engine. Warm the fluid to 140° F (60° C) by turning the restrictor
I-2024-0284
control (Item 5) [Figure 20-80-1] on the tester to about
1000 PSI (69 bar). DO NOT exceed system relief
Figure 20-80-2 pressure. Open the restrictor control knob and record the
free flow (GPM) at 2200 RPM.
S/N A8HL13000 & ABOVE, S/N A8HP13000 & ABOVE
There should be 13 GPM (55 L/min.) free flow. Turn the
restrictor control (Item 5) [Figure 20-80-1] on the tester
until the main relief opens. The correct pressure should
be 3844 PSI (265 bar).
If adjustment is needed (See Adjustment on Page 20-80-

2.).
2 1
P-97008A

MAIN RELIEF VALVE (CONT’D) Removal And Installation
Adjustment
Remove the rear cover.
Figure 20-80-4
IMPORTANT
damage the system.
I-2003-0888
Remove the rear cover.
Figure 20-80-6
1
P-50980

Locate the main relief valve on the front right side of the
control valve [Figure 20-80-4].
Figure 20-80-5
1 P-50980
Locate the main relief valve on the front right side of the
control valve.
2
Clean the area around the control valve.
Remove the main relief valve (Item 1) [Figure 20-80-6].
P-44331 Installation: Tighten the main relief valve to 33 ft.-lb. (45

N•m) torque.
Loosen the lock nut (Item 1) and turn the adjustment

screw (Item 2) [Figure 20-80-5] clockwise to increase
the pressure or counterclockwise to decrease the
pressure.
NOTE: A 1/4 of a turn = 150 PSI (10 bar).
Retest the main relief valve after adjustment.

QUICK-TACH CYLINDER Figure 20-90-3
Figure 20-90-1
1
P-32159
Remove the bolt (Item 1) [Figure 20-90-3] from each

P-32150 side of the cylinder.
Figure 20-90-4
Rotate the quick tach forward and place on the floor
[Figure 20-90-1].

Figure 20-90-2
1
1
P-32161
1
Remove the end bushing (Item 1) [Figure 20-90-4].
P-32160

the cylinder.

QUICK-TACH CYLINDER (CONT'D) Figure 20-90-7
Figure 20-90-5
1
2
P-32165
1
Remove the roll pin (Item 1) and remove the extension
P-32163 rod (Item 2) [Figure 20-90-7] from the cylinder rod.
Figure 20-90-8
Remove the roll pin (Item 1) [Figure 20-90-5].
Figure 20-90-6

2
1
P-32167
P-32164 Remove the cylinder (Item 1) [Figure 20-90-8].
Remove the washer (Item 1) and spring (Item 2) [Figure

20-90-6] from the cylinder rod extension.

QUICK-TACH CYLINDER (CONT'D)
1. Housing
2. Extension
3. Wiper
4. Seal
5. O-ring
6. Head Gland
7. Rod
8. Piston
9. Wear Ring

Disassembly
Figure 20-90-9
P-32171
Use the cylinder wrench to loosen the head gland

[Figure 20-90-11].
Figure 20-90-12
P-32169

Place the cylinder in a vise [Figure 20-90-9].
Figure 20-90-10
1
P-32172
1 Remove the rod assembly (Item 1) [Figure 20-90-12]

from the housing.
P-32170
Remove the two fittings (Item 1) [Figure 20-90-10].

Figure 20-90-13 1
P-32175
1
Remove the head (Item 1) [Figure 20-90-15] from each

P-32173 rod.
Figure 20-90-16
Use the cylinder wrench to loosen the second head gland
(Item 1) [Figure 20-90-13] on the opposite side.

Figure 20-90-14
1 1
1
P-32176
Remove the O-rings (Item 1) [Figure 20-90-16] from

P-32174 each head gland.

from the housing. (Both Sides)

Figure 20-90-17
1
P-32179
1
Remove the expander O-ring (Item 1) [Figure 20-90-19]

P-32177 from each piston.
Remove the seal (Item 1) and wiper (Item 2) [Figure 20-

90-17] from each head gland.

Figure 20-90-18
2 1
P-32178
Remove the wear ring (Item 1) and seal (Item 2) [Figure

20-90-18] from each piston.

Assembly
Use the following tools to assemble the cylinder: 1

compressed air.

2

P-32177
installation.
Always use new O-rings and seals. Install the wiper (Item 1) and seal (Item 2) [Figure 20-90-
22] in each head gland.
Figure 20-90-20
Figure 20-90-23

1
P-32179
1
Install a new expander O-ring (Item 1) [Figure 20-90-20] 1

on each piston.
P-32176
Figure 20-90-21
Install the two O-rings (Item 1) [Figure 20-90-23] on
each head gland.
1 2
P-32178
Install a new seal (Item 1) and wear ring (Item 2) [Figure

20-90-21] on each piston.

Assembly (Cont'd)
Figure 20-90-24
P-32180
Use the cylinder wrench to tighten both head glands

P-32175 [Figure 20-90-26].
Figure 20-90-27
Install each head gland (Item 1) [Figure 20-90-24] onto
the rod.

Figure 20-90-25
1 1
P-32170
Install the two fittings (Item 1) [Figure 20-90-27].

P-32174
Install each rod assembly (Item 1) [Figure 20-90-25] into

the housing.

FRAME LEVELING CYLINDER Figure 20-100-2
Figure 20-100-1
1 1
P-40479
Remove the two hoses (Item 1) [Figure 20-100-2].

S2050
Install caps and plugs.
Install jack stands under the frame to prevent the frame Figure 20-100-3
from tilting during cylinder removal [Figure 20-100-1].

Relieve hydraulic pressure.
WARNING 1

immediately.
S2049
W-2145-0290
Remove the snap ring (Item 1) and washer (Item 2)

[Figure 20-100-3].
IMPORTANT
damage the system.
I-2003-0888

FRAME LEVELING CYLINDER (CONT’D) Figure 20-100-5
Removal And Installation (Cont’d)
Figure 20-100-4
1 1
1
P-40483
Remove the four mounting bolts (Item 1) [Figure 20-100-

S2034 5].
Remove the frame leveling cylinder.

Remove the pivot pin (Item 1) [Figure 20-100-4].

FRAME LEVELING CYLINDER (CONT’D)
1. Relief Cartridge
2. Housing
3. Wear Ring
4. Seal
5. Set Screw
6. Piston
7. O-ring
8. Sleeve
9. Head Gland
10. Wiper
11. Bushing
12. Rod
13. Grease Fitting

4
5
1
3
6
7
1 8
7
4
10
13
7
9
3
11
12
B-19814

Disassembly
2
1
MEL1353 - Cylinder Gland Nut Wrench
Figure 20-100-6
2
P-40486
1 Remove the two relief cartridges (Item 1) and two fittings

1 (Item 2) [Figure 20-100-8].
Figure 20-100-9
P-40484

Remove the mounting blocks (Item 1) [Figure 20-100-6].
Figure 20-100-7
P-40487
P-40485
Remove the bushing (Item 1) [Figure 20-100-7] from

both mounting blocks.

Figure 20-100-10 1
P-40492

P-29868 from the housing.
Figure 20-100-13
20-100-10].

Figure 20-100-11
P-40493

P-40489 13].
Remove the head gland [Figure 20-100-11].

Figure 20-100-14
1
P-29879
Remove the expander O-ring (Item 1) [Figure 20-100-

P-40494 16].
Figure 20-100-17
Remove the set screw (Item 1) [Figure 20-100-14] from
the piston.

Remove the piston assembly (Item 2) [Figure 20-100-14]
from the rod.
Figure 20-100-15
1
1
1 P-29880

piston.
2
P-29877

[Figure 20-100-15] from the piston.

Figure 20-100-18 1
P-40497
Remove the head gland (Item 1) [Figure 20-100-20]

P-40496 from the rod.
Figure 20-100-21
Remove the sleeve (Item 1) [Figure 20-100-18] from the
rod.

Figure 20-100-19
1 2
P-29883
Remove the center seal (Item 1) and outer wear ring

P-40501 (Item 2) [Figure 20-100-21] from the head gland.

sleeve.

Figure 20-100-22
1
P-40509
Remove the bushing (Item 1) [Figure 20-100-24] from

P-29884 the rod end.
Remove the outer wear ring (Item 1) and wiper (Item 2)

[Figure 20-100-22]

Figure 20-100-23
P-29882
Remove the rod from the vise.

Assembly
1
MEL1353 - Cylinder Gland Nut Wrench

compressed air.
2
Always use new O-rings and seals. Lubricate all O-rings

and seals with hydraulic oil during installation. P-29884
Figure 20-100-25
20-100-27].
1
Figure 20-100-28

1
P-40509
Install the bushing (Item 1) [Figure 20-100-25] in the rod

end. P-29883
Figure 20-100-26
P-29882

the head gland.

Assembly (Cont’d)
Figure 20-100-29 1
P-40501
Install the O-ring (Item 1) [Figure 20-100-31] in the

P-29885 sleeve.
Figure 20-100-32
Install the center seal (Item 1) [Figure 20-100-29].

Figure 20-100-30
P-40496
Install the sleeve (Item 1) [Figure 20-100-32] on the rod.
P-40497
Put the rod end in a vise. Use care not to damage the
rod.
Install the head gland (Item 1) [Figure 20-100-30] onto

the rod.

Assembly (Cont’d)
Figure 20-100-33
1 1
1 2
P-29877

P-29880 [Figure 20-100-35].
Figure 20-100-36
Install the O-ring (Item 1) [Figure 20-100-33] in the
piston.

Figure 20-100-34
P-40508
1
Clean the threads and apply Loctite® 242 or equivalent
P-29879 to the threads on the rod [Figure 20-100-36].

onto the piston.

Assembly (Cont’d)
Figure 20-100-37
P-29887
Apply Loctite® 242 or equivalent to the set screw (Item 1)

P-40493 [Figure 20-100-39].
Figure 20-100-40
Install the piston (Item 1) [Figure 20-100-37] on the rod.
Figure 20-100-38

1
1
P-40494
P-29888 Install the set screw (Item 1) [Figure 20-100-40] into the
piston and tighten.
Align the hole (Item 1) [Figure 20-100-38] in the piston

with the hole in the end of the cylinder rod.

Assembly (Cont’d)
Figure 20-100-41
P-40491
Carefully peen the lock ring over and into the nut (Item 1)
P-40492 [Figure 20-100-43].
Remove the cylinder from the vise.

Put the housing in a vise. Use care not to damage the
housing. Figure 20-100-44

the housing. 2
Figure 20-100-42 1
2
P-40486
Install the two relief valve cartridges (Item 1) and two

fittings (Item 2) [Figure 20-100-44].
P-40490
Tighten the head gland [Figure 20-100-42].

Assembly (Cont’d)
Figure 20-100-45 1
P-40484
Install the two mounting blocks (Item 1) [Figure 20-100-

P-40485 46].
Install the bushing (Item 1) [Figure 20-100-45] on both

mounting blocks.

STEERING MODE VALVE BLOCK Figure 20-110-2

1
WARNING 2

and possible death if proper medical treatment by a 1
immediately.
W-2145-0290
P-50932
Figure 20-110-1
2].
NOTE: Mark the location of the valve on the block.

1
Remove the valve (Item 2) [Figure 20-110-2] from the

block.
IMPORTANT
1 When repairing hydrostatic and hydraulic systems,
P-50931 clean the work area before disassembly and keep all
Relieve hydraulic pressure. damage the system.
I-2003-0888
Remove the retainer screw (Item 1) [Figure 20-110-1]
from the two solenoids.
Remove the wire connectors from the two solenoids.
NOTE: Mark the location of the wire connectors for

correct installation.

STEERING MODE VALVE BLOCK (CONT’D) Figure 20-110-4
Figure 20-110-3
1
1
P-50936
1
1
P-50934 4] and remove the block.
Remove the four hoses (Item 1) [Figure 20-110-3].

NOTE: Mark the location of the hoses.

STEERING MODE VALVE BLOCK (CONT’D)
1
1. Nut
2. O-Ring
3. Solenoid
4. Shaft 2
5. Pin
6. Spring
7. Retainer 3
8. Spool
9. Housing
10. Bolt 4
11. Washer 2
12. Elbow 5
13. Adapter
14. Housing 6
7
10

11
8
9
3
2
2
1
12 13
*
* 10
* * 12
14
13
* Supplied with fitting. MS1152

STEERING MODE VALVE BLOCK (CONT'D)
Disassembly
IMPORTANT
Mark the location of the solenoids to the housing for
correct assembly. When repairing hydrostatic and hydraulic systems,
Figure 20-110-5 parts clean. Always use caps and plugs on hoses,
damage the system.
I-2003-0888
1
Figure 20-110-7
1 1
P-42291

Remove the four O-rings (Item 1) [Figure 20-110-5] from
the housing.
P-42294
Figure 20-110-6
Remove the solenoids (Item 1) [Figure 20-110-7] from

the solenoid shafts.
Figure 20-110-8
1
1 1
P-42292
Remove the nut (Item 1) [Figure 20-110-6] from each

solenoid.
P-42295
NOTE: Mark the location of the solenoids.
Remove the O-ring (Item 1) [Figure 20-110-8] from both

shafts.

STEERING MODE VALVE BLOCK (CONT'D) Figure 20-110-11
Figure 20-110-9
1 1
P-42299
Remove the O-ring (Item 1) [Figure 20-110-11] from

P-42296 each shaft.
Figure 20-110-12
Loosen the shafts (Item 1) [Figure 20-110-9].

Figure 20-110-10
5
1
4
2
1
3
P-42300
P-42297 Carefully remove the spool (Item 1) [Figure 20-110-12]

from the housing.
Remove the shaft (Item 1), pin (Item 2), spring (Item 3)
and spring retainer (Item 4) from the housing (Item 5)
[Figure 20-110-10]. (Both Sides)

STEERING MODE VALVE BLOCK (CONT'D) Assembly
Solenoid Testing Clean all components with solvent and dry with
compressed air.
Figure 20-110-13
Check all components for wear or damage. Replace any
worn or damaged components.
Always use new O-rings.
Lightly oil all parts.
Figure 20-110-14
1
P-42301
Use a circuit tester, touch one probe to the prong and the
other probe to the other prong [Figure 20-110-13], there

must be continuity. If there is no continuity, replace the
solenoid.
P-42300
Carefully install the spool (Item 1) [Figure 20-110-14].
Figure 20-110-15
P-42299
Install a new O-ring (Item 1) [Figure 20-110-15] on each

shaft.

Assembly (Cont'd)
1
Figure 20-110-16
5
2
1
3 P-42295
4
Install an O-ring (Item 1) [Figure 20-110-18] on each
P-42297 shaft.
Figure 20-110-19
Install the spring retainer (Item 1), spring (Item 2), pin
(Item 3) and shaft (Item 4) in the housing (Item 5) [Figure

20-110-16]. (Both Sides)
Figure 20-110-17
1
1 1
P-42293
Install the O-ring (Item 1) [Figure 20-110-19] on the two

solenoids.
P-42296
Tighten each shaft (Item 1) [Figure 20-110-17].

Assembly (Cont'd)
Figure 20-110-20 1
2
1
P-42291
2
Install the four O-rings (Item 1) [Figure 20-110-22] on the

P-42294 housing.
Install the solenoids (Item 1) on the shafts (Item 2)

[Figure 20-110-20].

Figure 20-110-21
1 1
P-42292
Install the nuts (Item 1) [Figure 20-110-21] on each shaft

and hand tighten.
NOTE: Do not overtighten the nuts.

BRAKE VALVE Figure 20-120-3
Figure 20-120-1
1 P-25249
Remove the accelerator cable (Item 1) from the pedal

P-52341 and mounting bracket (Item 2) [Figure 20-120-3].
Figure 20-120-4
Remove the dash cover/column cover. (See DASH
COVER / STEERING COLUMN COVER (S/N

A8HL12999 & BELOW, A8HP12999 & BELOW,
A8HK11001 & ABOVE) on Page 50-140-1.) or (See
DASH COVER / STEERING COLUMN COVER (S/N
A8HL13000 & ABOVE, A8HP13000 & ABOVE) on Page
50-141-1.)
Unplug the connector (Item 1) [Figure 20-120-1] from

the brake light switch.
Figure 20-120-2
1
P-25638
1
Remove the three hoses (Item 1) [Figure 20-120-4] from

the brake valve.
NOTE: Mark hoses for correct installation.
IMPORTANT
P-42865
Unplug the connector (Item 1) [Figure 20-120-2] from parts clean. Always use caps and plugs on hoses,
the inching switch. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

BRAKE VALVE (CONT’D) Disassembly And Assembly
Removal and Installation (Cont’d) Figure 20-120-6
Figure 20-120-5
1 2
P-42869
1 P-25637
Remove the bolt (Item 1) and spring (Item 2) [Figure 20-
120-6].
Remove the mounting bolts (Item 1) [Figure 20-120-5].
Figure 20-120-7

Remove the pedal assembly.
P-42870
Remove the roll pin (Item 1) and pedal (Item 2) [Figure

20-120-7].

BRAKE VALVE (CONT’D) Figure 20-120-10
Disassembly And Assembly (Cont’d)

1
Figure 20-120-8
1
1
1
P-42874
Remove the three bolts (Item 1) [Figure 20-120-10] from

P-42871 both bearing flanges.
Figure 20-120-11
Assembly: Align the hole (Item 1) in the pedal with the
hole (Item 2) [Figure 20-120-8] in the shaft.

Figure 20-120-9
P-42875
Remove the shaft and bearing assembly [Figure 20-120-

P-42872 11].
Loosen the two set screws (Item 1) [Figure 20-120-9] on

the two bearings.

BRAKE VALVE (CONT’D) Figure 20-120-14
Figure 20-120-12
1 2 1
1
2
P-42877
2 Remove the four bolts (Item 1) spacers (Item 2) [Figure

P-42876 20-120-14] and nuts from the brake valve.
Figure 20-120-15
Remove the flanges (Item 1) and bearings (Item 2)
[Figure 20-120-12].

Figure 20-120-13
P-42879
Remove the brake valve (Item 1) [Figure 20-120-15]

P-42878
Remove the three fittings (Item 1) [Figure 20-120-13]

from the brake valve.

GEAR PUMP Figure 20-130-2
Raise the boom and install the boom stop. (See Installing
The Approved Boom Stop on Page 10-150-1.)
Stop the engine.
Relieve the hydraulic pressure. Drain the hydraulic 1

reservoir. (See Replacing Hydraulic Fluid on Page 10- 2
100-2.)
WARNING P-56477
Hydraulic fluid escaping under pressure can have Remove the four bolts (Item 1) and remove the hose
sufficient force to enter a person’s body by (Item 2) [Figure 20-130-2] from the hydrostatic pump.
and possible death if proper medical treatment by a Figure 20-130-3
immediately.

W-2145-0290
IMPORTANT
damage the system.
I-2003-0888 P-56478
Figure 20-130-1 Remove the hose (Item 1) [Figure 20-130-3] from the
backside of the gear pump.
1
1
1
P-56463

the backside of the pump.

GEAR PUMP (CONT'D) Figure 20-130-6
Figure 20-130-4
1 P-56470
Loosen the hose clamp (Item 1) and remove the hose

P-56464 (Item 2) [Figure 20-130-6].
Figure 20-130-7
Remove the hose (Item 1) [Figure 20-130-4].

Figure 20-130-5
1
1 1
P-56482
P-56468 Install a chain hoist and lifting strap to lift and support the
gear pump [Figure 20-130-7].
Loosen the hose clamp (Item 1) [Figure 20-130-5] and Remove the two mounting bolts (Item 1) [Figure 20-130-
remove the hose. 7] from the gear pump.
Installation: Tighten the mounting bolts to 52-59 ft.-lb.

(50-80 N•m) torque.

GEAR PUMP (CONT'D)
Figure 20-130-8
P-56483
Remove the gear pump [Figure 20-130-8].

NOTE: It may be necessary to reposition any hose or
wires.

GEAR PUMP (CONT’D)
1. Fitting
2. O-ring 1
3. Spring
4. Spring Seat 2
5. Spool 3
6. Screen 8
4
7. Orifice Spool
8. Bolt 5
9. Housing 6
10. Plug 7
11. Bolt 14
12. Washer
13. Cover 9 16
14. Seal Ring 17
15. Housing
16. Backup Ring 18
19
17. Seal Ring
18. Holder 2 18
10

19. Gear 17
20. Drive Shaft 16
21. Mount Plate
22. Thrust Plate 13
15
23. Mount Plate
24. Seal 14
25. Snap ring 14
12
11
15
14
21 19
22
17
16
20
25 2
24
23
8 17
16
22
MS1423

Disassembly And Assembly
IMPORTANT
damage the system.
I-2003-0888
P-56449
Figure 20-130-9
Remove the flow divider from the housing [Figure 20-
130-11].
1
Figure 20-130-12
1
6

4 3 2 1
5
1
1
P-56447
Mark the pump housing for correct assembly and remove

P-25293
the fittings (Item 1) [Figure 20-130-9].
Figure 20-130-10 Remove the fitting (Item 1), O-ring (Item 2), spring (Item
3), spring seat (Item 4) and spool (Item 5) from the
housing (Item 6) [Figure 20-130-12].
1 1
NOTE: Always use new O-rings.
1 1
P-56448
Remove the four bolts (Item 1) [Figure 20-130-10].
Assembly: Tighten the bolts to 25 ft.-lb. (33 N•m) torque.

Disassembly And Assembly (Cont'd)
Figure 20-130-13
2
1
P-25296
P-25294 To remove the orifice assembly (Item 1) [Figure 20-130-

15] from the spool, make a holding fixture from a 0.750
in. thick x 1.500 in. wide x 2.0 in. long (19 mm thick x 38
Remove the plug (Item 1) and O-ring (Item 2) [Figure 20- mm wide x 50 mm long) piece of hardwood. Drill a 0.550
130-13] from the housing. in. (14 mm) hole in the center of the hardwood block. Cut
the block lengthwise [Figure 20-130-14].

Figure 20-130-14
Place both halves of the hardwood block around the
Cut spool. Clamp the blocks in a vise [Figure 20-130-15].
NOTE: Do not use anything other than hardwood

blocks to grip the spool, or the spool will be
damaged.
0.550” dia. Figure 20-130-16

2.0”
1.500” 1 2
B-14674
P-25295
Remove the screen (Item 1) from the orifice (Item 2)

[Figure 20-130-16] and clean.

Figure 20-130-17 1
2 1 3
1
2
1 1
P-56451
Remove the housing (Item 1) from the gear assembly

P-56450 (Item 2) [Figure 20-130-19].
Assembly: The position of the small opening (Item 3) on

Remove the four bolts (Item 1) and cover (Item 2) the gear holders will point towards the large port (Item 4)
[Figure 20-130-17]. [Figure 20-130-19] on the housing.

Figure 20-130-18 Figure 20-130-20
1
1
P-56454 P-56452
Remove the housing/gear assembly (Item 1) [Figure 20- Remove both O-rings (Item 1) [Figure 20-130-20] from
130-18] from the main housing. the housing.

Figure 20-130-21 1 1
1 1
2 P-25304
1
Remove the four bolts (Item 1) and drive shaft (Item 2)
[Figure 20-130-23].
P-56453
Assembly: Tighten the bolts to 25 ft.-lb. (33 N•m) torque.
Remove the backup ring (Item 1) and seal ring (Item 2) Figure 20-130-24
[Figure 20-130-21] from the gear holder.

Assembly: The seal ring (Item 2) [Figure 20-130-21] is
installed onto the gear holder first followed by the backup
ring.
Figure 20-130-22
P-25305
Turn the housing over and remove the mount plate

[Figure 20-130-24].
P-25322
Remove and discard the O-ring (Item 1) [Figure 20-130-

22] from the flange.


2
Figure 20-130-25
1
1
3
4
P-25310
Remove the O-ring (Item 1) and gear assembly (Item 2)

P-25306 [Figure 20-130-27] from the housing.
Assembly: The position of the V portion (Item 3) on the

Remove the snap ring (Item 1) [Figure 20-130-25]. thrust plate must point towards the larger port (Item 4)
[Figure 20-130-27] on the housing.
Figure 20-130-26

Figure 20-130-28
1
2 2
3 3
1 1
P-25307
P-25313
Remove the shaft seal (Item 1) [Figure 20-130-26].

Remove the two thrust plates (Item 1), seal ring (Item 2)
and backup ring (Item 3) [Figure 20-130-28] from the
gears.
Assembly: The seal ring (Item 2) will be installed on the

thrust plate (Item 1) first followed by the backup ring
(Item 3) [Figure 20-130-28].


FAN MOTOR Figure 20-140-2
Removal And Installation 3 3
IMPORTANT 4
When repairing hydrostatic and hydraulic systems, 2

damage the system.
I-2003-0888
1 1
S6837
Drain the radiator. (See Replacing The Coolant on Page
10-70-2.)
Remove the two mounting bolts (Item 1) and remove the
Figure 20-140-1 radiator support (Item 2) [Figure 20-140-2].
Loosen the two hose clamps (Item 3) and remove the

1 intercooler hose (Item 4) [Figure 20-140-2].
2

1 Figure 20-140-3
2
S6834
Loosen the two hose clamps (Item 1) and remove the

radiator hose (Item 2) [Figure 20-140-1].
S6835
Mark the location of the hood latch (Item 1). Remove the
two mounting bolts (Item 2) [Figure 20-140-3]. Remove
the hood latch.

FAN MOTOR (CONT’D) Figure 20-140-6
Figure 20-140-4 2
1
P-53264
Loosen the screw (Item 1) and unplug the connector

S6836 (Item 2) [Figure 20-140-6].
Figure 20-140-7
Remove the top hose (Item 1) [Figure 20-140-4] from the
fan motor. 1

Figure 20-140-5
1 S6845
Remove the two bolts (Item 1) [Figure 20-140-7] (both

S6848 sides) from the fan guard.
Tilt the cooler forward and carefully remove the fan

Remove the three hoses (Item 1) [Figure 20-140-5] from assembly.
the bottom of the fan motor.

Figure 20-140-8 2
1 2
1
1
1
1 P-53270
Remove the four fan guard mount bolts (Item 1) and

P-53269 remove the fan guard (Item 2) [Figure 20-140-10].
Figure 20-140-11
Remove the four bolts (Item 1) and remove the blade
assembly (Item 2) [Figure 20-140-8] from the fan motor.

NOTE: Mark the direction of the fan for correct
assembly.
1
Figure 20-140-9
1 P-53272
Remove the nut and lock washer (Item 1) [Figure 20-

140-11].
P-53271
Mark the location of the fan motor to the fan guard for
correct assembly (Item 1) [Figure 20-140-9].

FAN MOTOR (CONT’D)
Figure 20-140-12
P-53273
Remove the fan blade mounting flange (Item 1) [Figure

20-140-12] from the fan motor.

FAN MOTOR (CONT’D)

4
1. Seal
2. Check Valve
3. Housing
4. Gear Assembly
S2754

IMPORTANT
4
parts clean. Always use caps and plugs on hoses, 3
tubelines and ports to keep dirt out. Dirt can quickly 2
damage the system.
I-2003-0888 1
P-53276
Figure 20-140-13
Remove the plug (Item 1), spring (Item 2) and check
1 valve (Item 3) from the housing (Item 4) [Figure 20-140-
2
15].
Figure 20-140-16

P-53274
1
Remove the nut (Item 1) and solenoid (Item 2) [Figure
20-140-13].
Mark the housing for correct assembly. P-53277
Figure 20-140-14
plug. Replace as needed.
2
1
P-53275
Remove the solenoid (Item 1) and three fittings (Item 2)

[Figure 20-140-14].

Figure 20-140-17
1
1
1 1 P-53281
Remove the quad ring (Item 1) [Figure 20-140-19] from

P-53278 the housing.
Figure 20-140-20
Remove the four bolts (Item 1) [Figure 20-140-17] from
the end. 2

Assembly: Tighten bolts to 32-35 ft.-lb. (43-47 N•m) 1
torque.
Figure 20-140-18
P-53282
Remove the gear assembly (Item 1) from the housing

(Item 2) [Figure 20-140-20].
P-53279
Remove the end cover (Item 1) from the main housing

(Item 2) [Figure 20-140-18].

Figure 20-140-21
P-53285
1
Inspect the gears (Item 1) [Figure 20-140-23] for
P-53283 damage or wear
Remove the backup ring/seal (Item 1) [Figure 20-140-

21] from the gear holder.

Figure 20-140-22
P-53256
Remove the snap ring (Item 1) and remove the seal (Item
2) [Figure 20-140-22].
Assembly: The open part of the seal goes into the

housing first.

HYDRAULIC RESERVOIR Figure 20-150-3
Removal And Installation 2
Remove the engine / hydrostat assembly. (See Removal

And Installation on Page 70-90-1.)
Figure 20-150-1
1 S6856
Remove the hose (Item 1) [Figure 20-150-3] from the

tubeline.
Remove the mounting bolt (Item 2) [Figure 20-150-3].

P-56462
Figure 20-150-4

Remove the two bolts (Item 1) [Figure 20-150-1]. 1
Figure 20-150-2
1
2
S6857
Loosen the nut (Item 1) [Figure 20-150-4] on the

S6855 tubeline.
Remove the tubeline.

Remove the bolt (Item 1) and shield (Item 2) [Figure 20-
150-2]. Remove the two hoses (Item 2) [Figure 20-150-4] from
the filter.

HYDRAULIC RESERVOIR (CONT’D) Figure 20-150-6
Figure 20-150-5
P-55220
Figure 20-150-7
P-55217

tank.

1
S6858
Remove the two tank mounting bolts (Item 1) [Figure 20-

150-6] and [Figure 20-150-7].
Remove the hydraulic reservoir.

STEERING VALVE Figure 20-160-2

1
Remove the dash cover/column cover. (See DASH 1
50-141-1.) 1
Figure 20-160-1 1
P-27156
1
Remove the four bolts (Item 1) [Figure 20-160-2] and
remove the steering valve.

P-42863
Remove the five hoses (Item 1) [Figure 20-160-1] from

the steering valve.
IMPORTANT
damage the system.
I-2003-0888

STEERING VALVE (CONT’D)
1. Bolt
2. End Cap
3. Spacer Gear
4. O-ring
5. Geroler Assembly
6. Drive Shaft
7. Valve Plate 1
8. Spool
9. Sleeve
10. Springs
11. Drive Pin 3 2
12. Pin
13. Check Ball 4
14. Housing
15. Thrust Washer 5
16. Thrust Bearing 6
17. Quad Ring
18. Seal Housing

4
19. Seal
20. Retainer Ring 7
21. Ball Seat
22. Poppet 4
23. Spring
24. Plug 8
10
22
23
24
13 9
21
23
24 11
14
15
16 12
15 13
17
13
4
21
18
23
20 24
19 MS1226

STEERING VALVE (CONT'D) Figure 20-160-5
Disassembly
IMPORTANT
damage the system.
I-2003-0888 P-27160
Figure 20-160-3
Remove the end cap (Item 1) [Figure 20-160-5].
1 Figure 20-160-6
1
1
1 1

1
P-27158
P-27161
Remove the fittings (Item 1) from the steering valve
[Figure 20-160-3].
Figure 20-160-4
6].
P-27159
Remove the seven end cap bolts (Item 1) [Figure 20-

160-4].

Figure 20-160-7
1
P-27164

P-27162 valve plate.
Figure 20-160-10
Remove the spacer gear (Item 1) [Figure 20-160-7].
Figure 20-160-8

1
1
1
P-27165
P-27163 Remove the drive shaft (Item 1) [Figure 20-160-10].
Remove the geroler assembly (Item 1) [Figure 20-160-

8].

Figure 20-160-11 1
1
1
P-27168
Mark the location of the three ports (Item 1) [Figure 20-

P-27166 160-13] for correct assembly.
Figure 20-160-14
Remove the valve plate (Item 1) [Figure 20-160-11].
Figure 20-160-12

1
1
P-27169
P-27167 Remove the three pins (Item 1) [Figure 20-160-14] from

each port.
Remove the O-ring (Item 1) [Figure 20-160-12] from the NOTE: Record the location of each pin for correct
housing. assembly.

1
Figure 20-160-15
P-27172
Remove the seal housing (Item 1) [Figure 20-160-17] by

P-27170 prying upward.
Figure 20-160-18
Remove the three check balls (Item 1) [Figure 20-160-
15] from each port.

NOTE: Record the location of each check ball for 1
correct assembly.
Figure 20-160-16
P-27173
Remove and discard the seal (Item 1) [Figure 20-160-

18].
P-27171
Remove the seal retainer ring (Item 1) [Figure 20-160-

16].

Figure 20-160-19 1
1
2
P-27176
Remove the two thrust washers (Item 1) and thrust

P-27174 bearing (Item 2) [Figure 20-160-21] from the spool.
Figure 20-160-22
Remove and discard the quad ring seal (Item 1) [Figure
20-160-19].

Figure 20-160-20 2
3
1
P-27183
Remove the control spool/sleeve assembly (Item 1) from

P-27175 the metering end of the housing (Item 2) [Figure 20-160-
22].
Remove and discard the O-ring (Item 1) [Figure 20-160- NOTE: When removing the spool, keep the drive pin
20] from the housing. (Item 3) [Figure 20-160-22] horizontal. If the
pin becomes vertical, it may drop from the
spool and get caught in an oil passage inside
the housing.

1
Figure 20-160-23
P-27180
1
Remove the springs (Item 1) [Figure 20-160-25] from the

P-27178 spool.
NOTE: There are six springs positioned three per

Remove the drive pin (Item 1) [Figure 20-160-23]. side and back to back.
Figure 20-160-24 Figure 20-160-26

2
1
4
3
2
1
P-27179 P-27193
Remove the spool (Item 1) from the sleeve (Item 2) Remove the two check valve plugs (Item 1), springs (Item
[Figure 20-160-24]. 2), ball seat (Item 3) and check ball (Item 4) [Figure 20-
160-26] from the housing.
NOTE: If the spool and sleeve will not slide or rotate
within each other freely or in the housing, NOTE: Record the location of each check ball
they must be replaced. assembly for correct assembly.

STEERING VALVE (CONT'D) Inspection
Disassembly (Cont'd) Figure 20-160-28
Figure 20-160-27
2
1
P-27179
1
P-27194
Inspect the spool (Item 1) and sleeve (Item 2) [Figure
20-160-28] for any damage or wear. Replace as needed.
Remove the check valve plug (Item 1), spring (Item 2)
and poppet (Item 3) [Figure 20-160-27] from the Figure 20-160-29
housing.

NOTE: Record the location of the port for correct
assembly.
1
P-27185
Inspect the drive shaft (Item 1) [Figure 20-160-29] for

damage or wear.

Assembly
IMPORTANT 1

3
damage the system.
I-2003-0888 P-27193
Prior to assembly, clean and lightly oil all parts.

Install the check ball (Item 1), ball seat (Item 2), spring
(Item 3) and plug (Item 4) [Figure 20-160-32] into the
Figure 20-160-30
correct port marked earlier.
Turn each of the port plugs (Item 3) [Figure 20-160-31]

and (Item 4) [Figure 20-160-32] in the housing until they
1
are tight, then back each of them out 1-1/2 turns.

Figure 20-160-33
P-27190
Install a new O-ring (Item 1) [Figure 20-160-30] on the

three check valve plugs.
Figure 20-160-31
P-27180
Install the springs (Item 1) [Figure 20-160-33] into the

spool.
NOTE: There are six springs and should be

1 positioned three per side and back to back.
3
P-27194
Install the poppet (Item 1), spring (Item 2) and plug (Item
3) [Figure 20-160-31] into the correct port marked
earlier.

Assembly (Cont’d)
Figure 20-160-34 2
3
2
1
1
P-27183
Install the control spool/sleeve assembly (Item 1) into the

P-27181 metering end of the housing (Item 2) [Figure 20-160-36].
NOTE: When installing the spool assembly keep the

Install the spool (Item 1) into the sleeve (Item 2) [Figure drive pin (Item 3) [Figure 20-160-36]
20-160-34]. horizontal. If the pin becomes vertical it may
drop from the spool and get caught in an oil

NOTE: The spool should turn freely inside the sleeve. passage inside the housing.
Figure 20-160-35 Figure 20-160-37
1
1
2
P-27178 P-27176
Install the drive pin (Item 1) [Figure 20-160-35]. Install the two thrust washers (Item 1) and thrust bearing
(Item 2) [Figure 20-160-37] on the spool.

Assembly (Cont'd)
Figure 20-160-38 1
P-27173
Install a new seal (Item 1) [Figure 20-160-40].

P-27175
Figure 20-160-41
Install a new O-ring (Item 1) [Figure 20-160-38] into the

housing. 1

Figure 20-160-39
P-27182
Install the seal housing (Item 1) [Figure 20-160-41].
P-27174
Install a new quad ring seal (Item 1) [Figure 20-160-39].

Assembly (Cont'd)
Figure 20-160-42
P-27169
Install the three pins (Item 1) [Figure 20-160-44] in their

P-27171 proper port (marked earlier).
Figure 20-160-45
Install the seal retainer ring (Item 1) [Figure 20-160-42].
Figure 20-160-43

1
P-27167
P-27170 Install a new O-ring (Item 1) [Figure 20-160-45] into the

housing groove.
Install the three check balls (Item 1) [Figure 20-160-43]

in their proper port (marked earlier).

Assembly (Cont'd)
2
Figure 20-160-46
3
1
1
P-44864
P-27166
To assure proper geroler alignment, mark the top of the
drive shaft (Item 1) (as shown) parallel to the port face
(Item 2) [Figure 20-160-48].
Align and install the 14 hole valve plate (Item 1) [Figure
20-160-46] on the housing. Install a new O-ring (Item 3) [Figure 20-160-48] into the
valve plate groove.

Figure 20-160-47
Figure 20-160-49
3
1
1
2
2
2
3
P-44862
P-44863
Align the groove (Item 1) in the drive shaft with the drive
pin (Item 2) [Figure 20-160-47] and install the drive Install the geroler star (Item 1) [Figure 20-160-49] onto
shaft. Be sure the drive shaft is engaged with the pin. the valve plate and drive shaft.
NOTE: The pin (Item 2) must be parallel with the port NOTE: Align the two valleys (Item 2) of the star with
face of the housing (Item 3) [Figure 20-160- the mark on the drive gear (Item 3) [Figure 20-
47]. 160-49].

Assembly (Cont'd)
Figure 20-160-50 1
1
2
P-27159
Install the end cap using the seven bolts (Item 1) [Figure
20-160-52]. Tighten to 8 - 13 ft.-lb. (11 - 18 N•m) torque in
P-44865 a criss-cross pattern.
Figure 20-160-53
Install the outer gear (Item 1) onto the star (Item 2)
[Figure 20-160-50] and align the bolt holes without
1

disengaging the drive shaft. 1
1
Figure 20-160-51
1
1 2
1
P-27158
Install the fittings (Item 1) [Figure 20-160-53] as shown.
P-27161
Install the spacer gear (Item 1) and a new O-ring (Item 2)

[Figure 20-160-51] into the geroler plate groove.


HYDRAULIC CONTROL VALVE
Troubleshooting Chart (Controllers)

WARNING
must be done by authorized Bobcat Service Personnel. adjustments can cause injury or death.
W-2004-1285
PROBLEM CAUSE CORRECTION
None of the controllers work Insufficient power supply Check battery voltage
Insufficient pilot pressure Check pilot pressure

Plugged controller filter Clean filter
Only one controller works No actuation signal Check signal voltage
Unsuitable actuation signal Check signal voltage
Insufficient actuation power supply Check signal voltage
All controllers not working or jerky Plugged controller filter Clean filter

One controller not working or jerky Faulty actuation signal Check signal
Friction or jamming of the plunger Replace controller

One controller not working or jerky Contamination of the proportional Replace controller
in one direction valve in the controller
Controller creeps Neutral position incorrect Adjust neutral adjustment
Oil leakage between control valve Faulty seals Replace seal

and controller
Oil leakage between controllers Faulty controller couplers Replace controller couplers

HYDRAULIC CONTROL VALVE (CONT’D) Figure 20-170-2
Telescoping Valve Section Troubleshooting S/N A8HL13000 & ABOVE, S/N A8HP13000 & ABOVE
Record the serial number of the machine, control valve

and control module.
The following procedure must be done with the control

valve in the machine. The control valve is removed for
photo clarity. 1
With the engine OFF, the key switch in the run position,
move the joystick handle to relieve any hydraulic
pressure.
Remove the rear cover from machine. P-97008A
Figure 20-170-1
S/N A8HL12999 & BELOW, S/N A8HP12999 & BELOW, The hydraulic control function switch (Item 1) [Figure 20-
S/N A8HK11001 & ABOVE 170-1] and [Figure 20-170-2] must be ON (light is on) for
all testing procedures.
Figure 20-170-3
1

1
P-50943
1. Locate the telescoping valve section (Item 1) [Figure

20-170-3] on the control valve.
P-50797

Telescoping Valve Section Troubleshooting (Cont’d)
Figure 20-170-4
m
1 Maximu
l
Neutra
1
m
Minimu
P-47793
P-52155
2. With the engine OFF, the key in the run position,

check that the battery voltage on the controller 4. With the telescopic function switch (Item 1) [Figure

connector (Item 1) [Figure 20-170-4] (pin 1, blue 20-170-5] in the minimum (back) position check that
wire) is at least 12 volts or higher. the voltage on the controller connector (Item 1)
[Figure 20-170-4] (pin 3, brown wire) is 0.9 volts. If
3. With the engine OFF, the key in the run position, the voltage drops below 0.9 volts the controller will
check the regulated voltage on the controller interpret this as a failure.
connector (Item 1) [Figure 20-170-4] (pin 4, black
wire) is 5 volts. If 5 volts is not seen, replace the 5. With the telescopic function switch (Item 1) [Figure
controller. 20-170-5] in the neutral (middle) position check that
the voltage on the controller connector (Item 1)
[Figure 20-170-4] (pin 3, brown wire) is 2.5 volts.
6. With the telescopic function switch (Item 1) [Figure

20-170-5] in the maximum (forward) position check
that the voltage on the controller connector (Item 1)
If one of the three voltage readings in Steps 4, 5 and 6 is

not correct, replace the joystick handle. (See Removal
If all voltage readings in Steps 4, 5 and 6 are correct go to

step 7.

HYDRAULIC CONTROL VALVE (CONT’D) Checking Drain Pressure
Telescoping Valve Section Troubleshooting (Cont’d) Figure 20-170-8
Checking Pilot Pressure
Figure 20-170-6
1
1
P-42977
11. Remove the hose (Item 1) [Figure 20-170-8] from the

control valve, and install a tee fitting.
Figure 20-170-9

P-44343
7. Locate the test fitting (Item 1) [Figure 20-170-6] and

remove the cap.
Figure 20-170-7
P-52913
12. Install a 500 PSI (35 bar) gauge on the tee fitting
[Figure 20-170-9].
13. Start the engine, lower the restraint bar (if equipped)
P-44342 and run the engine at 2200 RPM. Record the
pressure. The pressure at the gauge should be 22
PSI (1,5 bar) maximum.
8. Install a 1000 PSI (70 bar) gauge on the test fitting
[Figure 20-170-7]. 14. Remove the gauge.

and run the engine at 2200 RPM. Record the
PSI (35 bar) maximum.
10. Remove the gauge.

Telescoping Valve Section Troubleshooting (Cont’d)
Figure 20-170-10
1 2
P-52901
17. If the telescopic function does not work, remove the

P-52155 two screws (Item 1) and remove the cover (Item 2)
[Figure 20-170-12].
15. With adequate room in front of the machine, start the 18. Start the engine, lower the restraint bar (if equipped)
engine, lower the restraint bar (if equipped) and run and run the engine at 2200 RPM.

the engine at 2200 RPM. Move the telescopic control
switch (Item 1) [Figure 20-170-10] forward and back Figure 20-170-13
to see if this function works. Stop the engine.
Figure 20-170-11
P-61126
P-47793 19. Manually push and pull the spool (Item 1) [Figure 20-
170-13] to test the movement of the telescopic
function in both directions.
16. If the telescopic function does not work, with the
engine running unplug the controller connector (Item NOTE: If by manually operating the spool, and the
1) [Figure 20-170-11] and plug it back in. telescopic function is working the controller
must be replaced.

Auxiliary Valve Section Troubleshooting S/N A8HL13000 & ABOVE, S/N A8HP13000 & ABOVE
Record the serial number of the machine, control valve

and control module.
The following procedure must be done with the control

valve in the machine. The control valve is removed for
photo clarity. 1
With the engine OFF, the key switch in the run position,
move the joystick handle to relieve any hydraulic
pressure.
Figure 20-170-14 P-97008A

S/N A8HL12999 & BELOW, S/N A8HP12999 & BELOW,
The hydraulic control function switch (Item 1) must be ON
(light is on) and the front auxiliary hydraulics ON/OFF
switch (Item 2) [Figure 20-170-14] and [Figure 20-170-
15] must be ON (top position).
1
Figure 20-170-16

1
P-50943
1. Locate the auxiliary valve section (Item 1) [Figure 20-

170-16] on the control valve.
P-50797

Auxiliary Valve Section Troubleshooting (Cont’d)
Figure 20-170-17
m
Maximu
1
l
Neutra
m
Minimu
1
P-47793
S7485
2. With the engine OFF, the key in the run position,

check that the battery voltage on the controller 4. With the auxiliary function switch (Item 1) [Figure 20-

connector (Item 1) [Figure 20-170-17] (pin 1, blue 170-18] in the minimum (back) position check that the
wire) is at least 12 volts or higher. voltage on the controller connector (Item 1) [Figure
20-170-17] (pin 3, brown wire) is 0.9 volts. If the
3. With the engine OFF, they key switch in the run voltage drops below 0.9 volts the controller will
position, check the regulated voltage on the controller interpret this as a failure.
connector (Item 1) [Figure 20-170-17] (pin 4, black
wire) is 5 volts. If 5 volts is not seen, replace the 5. With the auxiliary function switch (Item 1) [Figure 20-
controller. 170-18] in the neutral (middle) position check that the
voltage on the controller connector (Item 1) [Figure
20-170-17] (pin 3, brown wire) is 2.5 volts.
6. With the auxiliary function switch (Item 1) [Figure 20-

170-18] in the maximum (forward) position check that
the voltage on the controller connector (Item 1)
If one of the three voltage readings in Steps 4, 5 and 6 is

not correct, replace the joystick handle. (See Removal
If all voltage readings in Steps 4, 5 and 6 are correct go to

step 7.

HYDRAULIC CONTROL VALVE (CONT’D) Checking Drain Pressure
Auxiliary Valve Section Troubleshooting (Cont’d) Figure 20-170-21
Checking Pilot Pressure
Figure 20-170-19
1
1
P-42977
11. Remove the hose (Item 1) [Figure 20-170-21] from

the control valve, and install a tee fitting.
Figure 20-170-22

P-44343
7. Locate the test fitting (Item 1) [Figure 20-170-19] and

remove the cap.
Figure 20-170-20
P-52913
12. Install a 500 PSI (35 bar) gauge on the tee fitting
[Figure 20-170-22].
P-44342 and run the engine at 2200 RPM. Record the
PSI (1,5 bar) maximum.
8. Install a 1000 PSI (70 bar) gauge on the test fitting
[Figure 20-170-20]. 14. Remove the gauge.

and run the engine at 2200 RPM. Record the
PSI (35 bar) maximum.
10. Remove the gauge.

Auxiliary Valve Section Troubleshooting (Cont’d)
Figure 20-170-23
1 2
P-52901
17. If the auxiliary function does not work, remove the two
P-52155 screws (Item 1) and remove the cover (Item 2)
[Figure 20-170-25].
15. With adequate room in front of the machine, start the 18. Start the engine, lower the restraint bar (if equipped)
engine, lower the restraint bar (if equipped) and run and run the engine at 2200 RPM.

the engine at 2200 RPM. Move the auxiliary control
switch (Item 1) [Figure 20-170-23] forward and back Figure 20-170-26
to see if this function works. Stop the engine.
Figure 20-170-24
P-61228
P-47793 19. Manually push and pull the spool (Item 1) [Figure 20-
170-26] to test the movement of the auxiliary function
in both directions.
16. If the auxiliary function does not work, with the engine
running unplug the controller connector (Item 1) NOTE: If by manually operating the spool, and the
[Figure 20-170-24] and plug it back in. auxiliary function is working the controller
must be replaced.

HYDRAULIC CONTROL VALVE (CONT’D)
Troubleshooting Chart (Control Valve)

WARNING
W-2004-1285
PROBLEM CAUSE CORRECTION
Lack of strength at all actuators Load sense relief cartridge defective Replace relief cartridge
Load sense relief cartridge out of Make necessary adjustments

adjustment
Lack of force on one actuator only Secondary relief valve out of adjust- Reset to original pressure
ment
Secondary relief valve blocked open Replace relief valve
Lack of load hold Load check valve failure Replace load check valve
Excessive clearance between hous- Replace housing and spool

ing and spool
Simultaneous movement of con- Blockage of individual compensator Remove and clean orifice
trols orifice
Individual pressure compensator Replace housing and compensator

blocked
Load sense line leakage Replace load sense regulator
Engine remains under load after Flow regulator blocked Replace flow regulator
spools are returned to neutral
Flow regulator filter clogged Replace filter
Detent malfunction Controller defective Replace controller
Spool return difficult Tie rod bolts too tight Re-torque tie rod bolts
Spool leaking oil Defective spool seal Replace spool seal
Oil leakage between valve section Defective seals Replace seals

Relieve hydraulic pressure. Drain the hydraulic reservoir.

(See Replacing Hydraulic Fluid on Page 10-100-2.)
WARNING
1
sufficient force to enter a person’s body by 1
P-50942
immediately.
W-2145-0290
Remove the two tie straps (Item 1) [Figure 20-170-28]
and reposition the harness.
Figure 20-170-29
IMPORTANT

damage the system.
I-2003-0888
1
Figure 20-170-27
1 P-50943
NOTE: Mark all hoses and tubelines for correct

installation.
S7421
Remove the rear cover (Item 1) [Figure 20-170-27].


1
1
Figure 20-170-30
P-50946
1 Remove the six hoses (Item 1) [Figure 20-170-32] from

P-50944 the control valve.
Figure 20-170-33

Figure 20-170-31
1
1 P-50947
P-50945
the control valve.
Remove the five hoses (Item 1) [Figure 20-170-31] from
the control valve.

Figure 20-170-34
P-50950
Remove the mounting bolt (Item 1) [Figure 20-170-36]

P-50948 from the front of the control valve.
Figure 20-170-37
Unplug the two wire connectors (Item 1) [Figure 20-170-
34] from the main wire harness.

NOTE: Mark the location of the connectors for
Figure 20-170-35
1 1 1
1
P-50951
Remove the two mounting bolts (Item 1) [Figure 20-170-

37] from the control valve.
Installation: Tighten the mounting bolts to 18-19 ft.-lb.

P-50949 (24-26 N•m) torque.

Figure 20-170-38
P-50952
Install a hoist and lifting strap (Item 1) [Figure 20-170-38]

on the control valve.

Remove the hydraulic control valve.
Use care not to damage the tubelines or fittings.

1. End Housing
2. Lifting Valve Section
3. Tilting Valve Section
4. Telescoping Valve Section
5. Auxiliary Valve Section
6. Inlet-Outlet Valve Section

1
4 5
2 3 6
P-47794

IMPORTANT
damage the system.
I-2003-0888
P-47794
Figure 20-170-39
Remove all hydraulic fittings. Mark the valve sections for
proper assembly [Figure 20-170-40].
Figure 20-170-41

6 1
5 4 3 2
P-50956
Mark the valve sections for ease of assembly Inlet/Outlet

Valve Section (Item 1), Auxiliary/Frame Leveling Valve 1
P-47795
Section (Item 2),Telescoping Valve Section (Item 3),
Tilting Valve Section (Item 4), Lifting Valve Section (Item
5) and End Housing Valve Section (Item 6) [Figure 20- Remove the three nuts (Item 1) [Figure 20-170-41] from
170-39]. the tie rod bolts.
Assembly: Tighten the nuts to 26 ft.-lb. (35 N•m) torque.

End Housing Disassembly And Assembly
Figure 20-170-42
P-42985
1 Remove the O-ring (Item 1) [Figure 20-170-44] from the

P-47796 plug.
Remove the end housing (Item 1) [Figure 20-170-42].

Figure 20-170-43
1
2
P-42984
Remove the dust cap (Item 1) and plug (Item 2) [Figure

20-170-43] from the end housing.

Lifting Valve Section Disassembly And Assembly
Figure 20-170-45
1
1
P-42989

P-47797 valve section.
Figure 20-170-48
Remove the lifting valve section (Item 1) [Figure 20-170-
45].

Figure 20-170-46
1
2
1
P-42990
1 Remove the two O-rings (Item 1) and backup ring (Item

P-42987 2) [Figure 20-170-48] from the plug.
Remove the four O-rings (Item 1) [Figure 20-170-46]

from the valve section.


(Cont’d)
Figure 20-170-49
P-42993

1 cover.
P-42991
Figure 20-170-52
Loosen the four screws (Item 1) [Figure 20-170-49].

Assembly: Tighten the screws to 7 ft.-lb. (10 N•m)
torque.
Figure 20-170-50
2 2
1 1
P-42995
Remove the spring (Item 1) and spring retainer (Item 2)

[Figure 20-170-52] from the spool.
P-42992
Remove the four screws (Item 1) and cover (Item 2)

[Figure 20-170-50].


(Cont’d)
Figure 20-170-53
1
1
P-42997
P-42996 Assembly: Tighten the screws to 7 ft.-lb. (10 N•m)

torque.
Remove the relief valve (Item 1) [Figure 20-170-53] from Figure 20-170-56

the valve section.
Assembly: Tighten the relief valve to 33 ft.-lb. (45 N•m)

torque.
Figure 20-170-54 2
1
2
1
P-42998

[Figure 20-170-56] from the valve section.
P-42988
Remove the two O-rings (Item 1) and backup ring (Item

2) [Figure 20-170-54] from the relief valve.


(Cont’d)
Figure 20-170-57
P-44000
Remove the spool (Item 1) [Figure 20-170-59] from the

valve section.
P-42993
Figure 20-170-60

cover.
Figure 20-170-58
1
2
1
P-44275
Remove the two plugs (Item 1) [Figure 20-170-60] from

the valve section.
P-42999
Assembly: Tighten the plugs to 20-24 ft.-lb. (27-33 N•m)
torque.


(Cont’d)
Figure 20-170-61
1
2
1
P-44278
Loosen the plug (Item 1) [Figure 20-170-63].
P-44276 Assembly: Tighten the plug to 40-49 ft.-lb. (54-66 N•m)

torque.
Remove the spring (Item 1) and poppet (Item 2) [Figure Figure 20-170-64

20-170-61] from the plugs.
Figure 20-170-62
1
3
P-44279
P-44277 Remove the individual pressure compensator plug (Item

1) poppet (Item 2) and guide (Item 3) [Figure 20-170-64]
plugs.


(Cont’d)
Figure 20-170-65
1
1
P-44002

P-44280
Figure 20-170-68

plug.
Tilting Valve Section Disassembly And Assembly
Figure 20-170-66 1
P-44003
Remove the relief valve (Item 1) [Figure 20-170-68] from

the valve section,

P-44001 torque.
Remove the tilting valve section (Item 1) [Figure 20-170-

66]


(Cont’d)
Figure 20-170-69
1
1
P-44005

P-42988

Figure 20-170-70
P-44004
Loosen the four screws (Item 1) [Figure 20-170-70] on

the cover.

torque.


(Cont’d)
Figure 20-170-72
1
P-44007
Remove the relief valve (Item 1) [Figure 20-170-74] from

the valve section.
P-42993
torque.

cover. Figure 20-170-75
Figure 20-170-73
1
2
1
2
1
P-42988
P-44006


(Cont’d)
Figure 20-170-76
2
1
P-44010
1

P-44008
Figure 20-170-79

the cover.

torque.
1
Figure 20-170-77
2
P-44011
1

valve section.
P-44009



(Cont’d)
Figure 20-170-80 1
P-44277
1

plugs.
P-44275
Figure 20-170-83

the valve section.

torque. 1
Figure 20-170-81
2
1
P-44278
Assembly: Tighten the plug to 40-49 ft.-lb. (54-66 N•m)

torque.
P-44276
Remove the spring (Item 1) and poppet (Item 2) [Figure


HYDRAULIC CONTROL VALVE (CONT’D) Telescoping Valve Section Disassembly And
Assembly
(Cont’d) Figure 20-170-86
Figure 20-170-84
1
1 P-47799
P-44279
Remove the telescoping valve section (Item 1) [Figure
20-170-86].
Remove the individual pressure compensator plug (Item

1) poppet (Item 2) and guide (Item 3) [Figure 20-170-84] Figure 20-170-87
Figure 20-170-85
1 1
P-44013
P-44280 Remove the four O-rings (Item 1) [Figure 20-170-87]


plug.

Telescoping Valve Section Disassembly And

Assembly (Cont’d)
Figure 20-170-88
P-44016
1
controller assembly.
P-44014
Figure 20-170-91
Remove the two screws (Item 1) [Figure 20-170-88]

from the controller assembly.
Assembly: Tighten the screws to 10-12 ft.-lb. (14-

16 N•m) torque.
Figure 20-170-89
1
P-44017
Remove the two couplers (Item 1) [Figure 20-170-91]

1
P-44015
Remove the controller assembly (Item 1) [Figure 20-170-

89] from the valve section.


Assembly (Cont’d)
Figure 20-170-92
2
1
P-44020

[Figure 20-170-94] from the controller assembly.
P-44018
Figure 20-170-95
Remove the two O-rings (Item 1) [Figure 20-170-92]

from the couplers.
Figure 20-170-93
1 P-44021
Remove the seal (Item 1) [Figure 20-170-95] from the

cover.
P-44019

the controller assembly.
Assembly: Tighten the screws to 2-3 ft.-lb. (3-3,5 N•m)

torque.


Assembly (Cont’d)
Figure 20-170-96
1
2
P-44024
1
Remove the port block (Item 1) from the controller (Item

2) [Figure 20-170-98].
P-44022
Figure 20-170-99

cover.
Figure 20-170-97
3
1
2
1
4
P-47808
Remove the two valve cartridges (Item 1) and plunger

(Item 2) [Figure 20-170-99] from the controller.
P-44023
NOTE: The upper valve cartridge (Item 3) is for
extending the boom and the lower valve
Remove the O-ring (Item 1) [Figure 20-170-97] from the cartridge (Item 4) [Figure 20-170-99] is for
plug. retracting the boom.


Assembly (Cont’d)
Figure 20-170-100 1
1
P-44028
2
5
Remove the three O-rings (Item 1) [Figure 20-170-102]
4 from the port valve.
3
P-47810
Figure 20-170-103
Remove the cover (Item 1), poppet (Item 2), spool (Item

3) and spacer (Item 4) from the valve (Item 5) [Figure 20-
170-100].
Figure 20-170-101
1
2
1
P-47811

from the valve.
P-44027
Remove the spool (Item 1) and spring (Item 2) [Figure

20-170-101] from the port valve.
Assembly: The port valve, spool and spring must be

thoroughly cleaned before assembly.


Assembly (Cont’d)
Figure 20-170-104
1 1
P-44037
Loosen the screw (Item 1) [Figure 20-170-106] on the

piston.
P-44036
Assembly: Tighten the screw to 7 ft.-lb. (10 N•m) torque.
Remove the relief valve (Item 1) [Figure 20-170-104] Figure 20-170-107

Assembly: Tighten the valve to 33 ft.-lb. (45 N•m)

torque.
Figure 20-170-105
1
2
1 2
1
P-44038
Remove the screw (Item 1) and piston (Item 2) [Figure

20-170-107] from the adapter.
P-42988



Assembly (Cont’d)
1
Figure 20-170-108
P-42990
1 Remove the two O-rings (Item 1) and backup ring (Item

2) [Figure 20-170-110] from the plug.
P-44039
Figure 20-170-111

from the piston.
Figure 20-170-109
1
1
P-44041
Loosen the two screws (Item 1) [Figure 20-170-111] on

the cover.
P-44040
torque.
valve section.


Assembly (Cont’d)
Figure 20-170-112
1
P-44045
Loosen the adapter (Item 1) [Figure 20-170-114].
P-44042 Assembly: Tighten the adapter to 7-8 ft.-lb. (9-11 N•m)

torque.
Remove the two screws (Item 1) and cover (Item 2) Figure 20-170-115

Figure 20-170-113
P-44046
1
P-44044 Remove the adapter (Item 1) [Figure 20-170-115] from
the spool.
Install a hex wrench in the screw (Item 1) [Figure 20-

170-113] on the end of the spool.


Assembly (Cont’d)
Figure 20-170-116
P-44049
Assembly: Install the countersunk side of the washer

(Item 1) [Figure 20-170-118] into the valve section.
P-44047
Figure 20-170-119

the adapter.
Figure 20-170-117
P-44050

valve section.
P-44048
NOTE: When the spool is removed, use care not to
scratch the spool surface and do not
Remove the washer (Item 1) [Figure 20-170-117] from interchange spools and valve blocks.
the valve section.


Cut
Assembly (Cont’d)
Figure 20-170-120
3 0.710” 2.0”
2
1
1.500”
0.750”
B-14674
To remove the spring assembly from the spool, make a

holding fixture from a 0.750 in. thick x 1.500 in. wide x 2.0
P-44051 in. long (19 mm thick x 38 mm wide x 51 mm long) piece
of hardwood. Drill a 0.710 in. (18 mm) hole in the center
of the hardwood block. Cut the block lengthwise [Figure
Remove the O-ring (Item 1) seal (Item 2) and retainer 20-170-122].

(Item 3) [Figure 20-170-120] from the spool.
Figure 20-170-123
Figure 20-170-121
P-33886
P-44053
Using the wood blocks clamp the spool (Item 1) [Figure

Assembly: The lip on the seal (Item 1) [Figure 20-170- 20-170-123] in a vise.
121] fits inside the retainer (Item 3) [Figure 20-170-120].
damaged.
Loosen the screw (Item 2) [Figure 20-170-123].


Assembly (Cont’d)
2
Figure 20-170-124
1
1 P-44276
4
3
2 20-170-126] from the plugs.
P-44052
Figure 20-170-127
Remove the screw (Item 1), spring retainer (Item 2),

spring (Item 3) and spring retainer (Item 4) [Figure 20-
170-124] from the spool.
1
Figure 20-170-125
P-44277
1
the plugs.
P-44275

the valve section;

torque.


Assembly (Cont’d)
Figure 20-170-128
P-44280

the plug.
P-44278

Assembly: Tighten the plug to 40-49 ft.-lb. (54-66 N•m)
torque.
Figure 20-170-129
1
P-44279

1) poppet (Item 2) and guide (Item 3) [Figure 20-170-

Auxiliary / Frame Leveling Valve Section

Figure 20-170-131
P-44081
Remove the two screws (Item 1) [Figure 20-170-133]

P-44079
Assembly: Tighten the screws to 10-12 ft.-lb. (14-16
N•m) torque.
Remove the frame leveling valve section (Item 1) [Figure

20-170-131]. Figure 20-170-134
Figure 20-170-132
1 1
P-44082
P-44080
Remove the controller assembly (Item 1) [Figure 20-170-


Figure 20-170-135
2
1
P-44085
1 Remove the four screws (Item 1) and cover (Item 2)

[Figure 20-170-137] from the controller assembly.
P-44083
Figure 20-170-138

the controller assembly.
1
Figure 20-170-136
P-44021
1 Remove the seal (Item 1) [Figure 20-170-138] from the

cover.
P-44084
Assembly: Tighten the screws to 2-3 ft.-lb. (3-3,5 N•m)

torque.


Figure 20-170-139
2
1
P-44086
1
Remove the controller (Item 1) from the port block (Item

2) [Figure 20-170-141].
P-44022
Figure 20-170-142

cover.
Figure 20-170-140
1
P-47808
Remove the two valve cartridges (Item 1) and plunger

(Item 2) [Figure 20-170-142] from the controller.
P-44023

the plug.


Figure 20-170-143 1
2
5
3
4 P-44028
Remove the three O-rings (Item 1) [Figure 20-170-145]

from the port valve.
P-47810
Figure 20-170-146
Remove the cover (Item 1), poppet (Item 2, spool (Item

3) and spacer (Item 4) from the valves (Item 5) [Figure
20-170-143].
Figure 20-170-144
1
2
1
P-47811

from the valve.
P-44027
Remove the spool (Item 1) and spring (Item 2) [Figure

20-170-144] from the port valve.
Assembly: The port valve, spool and spring must be

thoroughly cleaned before assembly.


Figure 20-170-147
1 2 P-44093

from the connecting flange.
P-44091

the connecting flange.
Assembly: Tighten the screws to 7-8 ft.-lb. (9-11 N•m)

torque.
Controller Filter Removal And Installation
Remove the filter (Item 2) [Figure 20-170-147] from the

port.
NOTE: The valve assembly does not have to be

removed for this procedure.
Figure 20-170-148
P-44092
Remove the two screws (Item 1) and connecting flange

(Item 2) [Figure 20-170-148].


Figure 20-170-150
P-44097
1
the cover.
P-44094
torque.
Loosen the screw (Item 1) [Figure 20-170-150] on the

piston. Figure 20-170-153
Figure 20-170-151
2
1
P-44098
Remove the two screws (Item 1) and cover (Item 2)

P-44096 [Figure 20-170-153] from the valve section.
Remove the screw (Item 1) and piston (Item 2) [Figure

20-170-151] from the adapter.


Figure 20-170-154
P-44101
1 Remove the adapter (Item 1) [Figure 20-170-156] from

the spool.
P-44099
Figure 20-170-157
Install a hex wrench in the screw (Item 1) [Figure 20-

170-154].
Figure 20-170-155
1
P-44047

the adapter.
P-44100
Loosen the adapter (Item 1) [Figure 20-170-155].
Assembly: Tighten the adapter to 7-8 ft.-lb. (9-11 N•m)

torque.


Figure 20-170-158
P-44103

valve section.
P-44102
NOTE: When the spool is removed, use care not to
scratch the spool surface and do not
Remove the washer (Item 1) [Figure 20-170-158] from interchange spools and valve blocks.

the valve section.
Figure 20-170-161
Figure 20-170-159
3
2
P-44051
P-44049
Remove the O-ring (Item 1), seal (Item 2) and retainer

Assembly: Install the countersunk side of the washer (Item 3) [Figure 20-170-161] from the spool.
(Item 1) [Figure 20-170-159] into the valve section.


Figure 20-170-162
1
2
P-33886
Using the wood blocks clamp the spool (Item 1) [Figure

20-170-164] in a vise.
P-44053
Assembly: The lip on the seal (Item 1) [Figure 20-170- damaged.

162] fits inside the retainer.
Loosen the screw (Item 2) [Figure 20-170-164].
Figure 20-170-163
Cut
Figure 20-170-165
0.710” 2.0”
1.500” 4
0.750” 1
B-14674 3
2
To remove the spring assembly from the spool a holding
P-44052
fixture will have to be made from a 0.750 in. thick x 1.500
in. wide x 2.0 in. long (19 mm thick x 38 mm wide x 51
mm long) piece of hardwood. Drill a 0.710 in. (18 mm) Remove the screw (Item 1), spring retainer (Item 2),
hole in the center of the hardwood block. Cut the block spring (Item 3) and spring retainer (Item 4) [Figure 20-
lengthwise [Figure 20-170-163]. 170-165] from the spool.


Figure 20-170-166
1
P-44277
1
the plugs.
P-44281
Figure 20-170-169

the valve section.
1
Assembly: Tighten the plugs to 20 - 24 ft.-lb. (27 - 33
N•m) torque.
Figure 20-170-167
2
1
P-44282
Assembly: Tighten the plug to 40 - 49 ft.-lb. (54 - 66

N•m) torque.
P-44276


HYDRAULIC CONTROL VALVE (CONT’D) Inlet-Outlet Valve Section Disassembly And
Assembly
Disassembly And Assembly (Cont’d) Figure 20-170-172
Figure 20-170-170
3
2
P-44104
1
P-44283

1), poppet (Item 2) and guide (Item 3) [Figure 20-170- Figure 20-170-173
Figure 20-170-171
P-44105
P-44280 Remove the flushing valve plug (Item 1) [Figure 20-170-

Remove the O-ring (Item 1) [Figure 20-170-171] from Assembly: Tighten the plug to 74 ft.-lb. (100 N•m)
the plug. torque.

Inlet-Outlet Valve Section Disassembly And

Assembly (Cont’d)
Figure 20-170-174 1
P-44108

valve section.
P-44106
Assembly: Tighten the plug to 15 ft.-lb. (20 N•m) torque.
Remove the O-ring (Item 1) [Figure 20-170-174] from Figure 20-170-177

the plug.
Figure 20-170-175
P-44109
P-44107 Remove the O-ring (Item 1) [Figure 20-170-177] from

the plug.
Remove the spring, shims and piston (Item 1) [Figure

20-170-175] from the valve section.


Assembly (Cont’d)
Figure 20-170-178
1
1
P-44112
Remove the flow regulator valve (Item 1) [Figure 20-170-

P-44110
Assembly: Tighten the flow regulator valve to 15 ft.-lb.
(20 N•m) torque.
Remove the relief valve (Item 1) [Figure 20-170-178]

from the valve section. Figure 20-170-181

torque.
Figure 20-170-179
4
3
2 1
2
1
P-44265
1 Remove the plug (Item 1), shim (Item 2), spring (Item 3)
and spool (Item 4) [Figure 20-170-181] from the valve.
P-44111



Assembly (Cont’d)
Figure 20-170-182 1
1
1 2
P-44267

2) [Figure 20-170-184] from the flow regulator valve.
P-44268
Figure 20-170-185

the plug.
Figure 20-170-183
1
P-44114
Remove the test fitting (Item 1) [Figure 20-170-185] from

the valve section.
P-44269
Remove the screen (Item 1) [Figure 20-170-183] from

the valve.


Assembly (Cont’d)
Figure 20-170-186
1
P-44117

the test fitting.
P-44115

the test fitting.
Figure 20-170-187
P-44116
Remove the cap (Item 1) [Figure 20-170-187] from the

test fitting.

PORT RELIEF VALVES Figure 20-180-2
Adjustment Procedure
IMPORTANT 1

damage the system.
I-2003-0888
P-50958
A portable hydraulic hand pump will be used to test the
work port relief valves. The hand pump must have clean
hydraulic fluid that is compatible with the Bobcat Loosen the lock nut (Item 1) [Figure 20-180-2]
hydraulic fluid.
Turn the adjusting screw (Item 2) [Figure 20-180-2]
NOTE: The valve is shown removed from the clockwise to increase the pressure and counterclockwise
machine for photo clarity. to reduce the pressure.

Figure 20-180-1 NOTE: One-quarter turn is approximately 400 PSI
(27,58 bar). When the correct pressure setting
is obtained, tighten the locknut while holding
the adjustment screw from turning.
Adjust the port relief valve until the correct setting is

obtained.
P-50955
Install the hand pump, hose and a pressure gauge

(minimum of 5000 PSI) into the valve section work port in
which the port relief valve is located [Figure 20-180-1].
Pressurize this section with the hand pump until the port
relief valve opens and record the pressure reading.
If the port relief pressure setting needs to be adjusted,

release the hand pump pressure valve.


FLOW CONTROL VALVE Figure 20-190-3
Figure 20-190-1
1
1
P-44263
Remove and clean the filter (Item 1) [Figure 20-190-3].

S7421
NOTE: Check the filter for any damage. Replace the
filter if required.

Figure 20-190-2
P-44331
Remove the flow control valve (Item 1) [Figure 20-190-2]

from the right front of the hydraulic control valve.
Installation: Tighten the flow control valve to 15 ft.-lb.

(20 N•m) torque.


JOYSTICK Figure 20-200-3
For V723 Models With S/N A8HL12999 & Below, S/N

A8HP12999 & Below, S/N A8HK11001 & Above:
Remove the dash cover / steering column cover. (See

Removal And Installation on Page 50-140-1.)
Remove the joystick panel. (See Removal And

Installation on Page 50-140-1.)
1
Figure 20-200-1
S36357
Unplug the electrical connector (Item 1) [Figure 20-200-

3].
For All Models:
NOTE: The joystick is not serviceable and must be

1 replaced as a complete unit.
Figure 20-200-4
P-61622

1].
For V723 Models With S/N A8HL13000 & Above, S/N 1

A8HP13000 & Above:
Figure 20-200-2
1 P-61623
Raise the dust boot (Item 1) [Figure 20-200-4].
P-97028
Remove the fuse box cover (Item 1) [Figure 20-200-2].


JOYSTICK (CONT’D) Figure 20-200-6
Figure 20-200-5
2
1
1
1
2 P-61624
Remove the six hoses (Item 1) [Figure 20-200-6] from

P-61640 the joystick.
Mark the hoses for correct assembly.

Remove the four mounting bolts and spacers (Item 1)
[Figure 20-200-5]. Figure 20-200-7

Installation: The joystick harness (Item 2) [Figure 20-
200-5] must be positioned around the swivel joint as
shown.
WARNING
P-61623
immediately.
W-2145-0290
Remove the joystick assembly (Item 1) [Figure 20-200-

7].
IMPORTANT
damage the system.
I-2003-0888

PARKING BRAKE Figure 20-210-2
Pressure Switch Removal And Installation
Figure 20-210-1
1
2
1
P-44423
Unplug the two electrical connectors (Item 1) [Figure 20-

P-50821 210-2].
Figure 20-210-3
Relieve the hydraulic pressure.

Remove the three screws (Item 1) from the access panel
(Item 2) [Figure 20-210-1].
1
Remove the access panel.
WARNING
P-44424
immediately. Remove the hose (Item 1) [Figure 20-210-3].
W-2145-0290
IMPORTANT
damage the system.
I-2003-0888
Mark all hoses and electrical connectors for correct

installation.

PARKING BRAKE (CONT’D) Figure 20-210-6
Pressure Switch Removal And Installation (Cont’d)
Figure 20-210-4
P-44426
Remove the tubeline (Item 1) [Figure 20-210-6].

P-44425
Figure 20-210-7

Figure 20-210-5
2
1 1
P-44427
Reposition the pressure switch, loosen the screw (Item 1)

P-44444 and remove the electrical connector (Item 2) [Figure 20-
210-7]. Remove the pressure switch.

Pressure Switch Disassembly And Assembly
Figure 20-210-8
1
2
1
2
2 1 2
P-44436
1
Remove the three O-rings (Item 1) and four backup rings
P-44433 (Item 2) [Figure 20-210-10] from the spool.
Figure 20-210-11
Remove the nut (Item 1) and coil (Item 2) [Figure 20-

Figure 20-210-9 1
1
1
1
P-44437
Remove the fittings (Item 1) [Figure 20-210-11].

P-44434
Wash the components in clean solvent and dry with
compressed air.
Remove the spool (Item 1) [Figure 20-210-9].
Check the components for wear or damage. Replace any
worn or damaged components. Always use new O-rings
and backup rings. Apply clean hydraulic fluid to the
components during assembly.

Valve Removal And Installation
Remove the pressure switch. (See Pressure Switch

1
Figure 20-210-12
1 P-44431
Figure 20-210-15
P-44428

1
Remove the pin retainer (Item 1) [Figure 20-210-12].
Figure 20-210-13
P-44430
1
Support the brake valve (Item 1) [Figure 20-210-14] and

remove the two screws (Item 1) [Figure 20-210-15].
Remove the parking brake valve.
P-44429
Remove the pin (Item 1) [Figure 20-210-13] from the

lever.

Valve Disassembly And Assembly
Figure 20-210-16
3
1 2
P-44440
Remove the collar (Item 1), spring (Item 2) and shaft

P-44438 (Item 3) [Figure 20-210-18] from the housing.
Figure 20-210-19
Remove the fittings (Item 1) [Figure 20-210-16].

Figure 20-210-17
P-44441
P-44439 Remove the washer (Item 1) [Figure 20-210-19] from the

housing
Loosen the collar (Item 1) [Figure 20-210-17].
NOTE: Use care removing the collar. The collar is

under spring pressure.

PARKING BRAKE (CONT’D)
Valve Disassembly And Assembly (Cont’d)
Figure 20-210-20
P-44442
Remove the electrical connector (Item 1) [Figure 20-210-

20] from the housing.

PRESSURE REDUCING VALVE Figure 20-220-3
Testing
Figure 20-220-1
P-50928
Install a 1000 PSI (70 bar) gauge on the test fitting

[Figure 20-220-3].
Start the engine, lower the restraint bar (if equipped) and
S7421 run engine at 2200 RPM.

Record the pressure. The pressure at the gauge should
Remove the rear cover (Item 1) [Figure 20-220-1]. be 480 PSI (33.10 bar).
Figure 20-220-2 The pressure reducing valve is not adjustable. If the

pressure is incorrect, replace the pressure reducing
valve. (See Removal And Installation on Page 20-220-2.)
P-50930
Locate the test fitting (Item 1) [Figure 20-220-2] below

the control valve and remove the cap.

PRESSURE REDUCING VALVE (CONT’D)

WARNING
Relieve hydraulic pressure. Drain the hydraulic reservoir.
(See Replacing Hydraulic Fluid on Page 10-100-2.) Hydraulic fluid escaping under pressure can have
Figure 20-220-4 penetrating the skin. This can cause serious injury
immediately.
W-2145-0290
IMPORTANT
S7421
damage the system.
I-2003-0888

Figure 20-220-6
Mark the hoses and electrical connectors for correct
installation.
Figure 20-220-5
2
1
1 P-50938
Remove the top hose (Item 1) [Figure 20-220-6].

P-50937
Remove the screw (Item 1) and unplug the electrical

connector (Item 2) [Figure 20-220-5].

PRESSURE REDUCING VALVE (CONT’D) Disassembly And Assembly
Removal And Installation (Cont’d) Figure 20-220-9
Figure 20-220-7
1
P-44338
1
P-50939
Remove the nut (Item 1) and coil (Item 2) [Figure 20-
Figure 20-220-10

Figure 20-220-8
1
1
P-44337
P-50940
Remove the spool (Item 1) [Figure 20-220-10].

Remove the two mounting bolts (Item 1) and remove the
pressure reducing valve (Item 2) [Figure 20-220-8].

PRESSURE REDUCING VALVE (CONT’D) Figure 20-220-12
Figure 20-220-11
2 1
1
P-44341
1 2
1
2 Remove the fittings (Item 1) [Figure 20-220-12].
P-44340
Wash the valve in clean solvent and dry with compressed
air. Check the components for wear or damage. Replace
Remove the three O-rings (Item 1) and four backup rings any worn or damaged components. Always use new O-
(Item 2) [Figure 20-220-11] from the spool. rings and backup rings.

Apply clean hydraulic fluid to the components during
assembly.

ACCUMULATOR Figure 20-230-2
Removal And Installation S/N A8HL12999 & BELOW, S/N A8HP12999 & BELOW,
The accumulator is located below the control valve, and
can be seen through an access hole on the bottom of the
machine.
WARNING
immediately.
W-2145-0290
IMPORTANT

clean the work area before disassembly and keep all P-50796
damage the system. With the engine off, relieve the hydraulic pressure by
I-2003-0888 pressing the bottom of the button (Item 1) [Figure 20-
230-1] and [Figure 20-230-2].
Figure 20-230-1
Figure 20-230-3
2 1
1
P-97008A
P-50941
Remove the accumulator (Item 1) from the manifold (Item

2) [Figure 20-230-3].


TOW VALVE Figure 20-240-2
Open the engine cover.
Figure 20-240-1
S6839
Mark the hoses for correct installation. Remove the two

hoses (Item 1) [Figure 20-240-2].
S6838 Figure 20-240-3

Position the tow valve to towing position to relieve
hydraulic pressure [Figure 20-240-1].
2
WARNING 3

sufficient force to enter a person’s body by 1
S6892
immediately.
W-2145-0290
Remove the two bolts, nuts (Item 1) and strap (Item 2).
Remove the tow valve (Item 3) [Figure 20-240-3].
IMPORTANT
damage the system.
I-2003-0888

TOW VALVE (CONT’D) Figure 20-240-6
Clean the outside of the tow valve before disassembly.
Mark the outside of the tow valve for ease of assembly.
Figure 20-240-4
1
P-46750
Remove the retainer (Item 1) and stop plate (Item 2)

2 [Figure 20-240-6].
NOTE: Record the position of the stop plate for

1 proper assembly.
P-46747

Figure 20-240-7
Remove the screw (Item 1) and washer (Item 2) [Figure

20-240-4].
Figure 20-240-5
1
1 1
P-46752
Remove the two fittings (Item 1) [Figure 20-240-7].
P-46749
Remove the handle (Item 1) [Figure 20-240-5].

Figure 20-240-8 1
P-46755
1

P-46753 adapters.

fittings.

Figure 20-240-9
1 1
P-46754
Remove the two adapters (Item 1) [Figure 20-240-9].

Figure 20-240-11
1
P-46759
Figure 20-240-14
P-46756
Figure 20-240-12
1

2
1
P-46760
Assembly: Align the slot (Item 1) [Figure 20-240-13]

P-46758 with the notch (Item 1) [Figure 20-240-14] in the shaft.

valve (Both sides).
Assembly: The concave side of the seal (Item 1) [Figure

20-240-11] fits over the ball (Item 2) [Figure 20-240-12].
Turn the shaft (Item 1) until the shaft and ball (Item 2)
[Figure 20-240-12] are in the position shown. Remove
the ball.
Assembly: Record the position of the shaft and ball for

proper assembly.

Figure 20-240-15
1
1
P-46762

P-46763 housing.
Clean all parts in solvent and dry with compressed air.

Remove the shaft (Item 1) [Figure 20-240-15] by
pressing the shaft into the housing. Inspect all parts for wear or damage. Replace any worn

or damaged parts.
Figure 20-240-16
Always install new seals and O-rings. Lubricate all seals
and O-rings with clean hydraulic fluid before installation.
P-46761

shaft.


HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
HYDROSTATIC DRIVE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-20
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-22
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-9
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-21
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-25


HYDROSTATIC SYSTEM INFORMATION
WARNING
only. W-2004-1285
PROBLEM CAUSE
The VersaHANDLER does not move 1, 2
The VersaHANDLER does not move in a straight line. 3, 4
The hydrostatic system is overheating. 5, 6, 7, 8
Warning light comes ON. 5, 8, 9, 10, 11

1. The hydrostatic pump has damage.

2. The hydrostatic motor has damage.
3. The tires do not have the correct tire pressure.
4. The tires are not the same size.
5. The hydrostatic fluid is not at the correct level.
6. The oil cooler has a restriction.
7. The temperature sending switch is not operating correctly.
8. The VersaHANDLER is not being operated at the correct RPM.
9. The sender is defective.
10. Pump is defective or worn hydrostatics
11. Hydraulic filter is plugged.

HYDROSTATIC SYSTEM INFORMATION (CONT’D) The functions of the replenishing valves are:
Replenishing Valve Function 1. To give replacement fluid to the low pressure side of
the hydrostatic circuit. Replacement fluid is needed
Figure 30-10-1 because of normal internal leakage and the controlled
flow to the oil cooler for cooling; Function 1 [Figure
30-10-1].
2. To keep high pressure fluid out of the low pressure

side of the hydrostatic circuitry; Function 2 [Figure
30-10-1].
Valve Moves For

Function 1
Charge Oil
Replacement

Valve Stays on Seat
to Hold High
Pressure for
Drive
Function 2
B-2804
IMPORTANT
damage the system.
I-2003-0888

OIL COOLER
Description
The oil cooler is a combined radiator / oil cooler. (See OIL

COOLER / RADIATOR on Page 70-50-1.)


HYDROSTATIC DRIVE MOTOR
Remove the front axle. (See Removal on Page 40-30-1.)
Figure 30-30-1
1 1
P-22325

Install a chain hoist and lifting strap to lift and support the
drive motor [Figure 30-30-1].

1] from the drive motor.
Installation: Tighten the mounting bolts to 140 - 155 ft.-

lb. (190 - 210 N•m) torque.
Remove the hydrostatic drive motor from the axle

housing.

HYDROSTATIC DRIVE MOTOR (CONT'D)

Parts Identification (Cont’d)


HYDROSTATIC DRIVE MOTOR (CONT'D) Figure 30-30-4
Disassembly 1
IMPORTANT
damage the system.
I-2003-0888
P-29653
Figure 30-30-2
Remove the solenoid nut (Item 1) [Figure 30-30-4].
Figure 30-30-5

P-29652
Place the hydrostatic drive motor on a work surface,

mark the sections for correct assembly [Figure 30-30-2]. P-29654
Figure 30-30-3
Remove the solenoid (Item 1) [Figure 30-30-5] from the
shaft.
P-29651

remove the solenoid housing.

1
Figure 30-30-6
2
1
P-29657
Remove the solenoid shaft (Item 1) and O-ring (Item 2

P-29655 [Figure 30-30-8] from the housing.
Figure 30-30-9
Remove and discard the O-ring (Item 1) [Figure 30-30-6]
from the solenoid.

Figure 30-30-7 3
1 2
P-29659
Remove the O-ring (Item 1) and pin (Item 2) from the

P-29656 solenoid shaft (Item 3) [Figure 30-30-9].

housing.

Figure 30-30-10
P-29661
Remove the pin (Item 1) [Figure 30-30-12] from the

P-29660 housing.
Figure 30-30-13
housing.

Figure 30-30-11
1 1
P-29663
Remove the fitting (Item 1) [Figure 30-30-13].

P-29662

11] from the plug.

Figure 30-30-14
1 1
1
1 1
P-22345
Remove the eight bolts (Item 1) [Figure 30-30-16] from

P-29664 the end cap.
Figure 30-30-17
housing.

Figure 30-30-15
1
1
1 1
P-29667
1 1
1 Lift and remove the end cap (Item 1) [Figure 30-30-17]
P-29666 from the housing.
Remove and discard the seven O-rings (Item 1) [Figure

30-30-15] from the housing.

Figure 30-30-18
1
1
P-29670
Remove the orifice (Item 1) [Figure 30-30-20].

P-29668
NOTE: Mark the orifice location for correct assembly.
Remove the gasket (Item 1) [Figure 30-30-18] from the Figure 30-30-21
end cap.

Figure 30-30-19
P-29671
P-29669 Remove the spool (Item 1) [Figure 30-30-21].
Remove the plug (Item 1) [Figure 30-30-19].

Figure 30-30-22
1
P-29674
Remove the two orifices (Item 1) [Figure 30-30-24] from

P-29672 the spool.
NOTE: Mark the orifice location for correct assembly.

Remove the servo control spool (Item 1) [Figure 30-30-
22] from the housing. Figure 30-30-25

Figure 30-30-23
P-29675
P-29673
Remove the two spring seats and spring (Item 1) from
the servo spool hole (Item 2) [Figure 30-30-25].
Remove the two O-rings (Item 1) [Figure 30-30-23] from
the servo control spool.

Figure 30-30-26
P-29678

P-29676 28].
Figure 30-30-29
Loosen the large nut (Item 1) [Figure 30-30-26] on the
adjustment screw.

2
NOTE: Do not change the adjustment.
Figure 30-30-27
1
1
P-29679
Remove the four bolts (Item 1) and remove the end cap
(Item 2) [Figure 30-30-29].
P-29677
Remove the adjustment screw (Item 1) [Figure 30-30-

27] from the housing.

Figure 30-30-30
1
P-29682
Remove the inner set screw from the servo piston

P-29680 [Figure 30-30-32].
Figure 30-30-33

Figure 30-30-31
P-29683
P-29681 Remove the feedback lug (Item 1) [Figure 30-30-33]

from the servo piston.
Remove the outer set screw from the servo piston

[Figure 30-30-31].

Figure 30-30-34
1
1
P-29686

P-29684 the housing.
Figure 30-30-37
Remove the servo piston (Item 1) [Figure 30-30-34].

Figure 30-30-35
1
1
P-29687
P-29685 Remove the relief valve (Item 1) [Figure 30-30-37] from

the housing by loosening the larger nut.
Remove the two seals (Item 1) [Figure 30-30-35] from

the servo piston.

Figure 30-30-38
4
5 2 3
1 2 3 4
2
1
P-29690
Remove the plug (Item 1), spring (Item 2), spring seat
P-22501 (Item 3) and spool (Item 4) [Figure 30-30-40] from the
housing.
Remove the plug (Item 1), O-rings (Item 2), spring (Item Figure 30-30-41
3) and poppet (Item 4) from the relief valve housing (Item

5) [Figure 30-30-38].
Figure 30-30-39
P-29692
1

P-29689

Figure 30-30-42
3
2
1
P-29696

P-29693
Figure 30-30-45
Remove the plug (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-42] from the housing.

Figure 30-30-43
1
P-29697
P-29691 NOTE: Mark the location of the orifice for correct

assembly.

43] from the plug.

Figure 30-30-46
1
1
P-29698
Remove the valve segment (Item 1) [Figure 30-30-48]

P-29694 from the cylinder.
Figure 30-30-49

Figure 30-30-47 2
2
1 1
2
P-22386
P-29695 Remove and discard the O-ring (Item 1). Remove the
eight mounting bolts (Item 2) [Figure 30-30-49] from the
mounting plate.
NOTE: Mark the location of the orifice for correct

assembly.

Figure 30-30-50
2 1
P-22503
Remove the cylinder block (Item 1) and synchronizing

P-22504 shaft assembly (Item 2) [Figure 30-30-52] from the
housing.
Remove the mounting plate [Figure 30-30-50] using a NOTE: It is not important that the pistons are
suitable puller. installed in their original position.

Figure 30-30-51 Figure 30-30-53
P-22449 P-22459
Remove and discard the seal (Item 1) [Figure 30-30-51] Remove the bearing plate (Item 1) [Figure 30-30-53]
from the mounting plate. from the cylinder block.

Figure 30-30-54
P-22390
Press the piston/shaft assembly from the housing

P-22458 [Figure 30-30-56].
DO NOT damage the pistons.

Remove the bearing from the cylinder block [Figure 30-
30-54]. Figure 30-30-57

DO NOT damage the bearing plate surface of the
cylinder block.
Figure 30-30-55
1
P-22505
Pry up the peened notch (Item 1) [Figure 30-30-57] in

the ring nut.
P-22388

housing.

Figure 30-30-58
P-22446
Using a clamp, compress the spring seat and spring, and

P-22506 drive the pin (Item 1) [Figure 30-30-60] inwards. Release
the clamp.
Remove the ring nut (Item 1) [Figure 30-30-58] from the Figure 30-30-61
shaft.

Figure 30-30-59
2 3
3
1
1
P-22447
P-22507 Remove the pin (Item 1), spring (Item 2) and spring seat
(Item 3) [Figure 30-30-61] from the shaft assembly.
Remove the large bearing and race (Item 1), small

bearing and race (Item 2) and spacer (Item 3) [Figure
30-30-59] from the shaft.

HYDROSTATIC DRIVE MOTOR (CONT'D) Inspection
Disassembly (Cont'd) Clean all parts in solvent and use air pressure to dry
them. DO NOT use cloth or paper as small pieces of
Figure 30-30-62 material can get into the system and cause damage.
Figure 30-30-63
1
P-22508 2
P-22461
Remove the piston rings (Item 1) [Figure 30-30-62] from
the pistons.

Inspect the running (bronze) surface of the bearing plate
NOTE: If any portion of the shaft assembly, bearings (Item 1) and locating pin holes (Item 2) [Figure 30-30-63]
or races must be replaced, the complete shaft/ for wear. Replace if damaged or worn.
bearing assembly must be ordered. The only
serviceable part is the piston rings (Item 1) Figure 30-30-64
[Figure 30-30-62].
P-22462
Inspect the cylinder block assembly for wear or damage.

The piston bores (Item 1) must be smooth. The races for
the synchronizing shaft rollers (Item 2) [Figure 30-30-64]
must not be worn.
If there is any defect in the cylinder block or pistons, the

complete rotating group must be replaced.

Inspection (Cont'd)
Figure 30-30-65
B-15936
Inspect the valve segment for damage or wear on the

P-29685 sealing surface (Item 1) [Figure 30-30-67].
Check that the spindle is located correctly in the valve

Inspect the piston (Item 1) [Figure 30-30-65] for wear or segment by measuring distance "A" [Figure 30-30-67]. If
damage. this dimension is not within 1.36 - 1.37 in. (34,5 - 34,7

mm) the assembly must be replaced.
Figure 30-30-66
P-22349
Inspect the swash plate running surface (Item 1) [Figure

30-30-66] in the end cap for wear or damage.

Assembly
IMPORTANT
clean the work area before disassembly and keep all 1
damage the system.
I-2003-0888
P-22441
Clean and lightly oil all parts prior to assembly.
Figure 30-30-68 Install the pin (Item 1) [Figure 30-30-70] as shown.
NOTE: Clamp is removed for photo clarity.

3
Figure 30-30-71

1 2
P-22447 2
Install the spring (Item 1) and spring seat (Item 2) into the 1
shaft assembly (Item 3) [Figure 30-30-68].
P-22453
Figure 30-30-69
Support the shaft assembly in a press without causing

damage to the pistons, install the large bearing and race
(Item 1), spacer (Item 2) and small bearing and race
(Item 3) [Figure 30-30-71] into the shaft assembly.
NOTE: Be sure not to over press the bearings, they

should be able to roll freely.
P-22446
Using a clamp, compress the spring and spring seat

[Figure 30-30-69].

Assembly (Cont'd)
Figure 30-30-72
1
P-22455
Press the piston/shaft assembly into the housing [Figure

P-22505 30-30-74].
DO NOT DAMAGE THE PISTONS.

Install the ring nut (Item 1) [Figure 30-30-72] onto the
shaft. Figure 30-30-75

NOTE: Do not over tighten the ring nut and that there
is no noticeable looseness in the bearing.
Figure 30-30-73
P-22450
Install a new seal (Item 1) [Figure 30-30-75] into the

mounting plate until it is fully seated.
P-22509
Using a punch seat the ring nut into the groove in the
shaft. [Figure 30-30-73].

Assembly (Cont'd)
Figure 30-30-76
1
P-22386
Install a new O-ring (Item 1) [Figure 30-30-78] onto the

P-22388 mounting plate.
Figure 30-30-79
housing.

Figure 30-30-77
0.53 - 0.55”
(13.5 - 14.0 mm)
1 1
B-15933
1
Press a new bearing into the cylinder block until it is
1 P-22387 located 0.53 - 0.55 in. (13,5 - 14,0 mm) below the bearing
plate surface [Figure 30-30-79].
Install the mounting plate onto the housing, install the
eight mounting bolts (Item 1) [Figure 30-30-77] and
tighten to 46 ft.-lb. (63 N•m) torque.

Assembly (Cont'd)
Figure 30-30-80
1
1
2
P-22459
Install the bearing plate (Item 1) [Figure 30-30-82] with

P-22440 the bronze surface facing up onto the cylinder block.
Figure 30-30-83
Figure 30-30-81

Piston End
2 1
1
P-22464
B-15935
Position the housing on end, tip the three pistons (Item 1)

Install new piston rings (Item 1) [Figure 30-30-80] onto [Figure 30-30-83] closest to the minimum angle stop out
the pistons, make sure the spherical surface (Item 1) toward the housing.
[Figure 30-30-81] conforms to the shape of the piston.
An identification mark (Item 2) [Figure 30-30-80] and

[Figure 30-30-81] is on the "outer" side of the piston ring.
The ends of the piston rings must NOT overlap each

other.

Assembly (Cont'd)
1
Figure 30-30-84
B-15934
NOTE: The recess (Item 1) [Figure 30-30-86] on each

P-22511 roller MUST face the synchronizing shaft.
Figure 30-30-87
Install the synchronizing shaft support pin (Item 1)
[Figure 30-30-84] into the cylinder block and retain with

grease.
Figure 30-30-85
1
1
P-22512
Install the synchronizing shaft support pin (Item 1)

[Figure 30-30-87] into the motor shaft assembly and
P-22499 retain with grease.
Install the six synchronizing shaft rollers (Item 1) [Figure

30-30-85] onto the synchronizing shaft and retain with
grease.

HYDROSTATIC DRIVE MOTOR (CONT'D) Lift the cylinder block slightly and guide the three
remaining pistons in position.
Assembly (Cont'd)
Figure 30-30-90
Figure 30-30-88
1
1
2
3
2
P-22513
P-22500
Install the synchronizing shaft and rollers (Item 1) [Figure

If the cylinder block (Item 1) [Figure 30-30-90] is properly
30-30-88] into the motor shaft races. When properly
installed, there should be very little rotational free-play
installed the synchronizing shaft should move freely in all
between the block and the motor shaft.

directions.
NOTE: A brass rod may be used to guide the pistons
NOTE: The motor shaft end of the synchronizing
into their bores.
shaft is smaller than the cylinder end.
Lubricate the pistons and cylinder block bores with
Figure 30-30-89
hydraulic oil.
2 Figure 30-30-91
1
1 4
3
3
P-22511 1
When installing the cylinder block, the races (Item 1) P-29698
[Figure 30-30-89] in the cylinder block must be

positioned so the synchronizing shaft rollers (Item 2) and
pistons (Item 3) [Figure 30-30-88] and their bores (Item Install a new gasket (Item 1) [Figure 30-30-91] onto the
2) [Figure 30-30-89] are aligned. housing.
Install the six pistons (Item 3) [Figure 30-30-88] into the Install the valve segment (Item 2) [Figure 30-30-91] onto
cylinder bores, tilt the block so the synchronizing shaft the cylinder block and retain with heavy grease.
rollers enter their races in the block and the support pin
(Item 3) [Figure 30-30-89] enter the recess. NOTE: The hole (Item 3) in the valve segment should
be next to the minimum displacement
adjustment screw (Item 4) [Figure 30-30-91].

Assembly (Cont'd)
Figure 30-30-92
P-29697
Install the orifice (Item 1) [Figure 30-30-94] and tighten

P-29695 to 4 ft.-lb. (5 N•m) torque.
Figure 30-30-95
Install the orifice (Item 1) [Figure 30-30-92] and tighten
to 4 ft.-lb. (5 N•m) torque.

Figure 30-30-93
1
1
P-29696
Install the plug (Item 1) [Figure 30-30-95] and tighten to

P-29694 4 ft.-lb. (5 N•m) torque.

4 ft.-lb. (5 N•m) torque.

Assembly (Cont'd)
Figure 30-30-96
1
P-29691

P-29691 plug.
Figure 30-30-99
plug.

Figure 30-30-97
1
2
1 3
2
3
4 P-29693
Install the spring seat (Item 1), spring (Item 2) and plug
(Item 3) [Figure 30-30-99] into the housing and tighten to
P-29690
Install the spool (Item 1), spring seat (Item 2), spring
(Item 3) and plug (Item 4) [Figure 30-30-97] into the
housing and tighten to 30 ft.-lb. (41 N•m) torque.

Assembly (Cont'd)
Figure 30-30-100
1
1
3 4
5 4 2 1
P-29686
Install the two plugs (Item 1) [Figure 30-30-102] and

P-22501 tighten to 30 ft.-lb. (41 N•m) torque.
Figure 30-30-103
Assemble the poppet (Item 1) and spring (Item 2) into the
relief valve housing (Item 3) using new O-rings (Item 4)

and plug (Item 5) [Figure 30-30-100].
Figure 30-30-101
1
1
P-29685
Install the two seals (Item 1) [Figure 30-30-103] onto the

servo piston.
P-29687
Install the relief valve (Item 1) [Figure 30-30-101] into the

housing and tighten to 38 ft.-lb. (52 N•m) torque.

Assembly (Cont'd)
Figure 30-30-104
P-29682
While holding the feedback lug, install the pointed set

P-29684 screw into the groove in the feedback lug [Figure 30-30-
106].
Install the servo piston (Item 1) [Figure 30-30-104] into Do not tighten at this time.
the housing, make sure the hole is in the position shown

when the piston is fully installed. Figure 30-30-107
Figure 30-30-105
P-29680
P-29683
Install the feed back lug (Item 1) [Figure 30-30-105] into

the servo piston.
NOTE: The position of the flat side of the feed back

lug (Item 2) [Figure 30-30-105].

Assembly (Cont'd)
Figure 30-30-108
2 1
1
1
P-29677
Install the adjustment rod (Item 1) [Figure 30-30-110]

P-29679 into the housing and through the feed back lug. Tighten
the large nut to 15 ft.-lb. (20 N•m) torque.
Install the end cap and tighten the four bolts (Item 1) Figure 30-30-111
[Figure 30-30-108] to 58 ft.-lb. (78 N•m) torque.

Figure 30-30-109
P-29682
P-29678 Tighten the pointed set screw at this time [Figure 30-30-
111].
adjustment rod.

Assembly (Cont'd)
Figure 30-30-112
1
P-29674
Install the two orifices (Item 1) [Figure 30-30-114] into

P-29681 the spool and tighten to 18 in.-lb. (2 N•m) torque.
Figure 30-30-115
Install the second set screw and tighten [Figure 30-30-
112].

Figure 30-30-113
1
P-29673

P-29675
the spool.
Install the two spring seats and spring (Item 1) into the
servo piston hole (Item 2) [Figure 30-30-113].
NOTE: Apply assembly lube to help hold into correct

position.

Assembly (Cont'd)
Figure 30-30-116
1
P-29670
Install the orifice (Item 1) [Figure 30-30-118] into the

P-29672 housing and tighten to 4 ft.-lb. (5 N•m) torque.
Figure 30-30-119
Install the servo control spool (Item 1) [Figure 30-30-
116] into the housing.

Figure 30-30-117
1 P-29669

P-29671 4 ft.-lb. (5 N•m) torque.
Install the inner spool (Item 1) [Figure 30-30-117].

Assembly (Cont'd)
Figure 30-30-120
1 1
1
1
1
P-22345
Install the end cap housing and tighten the eight bolts
P-29668 (Item 1) [Figure 30-30-122] to 85 ft.-lb. (115 N•m) torque.
Figure 30-30-123
Install a new gasket (Item 1) [Figure 30-30-120] onto the
end cap.

Figure 30-30-121
1
1 1
2
1
1
1 1
1
P-29666
Install the seven O-rings (Item 1) [Figure 30-30-123].

P-29667
Align the feed back lug (Item 1) and the valve segment
(Item 2) [Figure 30-30-121].

Assembly (Cont'd)
Figure 30-30-124
P-29661
Install the pin into the housing as shown [Figure 30-30-

P-29664 126].
Figure 30-30-127
Install the spool (Item 1) [Figure 30-30-124] into the
housing.

NOTE: The position of the groove (Item 2) [Figure 30-
30-124]. 1
Figure 30-30-125
1 P-29662

plug.
P-29663
Install the fitting (Item 1) [Figure 30-30-125].

Assembly (Cont'd)
2
Figure 30-30-128
P-29657
Install a new O-ring (Item 1) and solenoid shaft assembly

P-29660 (Item 2) [Figure 30-30-130] into the housing.
Figure 30-30-131

Figure 30-30-129
1
P-29656
Install the spool (Item 1) [Figure 30-30-131] into the

P-29659 housing.

solenoid shaft.
Lightly lubricate the pin (Item 2) [Figure 30-30-129] and

install into the solenoid shaft.

Assembly (Cont'd) 1
Figure 30-30-132
P-29653
Install the solenoid nut (Item 1) [Figure 30-30-134] and

P-29655 hand tighten.
Figure 30-30-135
solenoid.

Figure 30-30-133
1
1
1
P-29651
Install the solenoid housing assembly. Tighten the bolts

P-29654 (Item 1) [Figure 30-30-135] to 58 ft.-lb. (78 N•m) torque.
Install the solenoid (Item 1) [Figure 30-30-133].

HYDROSTATIC PUMP Figure 30-40-2
Remove the gear pump. (See Removal And Installation

on Page 20-130-1.)
1
IMPORTANT 1

P-56485
damage the system.
I-2003-0888
Figure 30-40-1
Figure 30-40-3

1
1
P-56484
P-56486
Remove the hose (Item 1) [Figure 30-40-1] from the top

of the hydrostatic pump. Remove the tubeline (Item 1) [Figure 30-40-3].

HYDROSTATIC PUMP (CONT’D) Figure 30-40-6
Figure 30-40-4
P-56490
Remove the four bolt flange hose (Item 1) [Figure 30-40-

P-56488 6] from the front of the pump.
Figure 30-40-7
Remove the two wires (Item 1) [Figure 30-40-4] from the
solenoids.

Figure 30-40-5
1
1
P-56491

P-56489

tubeline.

HYDROSTATIC PUMP (CONT’D) Figure 30-40-10
Figure 30-40-8
1
P-56494
Lift and remove the hydrostatic pump [Figure 30-40-10].

P-56493
NOTE: It may be necessary to remove fittings from
the pump for complete removal.

Figure 30-40-9
P-56492
Install a chain hoist and lifting strap to lift and support the
pump.

9].

HYDROSTATIC PUMP (CONT'D)
1. Multi-Function Valve Assembly

2. O-Ring
3. Plug
4. Plug
5. Nut
6. Charge Relief
7. O-Ring
8. Spring
9. Poppet
10. Plug
11. Control Filter Screen
12. Bolt
13. Lip Seal
14. Cover
15. O-Ring
16. Retainer Plate
B-15899

1. Bolt
2. Bolt
3. Bolt
4. Solenoid
5. Gasket
6. Plug
B-15900

1
2
3
4
5

8
6
12 7
1. Key 13
2. Charge Pump Shaft
3. Pin 14
4. Wear Plate
11
5. Gears
6. Coupling 9
7. Seal 15
10
8. Charge Pump Cover
9. Retaining Plate
10. Bolt
11. O-Ring
12. Flange Adapter
13. Washer
14. Bolt
15. O-Ring
B-23195

HYDROSTATIC PUMP (CONT’D)
1. Valve Plate
2. Retaining Ring
3. Spring Retainer
4. Spring
5. Spring Seat
6. Cylinder
7. Bolt
8. Slipper Guide Bearing
9. Spacer
10. Slipper Guide
11. Piston
12. Bolt
13. Bolt

14. Block
15. Spring
16. Servo Arm
17. Pin
18. Washer
19. Swash Plate Guide
20. Pin
B-19856

HYDROSTATIC PUMP (CONT’D)
1. Snap Ring
2. Spring Guide
3. Spring

4. Spring Guide
5. Bolt
6. Bolt
7. Servo Spring Housing
8. Nut
9. Screw
10. Servo Cylinder
11. O-Ring
12. O-Ring
13. Nut
14. Nut
15. Bearing
16. Spacer
17. Snap Ring
18. Shaft
19. Piston Ring
20. O-Ring
21. Block
22. Servo Piston
23. O-Ring
24. O-Ring
25. Bolt
26. End Cap
27. Shim
28. Spring
B-19857
29 Spring Seat

HYDROSTATIC PUMP (CONT'D) Figure 30-40-13
Disassembly
IMPORTANT
damage the system.
I-2003-0888
P-18566
Figure 30-40-11
Remove the shaft and bearing assembly from the

housing [Figure 30-40-13].
1
NOTE: If the shaft or bearing assembly become stuck
in the housing, lightly tap on the shaft.

Figure 30-40-14
2
1
P-18550
Remove the retainer bolt (Item 1). Remove the coupler

gear (Item 2) [Figure 30-40-11] from the shaft.
Figure 30-40-12
1 P-18567
Remove the shaft seal (Item 1) [Figure 30-40-14] from

2 the shaft.
1
1
P-18565
Remove the three screws (Item 1) [Figure 30-40-12].
Remove the retainer plate (Item 2) [Figure 30-40-12]

from the pump housing.

Figure 30-40-15
1 1
2
P-18721
Remove the relief valve lock nut (Item 1) and the plug
P-18570 (Item 2) [Figure 30-40-17].
Figure 30-40-18
Remove the snap ring (Item 1) and spacer washer (Item
2) [Figure 30-40-15] from the shaft.

Figure 30-40-16
P-18722
Remove the spring and relief poppet from the charge

P-18572 pump housing [Figure 30-40-18].
Remove the bearing (Item 1) [Figure 30-40-16] from the

shaft.
Place the pump on the work surface with the charge

pump up.
Mark the pump housings for correct assembly.
Before removing the relief valve mark the plug, lock nut
and housing for approximate assembly adjustment.

Figure 30-40-19
P-18584
2
Lift and remove the charge pump (Item 1) [Figure 30-40-
P-18723 21] from the pump housing.
Figure 30-40-22
Remove the mounting bolt (Item 1) [Figure 30-40-19].

NOTE: Remove the lifting bracket (Item 2) [Figure 30-
40-19] from the pump. 1
1
1
Figure 30-40-20
1
1
2
1 1
1 2
1 1
P-18726
Remove the six bolts (Item 1) and remove the retaining

plate (Item 2) [Figure 30-40-22] from the charge pump.
P-18724

20] from the flange adapter.
Remove the flange adapter (Item 2) [Figure 30-40-20].

Figure 30-40-23
1
P-18728
Remove the coupler (Item 1) [Figure 30-40-25].

P-18727
Figure 30-40-26
Remove the charge pump cover (Item 1) [Figure 30-40-

23].

Figure 30-40-24
1
2
1
P-18729
2
Remove the charge pump shaft (Item 1) and key (Item 2)
[Figure 30-40-26] from the pump.
P-18558
Only if wear marks are present, remove the bushing

(Item 1) from the charge pump cover (Item 2) [Figure 30-
40-24].

Figure 30-40-27
1
1
2
P-18732
Remove the charge pump wear plate (Item 1) [Figure

P-18730 30-40-29].
Remove the O-ring (Item 2) [Figure 30-40-29].

Remove the charge pump gears (Item 1) [Figure 30-40-
27]. Figure 30-40-30

Figure 30-40-28
2 1
2 1
1
P-18585
P-18731
Remove the swash plate leveler spring shims (Item 1)

[Figure 30-40-30] from the spring pockets.
Remove the eccentric ring (Item 1) and alignment pin
(Item 2) [Figure 30-40-28] from the pump. Inspect the journal bearing (Item 2) [Figure 30-40-30].
Replace as needed.
Note the position of the alignment pin.

3 1
Figure 30-40-31
2
2
2
2
1 3
P-18586
Remove the gasket (Item 1) and the valve plate (Item 2)

P-18734 from the housing. Note the direction of the arrows (Item
3) [Figure 30-40-33] on the valve plate for proper
assembly.
For proper operation, if the plugs (Item 1) and (Item 2)
[Figure 30-40-31] are removed from the housing they Figure 30-40-34

must be returned to their original position.
Installation: Tighten the servo relief valve plug (Item 1)

to 9 ft.-lb. (12 N•m) torque. Tighten the rotation pipe plugs 1
(Item 2) [Figure 30-40-31] to 4 ft.-lb. (5.4 N•m) torque.
Figure 30-40-32
1
P-18588
Remove the two leveler springs (Item 1) [Figure 30-40-

1 34].
P-18735
Remove the multi-function valve assemblies (Item 1)

[Figure 30-40-32] from the housing.

Figure 30-40-35
1 1
1
1 1
1 1
1
P-18596
Remove the six bolts (Item 1) [Figure 30-40-37] from the

P-18589 side cover.
Figure 30-40-38
Remove both spring seats (Item 1) [Figure 30-40-35]
from the swash plate leveler.

Figure 30-40-36
P-18597
Remove the side cover/swash plate leveler assembly

P-18590 from the housing [Figure 30-40-38].
Remove the swash plate hold down spring (Item 1)

[Figure 30-40-36].
Mark the position of the side cover.

Figure 30-40-39 2
2 1
1 1 1
2
1
1
P-18601
1
Remove the six solenoid manifold mounting screws (Item
P-18598 1). Remove the manifold (Item 2) [Figure 30-40-41].
Figure 30-40-42
Remove and discard the O-ring (Item 1). Loosen and
remove both guide posts (Item 2) [Figure 30-40-39].

Figure 30-40-40
P-18602
2 Remove the gasket (Item 1) [Figure 30-40-42] from the

P-18599 manifold.
Remove the leveler (Item 1) and slide inserts (Item 2)

[Figure 30-40-40] from the side cover.
Inspect the slide inserts for wear or damage.
Replace if needed.

Figure 30-40-43
1 1
1
1
1
P-18605
1
Remove and discard the three O-rings (Item 1) [Figure

P-18603 30-40-45] from the solenoid.
Figure 30-40-46
Remove the four solenoid mounting screws (Item 1)
[Figure 30-40-43].

Figure 30-40-44
1
1
P-18606
1 Remove the anchor pin (Item 1) [Figure 30-40-46].

P-18604
Remove the solenoids (Item 1) [Figure 30-40-44] from

the manifold.

Figure 30-40-47
1
P-18610
Remove the swash plate/piston assembly (Item 1)

P-18607 [Figure 30-40-49] from the pump housing.
Figure 30-40-50
Remove the cage locator link (Item 1) [Figure 30-40-47]
from the swash plate.

1
Figure 30-40-48
1
1
P-18611
Remove the four slipper guide bearing retainer bolts

P-18609 (Item 1) [Figure 30-40-50].
Remove the cylinder block (Item 1) [Figure 30-40-48]

through the housing end opening. The swash plate and
piston assembly will remain in the housing.

Figure 30-40-51
P-18617
1
Remove the bronze slider block (Item 1) [Figure 30-40-

P-18615 53] from the servo piston.
Mark the position of the servo end covers.

Remove the swash plate bearings (Item 1) [Figure 30-
40-51] from the housing. Figure 30-40-54

Figure 30-40-52
1
1
1
P-18777
P-18616
Remove the three bolts and remove the servo end cover.
Remove and discard both O-rings (Item 1) [Figure 30-
Remove the swash plate bearing races (Item 1) [Figure 40-54].
30-40-52] from the housing.

Figure 30-40-55 3
2
1
1
1
P-18622
Remove the servo piston (Item 1) from the housing (Item

P-18778 2) [Figure 30-40-57].

Remove the three screws (Item 1) [Figure 30-40-55] and 57].
remove the servo adjustment cover.

Figure 30-40-56
P-18620
Measure and record the adjustment setting for

approximate installation adjustment [Figure 30-40-56].

Inspection
Clean all parts in solvent and use air pressure to dry

them. DO NOT use cloth or paper as small pieces of 1 1
material can get into the system and cause damage.
Figure 30-40-58
1 2
2
P-18628
Inspect the servo piston and seal rings (Item 1) [Figure

30-40-60] for wear. If worn, remove the seal rings and
expander O-rings from the piston.
Install new expander O-rings into the grooves in the

P-18769 servo piston. Carefully install the piston seal rings over

the expander rings. Do not overstretch the piston seal
rings.
Check the wear plate (Item 1) and charge pump gears
(Item 2) [Figure 30-40-58] for damage or wear. Figure 30-40-61
Figure 30-40-59
P-18622
P-18770
Lubricate the seal rings and carefully slide the servo
piston (Item 1) into the cylinder (Item 2) [Figure 30-40-
Check the valve plate [Figure 30-40-59], the surface 61]. Allow the assembly to set for 5 minutes to allow the
must be smooth and free of scratches. If scratches can seal rings to return to their original size.
be felt with a finger nail, replace the part.

Inspection (Cont'd)
Figure 30-40-62
1
P-18739
Servo arm (Item 1) [Figure 30-40-64] alignment is critical

P-18736 for proper pump operation. For this reason, removal of
the servo arm from the swash plate is not recommended.
Check the swash plate assembly surface, it must be If the servo arm must be removed from the swash plate.
smooth and free of scratches [Figure 30-40-62]. Remove the swash plate guide bolt (Item 2) and the

servo arm mounting bolt (Item 3) [Figure 30-40-64].
Figure 30-40-63
Installation: The servo arm (Item 1) [Figure 30-40-64]
must be carefully aligned with the slot and threaded holes
in the swash plate while installing, and must be pressed
completely into the swash plate slot.
Tighten the swash plate guide bolt and servo arm bolt to
Figure 30-40-65
1
P-18737
Inspect the swash plate guide (Item 1) [Figure 30-40-63]

for wear. Replace as needed.
Installation: Tighten the bolt to 24 ft.-lb. (32 N•m) torque.
P-18738
The threaded holes [Figure 30-40-65] in the swash plate

must be cleaned prior to assembly.

Inspection (Cont'd)
Figure 30-40-66
P-18773
1
Check the swash plate bearings [Figure 30-40-68] for
P-18739 wear and damage. Replace as needed.
Figure 30-40-69
Figure 30-40-67

2 1
P-18771
S2884
Check each piston (Item 1) and piston shoe (Item 2)

If the headed roll pin and flat washer (Item 1) [Figure 30- [Figure 30-40-69] for wear or scratches.
40-66] must be installed in the swash plate, the distance
between the washer and the side of the swash plate must
be 0.21 in. (5,33 mm) [Figure 30-40-67].

Inspection (Cont'd)
Figure 30-40-70
1
P-18568
Inspect the shaft seal (Item 1) [Figure 30-40-72].

P-18772 Replace if needed.

Check the cylinder block bores for wear or scratches 72].
[Figure 30-40-70].

Figure 30-40-73
If there is any defect in the cylinder block or pistons, the
complete rotating group must be replaced.
Figure 30-40-71
P-18741
Inspect the multi-function valve cartridge for damage to

P-18712 parts or O-rings.
Replace O-rings as needed [Figure 30-40-73].

Check the shaft for wear or damage in the spline and
bearing areas [Figure 30-40-71].
Check the bearing for correct operation. Remove the

race (Item 1) [Figure 30-40-71] from the shaft only if it is
necessary to replace the bearing.

Assembly
1
2
1
IMPORTANT
1
damage the system. 3 2
I-2003-0888 1
P-18611
Clean and lightly oil all parts prior to assembly.

Apply Loctite® #242 to four NEW retainer bolts (Item 1).
Figure 30-40-74 Install the slipper guide bearings (Item 2) and spacers
(Item 3) and bolts (Item 1) [Figure 30-40-76].
Tighten the four bolts to 10 ft.-lb. (13,5 N•m) torque.

NOTE: Always use NEW retainer bolts with proper
locking compound.
NOTE: The slipper guides and piston slippers must

slide freely on the swash plate.
Figure 30-40-77
P-18754
Put the piston assemblies into the slipper guide [Figure

30-40-74].
Figure 30-40-75
P-18756
Lubricate the pistons and cylinder block bores. Install the

assembled swash plate and pistons into the cylinder
block [Figure 30-40-77].
NOTE: The pistons and bores are not selectively

P-18755 fitted.
Lubricate the slipper running surface on the swash plate,

center the piston and guide on the swash plate [Figure
30-40-75].

Assembly (Cont'd)
Figure 30-40-78
1
1
P-18757
1
Install the bronze slider block (Item 1) [Figure 30-40-80]
on the swash plate servo arm.
P-18616
Figure 30-40-81
Install the swash plate bearing races (Item 1) [Figure 30-
40-78] into the housing. Note the locating pins are offset

in the housing to assure proper assembly.
Figure 30-40-79
P-18758
1 Carefully lower the cylinder block and swash plate

assembly into the housing [Figure 30-40-81].
P-18615
Assemble and lubricate the bearing cage (Item 1)

[Figure 30-40-79], and install it on the bearing races.

Assembly (Cont'd)
Figure 30-40-82
1
1
1
2
P-18595
Install new O-rings (Item 1) [Figure 30-40-84] on the

P-18617 servo end cap.
Lightly lubricate the O-rings and the inner surface of the

Holding the cylinder block and swash plate assembly end cap.
approximately 1/2 in. (12 mm) above the bearings.

Position the servo piston (Item 1) on the bronze slider Figure 30-40-85
block (Item 2) [Figure 30-40-82]. Take care not to wedge
the block, the parts should slide freely.
Figure 30-40-83
P-18594
Hold the servo piston in position and install the servo end
P-18760 cap [Figure 30-40-85].
Lower the cylinder block and swash plate assembly until

the swash plate is properly located on the bearings
[Figure 30-40-83].

Assembly (Cont'd)
Figure 30-40-86
3
1 1
1 1
P-18763
Align the slot in the swash plate bearing cage (Item 1)

P-18761 with the pin (Item 2) in the swash plate and the pin hole
(Item 3) [Figure 30-40-88] in the housing.
Install the three end cap mounting bolts (Item 1) [Figure Figure 30-40-89
30-40-86]. Tighten to 10 ft.-lb. (13,5 N•m) torque.

Lightly lubricate the O-rings and inner surface of the
adjustment cover.
Figure 30-40-87
3
1
P-18606
Hook the cage locator link (Item 1) over the pin (Item 2)
[Figure 30-40-89] between the swash plate and washer.
Rotate the link into the slot in the bearing cage.
P-18762
Install the anchor pin (Item 3) [Figure 30-40-89] through

the locator link and into the housing.
Install the servo adjustment cover over the servo piston
until the piston adjustment screw touches the cover.
Using a hex wrench, turn the adjustment screw
counterclockwise while holding the cover until it is in
position [Figure 30-40-87].
NOTE: Do not install the bolts at this time.

Assembly (Cont'd)
Figure 30-40-90 1
P-18598
Install the two guide post bolts (Item 1) [Figure 30-40-92]

P-18764 through the leveler and inserts. Install the sealing nuts
and tighten to 17 ft.-lb. (23 N•m) torque.
Push the swash plate assembly toward the servo piston Install a new O-ring (Item 2) [Figure 30-40-92] on the
until the swash plate guide contacts the bearing races. cover.

Check for clearance between the servo arm and the
slider block [Figure 30-40-90]. If no clearance is present, Figure 30-40-93
recheck the assembly of the bearing cage and races.
Figure 30-40-91
P-18742
1
1
P-18765 Lift the swash plate leveler and install the side cover
[Figure 30-40-93].
Position the two side cover inserts (Item 1) and swash

plate leveler (Item 2) on the side cover. Note the
orientation of the leveler and the notch (Item 3) [Figure
30-40-91] in the cover.

Assembly (Cont'd)
Figure 30-40-94
1 1
P18745
Rotate the side cover [Figure 30-40-96] (which will also

P-18743 rotate the leveler and swash plate) until the zero angle
position is established, as determined by a second depth
measurement.
Install the two side cover bolts (Item 1) [Figure 30-40-94]
finger tight. Figure 30-40-97

Apply a force of 5 - 10 ft.-lb. (22 - 44 N•m) to the swash
plate leveler to make sure both lever arms contact the
swash plate.
Make sure the swash plate assembly is seated correctly

on the bearings.
Figure 30-40-95
1 1
P-18743
1
After the zero angle position has been established,

tighten the two side cover bolts (Item 1) [Figure 30-40-
97].
P18744
Use a depth micrometer to measure the distance from

the end cap to the swash plate surface. Take a second
measurement at a point 90° (Item 1) [Figure 30-40-95]
from the first point of measurement. These
measurements must not vary more than 0.001 in. (0,025
mm).

Assembly (Cont'd)
Figure 30-40-98
1 1
2 2
P-18747
2 2
Turn the adjustment screw on the servo, which will rotate
P-18596 the swash plate assembly until a zero angle position is
established [Figure 30-40-100].
Install the four remaining side cover bolts, apply Loctite® Figure 30-40-101
#242 to the threads of the "thru" bolts (Item 1) [Figure

30-40-98].
First tighten the four side cover bolts (Item 2) to 24 ft.-lb.

(32,5 N•m) torque. Tighten the two remaining side cover
bolts (Item 1) [Figure 30-40-98] to 18.5 ft.-lb. (25 N•m)
torque.
Figure 30-40-99
P-18748
1
1
Use a depth micrometer to measure the distance from

1 the end cap to the swash plate surface [Figure 30-40-
101]. Take a second measurement at a point 180° from
the first point of measurement. These measurements
must not vary more than 0.001 in. (0,025 mm).
P-18746
Install the three servo adjustment cover mounting screws

(Item 1) [Figure 30-40-99]. Tighten to 10 ft.-lb. (13,5
N•m) torque.

Assembly (Cont'd)
Figure 30-40-102
1
1
P-18603
1
Lightly lubricate both solenoid spools and install into the
P-18749 manifold housing and retain with the four screws (Item 1)
[Figure 30-40-104].
Without turning the servo adjustment screw, install the Figure 30-40-105
sealed nut (Item 1) [Figure 30-40-102] and tighten.

Figure 30-40-103
1 P-18602
1
P-18605 Apply assembly lube on the gasket (Item 1) [Figure 30-
40-105] and install on the manifold housing.
Install new O-rings (Item 1) [Figure 30-40-103] on the
solenoid spool.

Assembly (Cont'd)
Figure 30-40-106
1
1
2
2 2 2
P-18589
2
2 Install the spring seats (Item 1) [Figure 30-40-108] on
P-18601 the leveler arms.
Figure 30-40-109
Install the manifold assembly (Item 1) on the pump with
the six screws (Item 2) [Figure 30-40-106].

Figure 30-40-107 1
1
1
P-18588
Install both springs (Item 1) [Figure 30-40-109] on the

P-18590 leveler spring seats.
Lubricate the running surface of the cylinder (Item 2)

Install the spring (Item 1) [Figure 30-40-107] on the [Figure 30-40-109].
servo arm link.

Assembly (Cont'd)
Figure 30-40-110 1 2
2
2
2
P-18585
Lubricate the end cap journal bearing (Item 1). Install the
P-18587 hardened shims (Item 2) [Figure 30-40-112] in the
charge pump pockets for the swash plate leveler springs.
Retain the shims with assembly lube.
Install the valve plate (Item 1) [Figure 30-40-110] on the
alignment pins. Turn the charge pump housing over.

NOTE: Ensure the direction of the arrow cut outs Figure 30-40-113
(Item 2) [Figure 30-40-110] in the valve plate
are positioned as shown.
Figure 30-40-111
1
1
P-18750
Lightly lubricate the alignment pin (Item 1) [Figure 30-40-

P-18586 113] and install into the charge pump housing, in the
position marked at time of disassembly. This will properly
align the wear plate and eccentric ring.
Install a new gasket (Item 1) [Figure 30-40-111] on the
housing. Install a new O-ring (Item 2) [Figure 30-40-113].

Assembly (Cont'd)
Figure 30-40-114
1 2
1
2
1
3
P-18729
Apply assembly lube and install the charge pump gears

P-18751 (Item 1), charge pump shaft (Item 2) and key (Item 3)
[Figure 30-40-116] into the pump.
Lubricate both sides of the wear plate (Item 1) and install Figure 30-40-117
in the charge pump. Align the wear plate with the

alignment pin (Item 2) [Figure 30-40-114].
Figure 30-40-115
1
2 1
P-18728
Install the coupler (Item 1) [Figure 30-40-117].

P-18731
Install the eccentric ring (Item 1) in the charge pump and

align with the alignment pin (Item 2) [Figure 30-40-115].

Assembly (Cont'd)
Figure 30-40-118
P-18752
Lower the charge pump onto the pump housing while

P-18727 positioning the three springs in their pockets [Figure 30-
40-120].
Install the charge pump cover (Item 1) [Figure 30-40- When properly installed, the charge pump will engage
118]. the alignment pins, but the springs will hold the charge

pump housing 1/8 to 1/4 (3 to 8 mm) away from the pump
Rotate until pin hole in cover aligns with the pin. housing.
Figure 30-40-119 Figure 30-40-121
2
2
2 1
2 2
2
2 2 2
2 1
P-18726 P-18724
Install the retaining plate cover (Item 1) and six bolts Install the flange adapter (Item 1) and four bolts (Item 2)
(Item 2) [Figure 30-40-119]. Tighten the bolts to 10 ft.-lb. [Figure 30-40-121]. Tighten the bolts to 90 ft.-lb.
(13,5 N•m) torque. (122 N•m) torque.

Assembly (Cont'd)
Figure 30-40-122
P-18721
2
Install the plug with lock nut (Item 1) [Figure 30-40-124],
P-18723 align the marks made at disassembly. Tighten the lock
nut to 38 ft.-lb. (52 N•m) torque.
Install the mounting bolt (Item 1) [Figure 30-40-122] and Figure 30-40-125
tighten to 28 ft.-lb. (38 N•m) torque.

NOTE: Install the lifting bracket (Item 2) [Figure 30-
40-122].
Figure 30-40-123 1 1
P-18753
Lightly lubricate and install both multi-function valve

assemblies (Item 1) [Figure 30-40-125] in the charge
pump. Tighten to 66 ft.-lb. (89 N•m) torque.
P-18722
Install the spring and relief poppet into the charge pump
[Figure 30-40-123].

Assembly (Cont'd)
Figure 30-40-126
3
1
2
P-18767
Install a new O-ring (Item 1) [Figure 30-40-128].

P-18570
Lubricate the seal with assembly lube and install the seal
assembly on the drive shaft and in the housing [Figure
Install the bearing (Item 1), the spacer washer (Item 2) 30-40-127].
and the snap ring (Item 3) [Figure 30-40-126] on the

drive shaft. Figure 30-40-129
Position the pump on the charge pump end.
Figure 30-40-127
2 2
2 P-18768
Install the retainer plate (Item 1) and three screws (Item

P-18766 2) [Figure 30-40-129]. Tighten the screws in a
sequenced pattern to 12 ft.-lb. (16 N•m) torque.
Install the shaft and bearing assembly, aligning the shaft
spline with the cylinder block spline. Continue to lower
the shaft and align with the charge pump journal bearing
and charge pump coupler [Figure 30-40-127].

Assembly (Cont'd)
Figure 30-40-130
3
2
.0625”
(1.59 mm)
P-18550
Install the coupler gear (Item 1) on the shaft and install

the bolt (Item 2) [Figure 30-40-130].

Figure 30-40-131
.0625”
(1.59 mm)
B-15045
NOTE: When installing the coupler, maintain a 0.337

in. (8,56 mm) gap from the pump mount flange
to the coupler [Figure 30-40-130] and [Figure
30-40-131].
Remove the case plug (Item 3) [Figure 30-40-130] and

fill with clean hydraulic fluid prior to start up. Rotate the
pump shaft with a torque wrench to assure correct
assembly. The torque required to turn the shaft (after
"break away") should be within:
Minimum Maximum
4 ft.-lb. (5,4 N•m) 9 ft.-lb. (12,2 N•m)


DRIVE SYSTEM
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
AXLE AND DIFFERENTIAL (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-2
Steering Knuckle And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-20-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-8
Drive Axle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-10
Brake System Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-12
Brake System Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-13
Differential Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-17
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-18
Bevel Pinion Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-23
Bevel Pinion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-24
Pinion Group Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-27
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-35
Brake System Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-41

Drive Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-47
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-49
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-52
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-56
AXLE AND DIFFERENTIAL (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Planetary Carrier Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-1
Planetary Carrier Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-2
Steering Knuckle And Drive Axle Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . 40-21-7
Steering Knuckle Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-8
Differential And Bevel Pinion Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-10
Differential Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-21-11
Bevel Pinion Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-15
Bevel Pinion Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-18
Differential Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-26
Steering Knuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-31
Planetary Carrier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-34
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-21-38
FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-8
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-40-1
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Releasing The Brake For Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-1

Re-Activating The Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-50-2
STEERING ANGLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-60-1
DRIVESHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-70-1
SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
Bleeding The Brake Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-80-1
REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-90-4

TROUBLESHOOTING
Chart
The following Troubleshooting Chart is provided for assistance in locating and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Pinion or Ring gear tooth broken 1, 2, 3, 4, 5, 6
Pinion teeth pitted 5, 11
Axle housing bent 12, 13
Worn or pitted bearings 3, 5, 6, 8, 11, 14
Oil leakage 6, 9, 10, 14, 15
Excessive wear on input shaft splines 3, 16, 17, 19
Pinion teeth fatigue 7, 12, 17, 19
Side gear spline worn 17, 19
Thrust washer surface worn 5, 6, 7
Inner diameter of tapered roller bearing worn 5, 6, 18, 19
Bent or broken half shaft 19
Half shaft broken at wheel side 20, 21

1. Excessive gear load
2. Incorrect gear adjustment (excessive play)
3. Pinion nut loose
4. Incorrect gear adjustment (insufficient play)
5. Insufficient lubrication
6. Contaminated oil
7. Incorrect lubrication
8. Worn bearings
9. Operation at high temperature
10. Low oil level
11. Excessive use
12. Overloaded
13. Accident
14. Normal Wear
15. Lip seal damaged
16. Pinion axle play
17. Continuous overload
18. Excessive pinion axle play
19. Vehicle intensively operated or overloaded
20. Wheel loose
21. Beam housing bent


AXLE AND DIFFERENTIAL (FRONT)
General Information
For photo clarity, the following axle procedures are done • Rear Axle removal. (See Removal on Page 40-90-1.)
with the complete axle assembly removed from the
machine, although the planetary carrier, wheel hub, • Rear steering cylinder removal. (See Removal on
steering knuckle and drive axle procedures may be done Page 20-61-1.)
with the axle assembly installed in the machine. For
complete axle repair, the following must be done.
Planetary Carrier Parts Identification
1. Seal
2. Bearing
3. Wheel stud
4. Wheel hub
5. O-ring
6. Snap ring
7. Ring gear

8. Ring gear support
9. Locking plate
10. Snap ring
11. Planet gear
12. Bearing
13. Nut
14. O-ring
15. Plug
16. Countersunk bolt
17. Planet gear carrier
18. Snap ring
19. Stud
S2668

AXLE AND DIFFERENTIAL (FRONT) (CONT’D) Figure 40-20-3
Planetary Carrier Disassembly
Figure 40-20-1 1
1
S2465X
S4845
Remove the securing bolts and lift the planet gear carrier
(Item 1) [Figure 40-20-3].
S4843
Figure 40-20-4
so that later when you pry the planet gear carrier loose, is
does not fall.

Figure 40-20-2 1
1 2
S2466
S4844
Remove the planet gear carrier (Item 1) from the steering

case (Item 2) [Figure 40-20-2] by alternatively forcing a
screwdriver into the appropriate slots.

Planetary Carrier Disassembly (Cont’d)
Figure 40-20-5 1
1
2
S2468
Using a puller, remove the complete ring gear (Item 1)

S2466B [Figure 40-20-7] by acting on the stud bolts.
Figure 40-20-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-20-5].
Figure 40-20-6 1

1
S2469
Partially extract the wheel hub (Item 1) [Figure 40-20-8]

S2467 using a plastic hammer.
NOTE: Alternately hammer on several equidistant

Remove the locking plate (Item 1) [Figure 40-20-6].
points.

Figure 40-20-9
1
1
1 1
S4848
Remove the snap rings (Item 1) [Figure 40-20-11].

S4846
Figure 40-20-12
Remove the external bearing (Item 1) [Figure 40-20-9].
Figure 40-20-10

1
S4849
With the help of a puller, remove the planet wheel gears

S4847 (Item 1) [Figure 40-20-12].
Remove the complete wheel hub (Item 1) [Figure 40-20- NOTE: Mark the assembly side of the planet wheels.
10] by hand.


1
Figure 40-20-13
S4850
1
Remove the sealing ring Item 1) from the wheel hub

(Item 2) [Figure 40-20-15].
S2475
Figure 40-20-16
Remove the snap ring (Item 1) from the ring gear (Item 2)
[Figure 40-20-13].
1

Figure 40-20-14
S4851

S2476
Remove the ring gear support (Item 1) [Figure 40-20-14]

.

AXLE AND DIFFERENTIAL (FRONT) (CONT’D)
Figure 40-20-17
S4852
Remove the external bearing races from the bearing

forcing a pin-driver into the appropriate slots on the hub

(Item 1) [Figure 40-20-17].
NOTE: Hammer in an alternate way so as to avoid

crawling or deformation of the bearing races.

Steering Knuckle And Drive Axle Parts Identification

1 1. Snap ring
2
3 2. Snap ring
4
5 3. Ball bearing
6
4. Seal
7
5. Reduction bushing
6. O-ring
7. Joint
36
8. Thrust bushing
9. Thrust bushing
10
35 8 10. Plug
32 9
15. Cover
17. Pivot pin
18. Grease fitting
19. Grease fitting
15 20. Plug
24
21. Shim

16
19 22. Seal
25
17 23. Bushing
26
18
24. Nut
20
25. Washer
21
32 26. Stud
22 27(RIGHT)
23
27. Steering case
28(LEFT) 28. Steering case
34 29. Articulation
33 30. Pivot pin
37
31. Bolt
29 32. Articulated tie rod
32 22 33. Bushing
17 34. Nut
30
18 35. Cylinder
31
20 36. Bolt
37. Bushing assembly
S2671

Steering Knuckle Disassembly
Figure 40-20-18
1 2
1
3
2
2 S4853
1
Using two levers, remove the top tie rod (Item 1)
S2591 complete with front sealing ring (Item 2) and shims
(Item 3) [Figure 40-20-20].
Loosen and remove the fitting bolts (Item 1) from the tie
rod (Item 2) [Figure 40-20-18]. Figure 40-20-21
Figure 40-20-19

2
1
3
UPPER TIE ROD BOTTOM TIE ROD

S1393
1
Configuration of the upper (Item 1) tie rod with shims
S2427 (Item 2) and the bottom tie rod (Item 3) [Figure 40-20-
21].
Using two levers, remove the bottom tie rod (Item 1)
complete with front sealing ring (Item 2) [Figure 40-20-
19].

Steering Knuckle Disassembly (Cont’d) 1
Figure 40-20-22
1 2
3
4
S1387
Use a puller to remove the centering ring (Item 1), the

S2539
sealing ring (Item 2) and the bearing (Item 3) from the
steering case (Item 4) [Figure 40-20-23].
Remove the complete steering case (Item 1) [Figure 40- NOTE: Note down the orientation of both centering
20-22]. and sealing ring.

Drive Axle Disassembly
Figure 40-20-24
1
2
1 S1402
Remove the snap ring (Item 1) from the bushing unit

(Item 2) [Figure 40-20-26].
S2592
Figure 40-20-27
Loosen and remove the top and bottom check nuts
(Item 1) from the dowels (Item 2) [Figure 40-20-24].
1
Figure 40-20-25

2
S1403
Position the entire drive axle (Item 1) under a press and

remove the complete bush (Item 2) [Figure 40-20-27].
S2593
Remove the entire drive axle (Item 1) [Figure 40-20-25].
NOTE: To remove the drive axle use, if necessary, a

plastic hammer or a lever.

Drive Axle Disassembly (Cont’d)
Figure 40-20-28
2
1
2 1
S1404
Use a puller to remove the bearing (Item 1), the sealing

ring (Item 2) [Figure 40-20-29] and the O-ring.
S3567
Remove the snap ring (Item 1) from the bearing (Item 2)

[Figure 40-20-28].

Brake System Identification
Figure 40-20-30
1. Spacer
2. Spring
3. Piston
4. O-ring
5. O-ring
6. Back-up ring
7. Plug
8. Bleed fitting
9. Bolt
10. Seal washer
11. Cover
12. O-ring

13. Back-up ring
14. Piston
15. Intermediate brake
disc
16. Spring
17. Adjusting bolt
18. Adjusting bolt
19. Spring
20. Bolt
21. Nut
22. Lock washer
23. Shim
24. Spacer
25. Intermediate brake
disc
26. Brake disc
S2672

Brake System Disassembly 2
Figure 40-20-31
S2615
1
Remove the adjusting bolts (Item 1) from the

S2595 intermediate brake disc (Item 2) [Figure 40-20-33].
Figure 40-20-34
Sling the arms to be removed and connect it to a hoist.
Loosen and remove the bolts (Item 1) that fix the arm
(Item 2) to the central body (Item 3) [Figure 40-20-31].

Figure 40-20-32
2
1
1
S2616
Remove the pin bolts (Item 1) guiding the intermediate

2 brake disc (Item 2) [Figure 40-20-34].
S2596
If the bolts are to be replaced, mark down the different

colors for the different brake gaps.
Remove arm (Item 1) together with the pack of the
braking discs (Item 2) [Figure 40-20-32]. Place the arm
on a bench.

Brake System Disassembly (Cont’d)
Figure 40-20-35
S2620
1 Remove the cover (Item 1) [Figure 40-20-37].

S2617
Figure 40-20-38
Remove the intermediate brake disc (Item 1) [Figure 40-
20-35].
Figure 40-20-36

1
1
S2621
1
Remove the Belleville washers (Item 1) [Figure 40-20-
38] and note down direction of assembly.
S2618
Loosen the four studs (Item 1) [Figure 40-20-36].

Figure 40-20-39
S2624
1
Slowly introduce low-pressure compressed air through

S2622
the connection member for the service brake, in order to
extract the piston (Item 1) [Figure 40-20-41].
Slowly introduce low-pressure compressed air through Figure 40-20-42

the connection member for the service brake, in order to
extract the piston (Item 1) [Figure 40-20-39].

Figure 40-20-40
S2625
Remove the braking discs (Item 1) [Figure 40-20-42],

S2623 noting down direction of assembly.
NOTE: If disks are not to be replaced, avoid changing

Mark down their order of assembly and remove negative
their position
piston. Mark the position [Figure 40-20-40].

Figure 40-20-43
S2626
Remove the braking discs, noting down direction of

assembly (Item 1) [Figure 40-20-43].
NOTE: If disks are not to be replaced, avoid changing

their position.

Differential Parts Identification
1. Lock nut
2. Cylinder bolt
1 2 3. Taper roller bearing
3 4. Cylinder bolt
5. Bolt
4 6. Pin
7. Snap ring
8. Snap ring
5 9. Friction washer
8
10. Differential pinion
11 7
11. Ring and Pinion
6
9 Gear Set
10 12. Differential side
14
gear

12 8 13. Differential carrier
7
6 14. Limited slip discs
12 15. Limited slip discs
6 14
16. Limited slip discs
7
8
10
6
9
7
15
16
13
2
1
4
S4854

Differential Disassembly
Figure 40-20-44
T13
2
1
S1409
Apply tool T13 [Figure 40-20-46] and remove the ring

S2597
nuts.
Figure 40-20-47
Mark the position of the ring nut (Item 1). Remove the
cylinder bolts (Item 2) [Figure 40-20-44] from the ring
nut.
1 2

Figure 40-20-45
S2600
Remove the fitting bolts (Item 1) from the middle cover

(Item 2) [Figure 40-20-47].
S2598
Uniformly heat the ring nuts (Item 1) [Figure 40-20-45]

up to a temperature of 80°C.

Differential Disassembly (Cont’d)
Figure 40-20-48
2 1
S2675

S2601
Figure 40-20-51
Insert a screwdriver in the opposing slots then force and
remove the middle cover (Item 1) and the complete
differential unit (Item 2) [Figure 40-20-48].

Figure 40-20-49
4
2
1
S2676
3 1
5
S1412
If the bearings need replacing, extract the bearing race

(Item 1 and 2) from the middle cover (Item 3) and central
body (Item 4) [Figure 40-20-49].
NOTE: Check for damaged O-rings (Item 5) [Figure

40-20-49].


1
Figure 40-20-52
2
S1416
Remove the shim washer (Item 1) and the planetary gear

(Item 2) [Figure 40-20-54].
S1414
Figure 40-20-55
Remove the fitting bolts (Item 1) from the crown (Item 2)
[Figure 40-20-52].

Figure 40-20-53
1
1
2
S1417
If the bearing needs to be replaced, extract the bearing

S1415 (Item 1) from the differential carrier (Item 2) [Figure 40-
20-55].

(Item 1) and remove the crown (Item 2) [Figure 40-20-
53].


2
Figure 40-20-56
3
1
2
1
S1421
2
Place the differential carrier (Item 1) under a press,

S1418 position a bushing (Item 2) and insert a pin (Item 3)
[Figure 40-20-58]. Press the pin of the upper planet
wheel gear into the tool T [Figure 40-20-57].
Remove the snap rings (Item 1) from the four pins
(Item 2) [Figure 40-20-56] of the planet wheel gears. Figure 40-20-59
Figure 40-20-57

T
2 1 2
1
S1422
S1419
Remove pinion and bushing [Figure 40-20-59].
Insert a tool T between two planet wheel gears (Item 1) NOTE: In this condition the tool contains the pin.
[Figure 40-20-57].
NOTE: Make sure that the tool is perfectly lined up

with the pins (Item 2) [Figure 40-20-57] when
locked.


1
Figure 40-20-60
2
S1425
Remove the tool T and remove the planet wheel gears

S1423 (Item 1) and the relative shim washers (Item 2) from the
differential carrier (Item 3) [Figure 40-20-62].
Remove the tool with inside the pin of the planet wheel
gear [Figure 40-20-60].
Figure 40-20-61

1
2
S1424
Leave the released planet wheel gear (Item 1) [Figure

40-20-61] in position and again lock the tool.
Repeat the operations for the extraction of the pin of the

2nd planet wheel gear (Item 2) [Figure 40-20-61].
Repeat the operations for the two remaining pins.

Bevel Pinion Parts Identification
1. Cover
2. Gear
3. Snap ring
4. Ball bearing
5. Snap ring
6. Ring and Pinion
Gear Set
7. Taper roller bearing
8. Shim
9. Shim
10. Spacer
11. Lock nut
12. Seal

13. Ball bearing
14. Gear
15. Snap ring
16. Ball bearing
17. Seal
18. Plug
19. Spring washer
20. Hexagon bolt
21. Magnet plug
22. Dowel
23. Plug
24. Flange
25. O-ring
26. Cylinder bolt
S1568
S2672

Bevel Pinion Disassembly
Figure 40-20-63
S2605
Place two levers into the appropriate slots [Figure 40-20-

65].
S2603
NOTE: Look out not to damage the surfaces.

Remove cylinder bolts (Item 1) [Figure 40-20-63] of the
drive side flange cover. Figure 40-20-66

Figure 40-20-64
S2606
2604
Lift off the cover (Item 1) [Figure 40-20-66].
Make the drive side flange cover loose using a plastic

hammer. [Figure 40-20-64]

Bevel Pinion Disassembly (Cont’d)
Figure 40-20-67
1 1
S2733
Extract the pinion (Item 1) [Figure 40-20-69] complete

S2607 with the internal bearing, the distance piece and shims.
NOTE: The bearing races of the bearings remain in

Remove the sealing ring (Item 1) [Figure 40-20-67]. the central body (Item 2) [Figure 40-20-69].
Figure 40-20-68 Figure 40-20-70

T20
S2602
S2473
Position tool T20A (or T20B), so as to avoid pinion

rotation. Loosen and remove the nut; also remove the O- Remove the pinion (Item 1) [Figure 40-20-70], shims
ring [Figure 40-20-68]. and distance piece.

Figure 40-20-71
1 1
S2575
Insert a drift in the appropriate holes and remove the

S1565
bearing race (Item 1) as well as the shim
washers (Item 2) [Figure 40-20-73].
Using a puller and a press, remove the inner bearing
(Item 1) from the pinion (Item 2) [Figure 40-20-71].
Figure 40-20-72

1
S2574
Remove the bearing race (Item 1) [Figure 40-20-72].

Pinion Group Assembly
Figure 40-20-74
T25C
DG
T24 1
T25A
S2576
Partially insert the bearing race (Item 1) [Figure 40-20-

S1569 76]
Figure 40-20-77
Using a surface plate, reset a magnetic based dial
indicator and placing it on the measurement ring T24
(with a thickness of 30.2 mm) [Figure 40-20-74].

Preset the indicator to approx. 2mm. T25B T24 T25C T25A
Figure 40-20-75
2 1
S1572
Install tension rod T25C, measurement ring T24 and front

guide tool T25A on the bearing race (Item 1) [Figure 40-
20-77].
1
S1570
Bring the internal bearing (Item 1), complete with its

bearing race, under the indicator (Item 2) [Figure 40-20-
75].
Determine overall thickness “D” of the bearing checking
the discrepancy between this size and the size of the
measurement ring.
NOTE: Press the bearing race in the centre and take

several measurements while rotating the
bearing race.

Pinion Group Assembly (Cont’d)
Figure 40-20-78
1
GB
GB
S1575
Fit a depth gauge with long stem into a perfectly flat bar
(Item 1) [Figure 40-20-80]; when the bar rests on two
S2577
gauge blocks “GB” of 57mm size, reset the indicator.
Connect the tension rod to the press and move the

bearing race (Item 1) [Figure 40-20-78] into its seat. Preset the indicator to approx. 2 mm.

Figure 40-20-81
Disconnect the press and remove the tension rod.
NOTE: Before starting the next stage, make sure that

the bearing race has been completely inserted
into its seat.
T26 (2)
Figure 40-20-79
T26 (2) T26 (1)

T24
S2579
1
Lay the bar (Item 1) [Figure 40-20-81] on tool T26 and
take the size “A” at about 57 mm corresponding to the
maximum diameter of arms centring.
S2578 See [Figure 40-20-82] for a sectional view.
Assemble the different parts of tool T26 complete with

external bearing (Item 1) [Figure 40-20-79],
measurement ring T24.
Tighten manually.

Figure 40-20-82
T24 T26 (2)
R115
( )S
T26 (1) D Z
C=Z+D C
S1579
A
30.2 61
Calculate size “C” which represents the second value for
(61-A)+115+30.2=B B S1577 calculating the size of the shims “S” that are to be placed
under the bearing race [Figure 40-20-84].
Calculate size “B” which will be the first useful value for
Figure 40-20-85
calculating the size of the shims that are to be inserted
1

Figure 40-20-83
1
X
Y S
Find shim(s) to
obtain size “S”
S1580
Calculate the difference between sizes “B” and “C” so as

S1578 to obtain the size “S” of the shim (Item 1) [Figure 40-20-
85] that will go under the bearing race.
Check the nominal size (X) marked on the pinion
(Item 1) [Figure 40-20-83] and add or subtract the
indicated variation (Y) so as to obtion size (Z).
e.g.: Z= 118 + 0,1= 118.1
Z= 118 - 0.2= 117.8

Figure 40-20-86
T26 (2)
1 2 T26 (1)
S2582
2 Position tool T26 complete with tapered bearings

S2580
(Items 1 and 2) [Figure 40-20-88]; manually tighten until
a rolling torque has been obtained.
Insert shim “S” (Item 1) and the bearing race of the Figure 40-20-89
internal bearing (Item 2) [Figure 40-20-86] in the central
body.

1
Figure 40-20-87
S2583
T25C Insert the stem of a depth gauge (Item 1) in either side

hole of tool T26(1); reset the indicator with a presetting of
S2581
approx. 3 mm [Figure 40-20-89].
Connect the tension rod to the press, fasten the bearing

race and then remove the tools [Figure 40-20-87].
NOTE: Before going on to the next stage, make sure

that the bearing race has been completely
inserted.


1 S1
Figure 40-20-90
T25C
2 1 3
T26 (1)
S1587
The variation is to be added to a set value of 0,12-

0,13 mm, so as to obtain the size of shim “S1”
S1585 (Item 1) [Figure 40-20-92] which will be inserted
between the external bearing (Item 1) [Figure 40-20-91]
Remove the indicator and release tools and bearings and the distance piece (Item 1) [Figure 40-20-90] and
from the central body. subsequently, to determine the preload for the bearings.
Figure 40-20-93

Re-install all and insert the distance piece (Item 1)
between both bearings (Items 2 and 3) [Figure 40-20-
90]; manually tighten the whole pack.
Figure 40-20-91
H 2
DDG
T26 (2) 1
1 S1588
T26 (1)
Position the internal bearing (Item 1) and the pinion
(Item 2) [Figure 40-20-93] under a press. Force the
bearing onto the pinion.
S1586
Insert depth gauge into tool T26 and measure variation

“H” in relation to the zero setting performed in [Figure
40-20-91].

Figure 40-20-94
1
4 1 3
S2585
2
Connect the pinion (Item 1) [Figure 40-20-96] to the tie
S2584
rod T28A and T28B. Connect the tie rod T28C to the
press and block.
Fit the pinion (Item 1), shim “S1” (Item 2) and the Figure 40-20-97
distance piece (Item 3) in the main body
(Item 4) [Figure 40-20-94].

NOTE: If multiple shims are used, always position the
thinner shims in between the thicker shims. 1
Figure 40-20-95
1
S1592
Apply Loctite® 242 to the thread of the ring nut

(Item 1) [Figure 40-20-97] and screw the nut onto the
pinion.
S1590
Insert the external bearing (Item 1) [Figure 40-20-95] in

the central body in order to complete the pack arranged
as in the figure.

Figure 40-20-98
T19
T21
S2609
T22
The rolling torque of the pinion shaft must be checked.

Using a dial indicator torque wrench, measure the rolling
S2608
torque. The correct torque is 0.88 - 1.25 ft.-lb. (1,20-
1,70 N•m) [Figure 40-20-99].
Apply special wrench T22 to the ring nut (Item 1) [Figure
40-20-98] and bar-hold T21 to the pinion NOTE: If torque exceeds the maximum value, then
(Item 2) [Figure 40-20-98]. the size of shim “S1” between the bearing and
the distance piece needs to be increased.

Lock the wrench T22 and tighten the pinion to minimum
370 ft.-lb. (500 N•m) torque. NOTE: If torque does not reach the set value,
increase the torque setting of the ring nut in
different stages to obtain a maximum value of
420 ft.-lb. (570 N•m) (see the step under
[Figure 40-20-97]).
NOTE: If torque does not reach the minimum value,

then the size of shim “S1” needs to be
reduced.
NOTE: When calculating the increase or decrease in

size of shim “S1”, bear in mind that a variation
of shim of 0,01 mm corresponds to a variation
of 0.44 ft.-lb. (60 N•m) in the torque of the
pinion.

Figure 40-20-100
S2461
T27
2 Tighten the bolts (Item 1) [Figure 40-20-102] of the drive
side flange cover.
S2610
Lubricate the outer surface of the new sealing ring

(Item 1) and fit it onto the central body (Item 2) [Figure
40-20-100] using tool T27.

NOTE: Check that it is properly oriented.
Figure 40-20-101
S2606
Install the drive side flange cover (Item 1) [Figure 40-20-

101].

Differential Assembly
2
Figure 40-20-103
1
2
S1534
With the help of a bar, position the second planet wheel

S1532 gear (Item 1) and the relative thrust washer
(Item 2) [Figure 40-20-105].
Insert the thrust washer (Item 1) and the planetary gear Figure 40-20-106
(Item 2) in the differential carrier (Item 3) [Figure 40-20-
103].

Figure 40-20-104
1
1
3
S1535
Insert a tool between the two planetary gears and line up

S1533 the entire unit by pushing the bar (Item 1) [Figure 40-20-
106] all the way down until it is ejected.
Position the thrust washer (Item 1) and the first planet

wheel gear (Item 2). Temporarily hold them in position
using a bar (Item 3) [Figure 40-20-104].

Differential assembly (Cont’d) 2

1
Figure 40-20-107
2
1
1
S1538
Place the differential carrier under the press, position

bushing (Item 1) and insert the planet wheel pin
S1536
(Item 2) [Figure 40-20-109].
Lock tool (Item 2) behind the planet wheel gears Figure 40-20-110
(Item 1) [Figure 40-20-107].

Figure 40-20-108
2
1
S1539
Put a tool pin on top of the planet wheel pin

S1537
(Item 1) [Figure 40-20-110].
Fit the snap rings (Item 1) onto the pins (Item 2) [Figure
40-20-108].

Differential assembly (Cont’d)
Figure 40-20-111
1
1
S1542
Position the second planetary gear (Item 1) in the

S1540 differential carrier (Item 2) [Figure 40-20-113].
Figure 40-20-114
Press the pin all the way down (Item 1) [Figure 40-20-
111].

Figure 40-20-112 1
2
S1543
Position the thrust washer (Item 1) on the crown

(Item 2) [Figure 40-20-114].
S1541
NOTE: In order to hold the shim washer in position,

Remove the tool pin, bushing and fit the snap ring apply grease to it.
(Item 1) on the pin (Item 2) [Figure 40-20-112].
NOTE: Make sure that the snap ring centers the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle.

Figure 40-20-115
1
3
1
S1546
2 If the bearings are replaced, insert the external bearing

S1544 races in the middle cover (Item 1) [Figure 40-20-117]
and in the central body.
Position the crown (Item 1) on the differential carrier Figure 40-20-118

(Item 2) and lock the bolts (Item 3) [Figure 40-20-115]
with Loctite® 242.
3

1
Tighten the bolts to 95 - 105 ft.-lb. (128-142 N•m) torque. 2
NOTE: Secure the bolts using the cross tightening

method.
Figure 40-20-116
S1547
T17
1
T17 Position the differential unit in the central body
1 (Item 1) with the help of a bar and fit the middle cover
(Item 2) [Figure 40-20-118].
NOTE: Thoroughly check the state of the O-ring

(Item 3) [Figure 40-20-118] and make sure that
the cover is with the hole (see arrow on
S1545 [Figure 40-20-118]) in the lower position.
Install the bearing races (Items 1 and 2) [Figure 40-20-

116] using tool T17.

Figure 40-20-119
T19
S1550
Pre-set the bearings by means of the ring nut situated on

S2613
the opposite side of the crown, so as to increase pinion
torque up to 1.0 - 1.55 ft.-lb. (1,40- 2,10 N•m) [Figure 40-
20-121].
Lock the middle cover (Item 1) with bolts
(Item 2) [Figure 40-20-119]. NOTE: If bearings are not new, check the static
torque. If bearings are new, check the

continuous torque.
Tighten the bolts to 17.5 - 19.5 ft.-lb. (23.8-26.2 N•m)
torque. Figure 40-20-122
Setting Ring And Pinion Backlash
Figure 40-20-120
A
2
T13 1
1 S2667
Introduce a dial indicator with rotary key “A” through the

S2614 plug hole (Item 1). Position the indicator on the centre of
one of the teeth of the crown (Item 2) [Figure 40-20-
122] and pre-set it to 1 mm and reset it.
NOTE: If the ring nuts (Item 1) [Figure 40-20-120] was
removed, apply some Loctite® 242 to them.
Tighten ring nuts on the crown side until
clearance between pinion and crown is zero,
then lock the crown. Go back 1/4—1/2 turn.

Figure 40-20-123
A
1
S2682
Apply Loctite® 242 to the bolts (Item 1) [Figure 40-20-

S2667 125], fit them into one of the two holes and tighten.
Manually move the crown (Item 1) [Figure 40-20-123] in

both directions in order to check the existing backlash Tighten the bolts to17.5 - 19.3 ft.-lb. (23.8 - 26.2 N•m)
between the pinion and the crown. torque.

Figure 40-20-124
Fit the plug in the hole (Item 1) [Figure 40-20-122] after
applying flexible gasket compound for seals to the rims.
T13
S2614
Adjust the backlash between the pinion and the crown by

unloosing one of the ring nuts (Item 1) [Figure 40-20-
124] and tightening the opposite to compensate.
Normal backlash: see table.
CLEARANCE
RATIO
MIN. MAX.
14 – 32 0.18 0.23
NOTE: Difference between MIN and MAX clearance

for whole circumference should not exceed
0.09 mm.

Brake System Assembly
Figure 40-20-126

W U R
68 mm
Y = Brake gap
Y = 0.75 mm
S2735

Brake System Assembly (Cont’d)
Figure 40-20-127
1
S2629
Fit O-rings (Item 1) [Figure 40-20-129] onto the piston.

S2627 Lubricate the piston and the O-rings and install the unit
into the cylinder.
Fit O-rings (Item 1) [Figure 40-20-127] onto the piston. Figure 40-20-130
Lubricate the piston and the O-rings and install the unit
into the cylinder.

Figure 40-20-128
2
1
1 S2631
Using a plastic hammer, tap the piston (Item 1) into the

NOTE: Lightly hammer all around the edge in an

Using a plastic hammer, tap the piston (Item 1) into the alternate sequence.
cylinder (Item 2) [Figure 40-20-128].
NOTE: Lightly hammer all around the edge in an

alternate sequence.

Figure 40-20-131
S2634
1
Install the O-ring (Item 1) [Figure 40-20-133].
S2632
Figure 40-20-134
Clean and grease the surface, position one Belleville

washer (Item 1) [Figure 40-20-131] with the concave
side onto the cylinder. See [Figure 40-20-126] for a

sectional view.
Figure 40-20-132
S2620
1 Engage the cylinder while holding the Belleville washers

into their position (Item 1) [Figure 40-20-134].
NOTE: Check the relative centring of the washers.

S2633
Position the second Belleville washer (Item 1) [Figure

40-20-132] with the concave side onto the other cylinder.
See [Figure 40-20-126] for a sectional view.

Figure 40-20-135
1
1
1
S2636
Insert the stroke automatic regulation springs (Item 1)

S2619 [Figure 40-20-137], place them in line with the piston.
Figure 40-20-138
Tighten the studs (Item 1) [Figure 40-20-135] to 22 - 33
ft.-lb. (30 - 45 N•m) torque.
Figure 40-20-136

1
S2612
1
Insert the intermediate disk (Item 1) [Figure 40-20-138].
S2635
Connect an external pump to the negative brake (Item 1)

[Figure 40-20-136] and introduce pressure to 217 -
435 PSI (15 - 30 bar). Always use Bobcat hydraulic fluid.

Figure 40-20-139
S2638 / S2639
2 3
Take measure from the surface of the intermediate disk
S2637 to the cover sealing surface with 435 PSI (30 bar) of
pressure introduced [Figure 40-20-141]. (example: 25,4
Install the six springs (Item 1) and the bolts (Item 2) into mm).
Figure 40-20-142
Figure 40-20-140

S2640
S2615
Put the brake disc pack including the shim under a press,
Fit the pin bolts making sure that they are all of the same load with 220 lb. (100 kg) and take the measure “V”
color. [Figure 40-20-142]. (example: 40 mm)
Apply Loctite® 270 to the thread.
Tighten the bolts to 3.7 - 5.2 ft.-lb. (5 - 7 N•m) torque

[Figure 40-20-140].

Figure 40-20-143
S2596
Check integrity and position of the arms’ O-ring (Item 1)

S2642 [Figure 40-20-145], install the complete arm.
NOTE: To assist axle shaft centring, slightly move

S = 68 mm - (x + y + v) = Thickness of shims to insert the wheel hub.
under the shim washer.
Figure 40-20-146

See figure [Figure 40-20-126] for a sectional view
showing these dimensions.
Figure 40-20-144
1 3
1
4
1 2
S2645
Install the four washer (Item 1) and nuts (Item 2), tighten
nuts to 150 ft.-lb. (200N•m) torque. Install the twelve
washer (Item 3) and bolts (Item 4) [Figure 40-20-146],
S2643
tighten the bolts to 209 ft.-lb. (283 N•m).
Slightly lubricate the braking disks with Bobcat hydraulic NOTE: Tighten using the criss-cross method.
fluid and fit them in the arm following the correct
sequence. Orient them so that the oil circulation holes
and the holes (Item 1) [Figure 40-20-144] are perfectly
lined up.

Drive Axle Assembly
Figure 40-20-147
1
T5 T6
1 2 S1399
3
3 Heat the bush in oil at an approx. temperature of 100°C
S1397 and fit the entire bush (Item 1) on the drive axle
(Item 2) [Figure 40-20-149].
Using tools T5 and T6, insert the sealing ring (Item 1) Figure 40-20-150
and the bearing (Item 2) in the bush (Item 3) [Figure 40-
20-147].

NOTE: Carefully check the assembly side of the
sealing ring.
3
Figure 40-20-148
2
1
S1400
2 1
Install the snap ring (Item 1) on the axle shaft (Item 2).
After the bearing has cooled, install the O-ring
(Item 3) [Figure 40-20-150].
S1398
Fit the snap ring (Item 1) on the bearing (Item 2) [Figure

40-20-148].

Drive Axle Assembly (Cont’d)

1
Figure 40-20-151 2 1
2
S1507
Screw the check nuts (Item 1) of the dowels

S2592 (Item 2) [Figure 40-20-152] and lock them using a
dynamometric wrench: 90 ft.-lb. (122 N•m).
Insert the drive axle and tighten the top and bottom
dowels (Item 1) [Figure 40-20-151]. Tighten to max. 11
ft.-lb. (15 N•m) torque.

NOTE: Centre the point of the check dowels in the
slot.

Steering Knuckle Assembly
Figure 40-20-153
2
1
T7
1
S1496
Lubricate the terminal of the drive axle and install the

S1447
Lubricate the bushing (Item 1) and the seat of the Pay due attention not to damage the dust cover rings and
steering case (Item 2). Install the bushing the sealing rings.
(Item 1) [Figure 40-20-153], using tool T7.
Figure 40-20-156

Figure 40-20-154
2
1 2
T8
S1497
S1448
Prepare a series of shims (Item 1) of 0,85 mm. To be

Lubricate the outer surface of the sealing ring (Item 1) assembled under the upper pin (Item 2) [Figure 40-20-
and centering ring (Item 2) [Figure 40-20-154]. Fit them 156].
into their seat using tool T8.

Steering Knuckle Assembly (Cont’d)
Figure 40-20-157
1
3
3
2 1 2
BOTTOM TIE ROD
S1500
UPPER TIE ROD
Install the seal (Item 1). Make sure the seal (Item 1) is
orientated as shown in the inset. Lubricate the pivot pin
S1498 (Item 3) and the seal (Item 1). Install the pivot pin (Item 3)
and the six bolts (Item 2) [Figure 40-20-159]. (Bolts not
shown in photo.) Tighten the bolts to 103 ft.-lb. (140 N•m)
Install the seal (Item 1). Make sure the seal (Item 1) is
torque.
orientated as shown in the inset. Lubricate the pivot pin
(Item 3) and the seal (Item 1). Install the pivot pin (Item 3)
Figure 40-20-160

and the six bolts (Item 2) [Figure 40-20-157]. (Bolts not
shown in photo.) Tighten the bolts to 103 ft.-lb. (140 N•m)
torque.
Figure 40-20-158
S1501
Tighten the fitting bolts (Item 1) [Figure 40-20-160] of

the bottom tie rod in sequence using the cross tightening
S1499
method, to 103 ft.-lb. (140 N•m) torque.
Lubricate the group with grease and mount it in the


Figure 40-20-161
S1503
Check the torque of the pins, which has to be between 30

and 44 ft.-lb. (60 N•m). If the preliminary measured value
S2568
is too high, the shims have to be increased [Figure 40-
20-162].
Install a magnetic based dial indicator on the steering

housing. Check by means of a lever that there is no
vertical gap. In case there is any gap, determine the

width and reduce it by removing shims [Figure 40-20-
161].

Planetary Carrier Assembly
Figure 40-20-163
T9B
T9A
S1451
Position the upper part of tool T9B and press the bearing
S1449 races into the hub (Item 1) [Figure 40-20-165] all the
way down.
Position the lower part of tool T9A and the bearing race Figure 40-20-166
of the external bearing (Item 1) [Figure 40-20-163]
under the press.

Figure 40-20-164
2
1
S2587
Fit the bearing (Item 1) [Figure 40-20-166] into the

T9A
S2586
bearing race.
Lubricate the seats of the bearings and position the hub

(Item 1) on tool T9A. Position the bearing race
(Item 2) [Figure 40-20-164] (wide side up).
NOTE: Check that the bearing race is correctly

oriented.

Planetary carrier Assembly (Cont’d)
Figure 40-20-167
2 3
T10
S1456
1
Insert the snap ring (Item 1) in order to fix the flange

S2588 (Item 2) in the crown (Item 3) [Figure 40-20-169].
Position tool T10 and press the sealing ring NOTE: Make sure the snap ring is firmly seated in the
(Item 1) [Figure 40-20-167] into its seat. groove.
Figure 40-20-168 Figure 40-20-170

DOWN
1 T11
1
2 2
S1457
S1455
Insert the flange (Item 1) in the crown (Item 2) [Figure With the help of tool T11, insert the planet wheel gears
40-20-168]. (Item 1) into the cover (Item 2) [Figure 40-20-170].
Accurately check the orientation.

Figure 40-20-171
2
1
S4856
Install the external bearing (Item 1) [Figure 40-20-173].

S4855
NOTE: Using a plastic hammer, drive the bearing to

the limit stop by lightly hammering around the
Install the four snap rings (Item 1) [Figure 40-20-171].
edge.
Figure 40-20-172
Figure 40-20-174

1 1
S4857
S2646
Install the hub (Item 1) [Figure 40-20-172].

Fit the complete crown flange (Item 1) [Figure 40-20-
174].
NOTE: In order to fasten the flange, use a plastic

hammer and alternatively hammer on several
equidistant points.

Figure 40-20-175 2
3
1
2
1
S4858
Fit the planetary carrier cover (Item 1) onto the hub

S2467 (Item 2) [Figure 40-20-177].
Apply silicone-based grease to the surface of the flange NOTE: Check that the O-ring (Item 3) [Figure 40-20-
(Item 1) which touches the crown flange (Item 2) [Figure 177] is in good condition and in position.
40-20-175].
Figure 40-20-178

Fit the flange (Item 1) [Figure 40-20-175].
Figure 40-20-176 1
2 2
1
S2648
Lock the planetary carrier cover (Item 1) by tightening the

S2647 bolts (Item 2) [Figure 40-20-178]. Tighten the bolts to
30 - 37 ft.-lb. (40 - 50 N•m) torque.
Apply silicone based grease to the surface of the flange

(Item 1) which touches the crown flange (Item 2) [Figure
40-20-176].
Cross tighten the nuts (Item 1) [Figure 40-20-176] in two

stages.
Initial torque: 89 ft.-lb. (120 N•m)

Final torque: 188 - 210 ft.-lb. (255 - 285 N•m)

Special Tools
TOOL
BOBCAT P/N IMAGE DESCRIPTION
NR.
6912190 WHEEL HUB SEAL T10
6912192 DIFFERENTIAL RING NUT T13
6912196 DIFFERENTIAL BEARING T17

INNER RINGS

6912197 PINION RING NUT T19
T21
T22
6912199 PINION DUMMY BEARING T24
6912201 DUMMY PINION T26
6912202 PINION TAIL SEAL T27

AXLE AND DIFFERENTIAL (REAR) steering knuckle and drive axle procedures may be done
with the axle assembly installed in the machine. For
General Information complete axle repair, the following must be done.
• Rear Axle removal. (See Removal on Page 40-90-1.)
For photo clarity, the following axle procedures are done
with the complete axle assembly removed from the • Rear steering cylinder removal. (See Removal on
machine, although the planetary carrier, wheel hub, Page 20-61-1.)
Planetary Carrier Parts Identification
3 1. Seal
1
2 4 2. Bearing
5 3. Wheel stud
4. Wheel hub
2
5. O-ring
6. Snap ring
7. Ring gear
8. Ring gear support
9. Locking plate

10. Snap ring
11. Planet gear
12. Bearing
13. Nut
20
6
14. O-ring
7
8 15. Plug
16. Countersunk bolt
9 10 17. Planet gear carrier
11 18. Snap ring
12
19. Stud
13
14
19
18
16
17 15
S2668

AXLE AND DIFFERENTIAL (REAR) (CONT’D) Figure 40-21-3
Planetary Carrier Disassembly
Figure 40-21-1 1
1
S2465X
S4845
Remove the securing bolts and lift the planet gear carrier
S4843 (Item 1) [Figure 40-21-3].
Figure 40-21-4
so that later when you pry the planet gear carrier loose, is
does not fall.

1
Figure 40-21-2
2
1
S2466
S4844
Remove the planet gear carrier (Item 1) from the steering

case (Item 2) [Figure 40-21-2] by alternatively forcing a
screwdriver into the appropriate slots.

Figure 40-21-5 1
1 2
S2468
Using a puller, remove the complete ring gear (Item 1)

[Figure 40-21-7] by acting on the stud bolts.
S2466B
Figure 40-21-8
Remove the nuts (Item 1) from the ring gear support
(Item 2) [Figure 40-21-5].
1

Figure 40-21-6
1
S2469
Partially extract the wheel hub (Item 1) [Figure 40-21-8]

S2467 using a plastic hammer.
NOTE: Alternately hammer on several equidistant

Remove the locking plate (Item 1) [Figure 40-21-6]. points.

Figure 40-21-9
1
1
1
1
1
S4848
Remove the snap rings (Item 1) [Figure 40-21-11].

S4856
Figure 40-21-12
Remove the external bearing (Item 1) [Figure 40-21-9].
Figure 40-21-10

1
S4849
With the help of a puller, remove the planet wheel gears

S4857 (Item 1) [Figure 40-21-12].
NOTE: Note the assembly side of the planet wheels.

Remove the complete wheel hub (Item 1) [Figure 40-21-
10] by hand.


1
Figure 40-21-13
S4850
1
Remove the sealing ring (Item 1) from the wheel hub

(Item 2) [Figure 40-21-15].
S1382
Figure 40-21-16
Remove the snap ring (Item 1) from the ring gear (Item 2)
[Figure 40-21-13].
1

Figure 40-21-14
S4851

S2476
Remove the ring gear support (Item 1) [Figure 40-21-

14].

AXLE AND DIFFERENTIAL (REAR) (CONT’D)
Figure 40-21-17
S4852
Remove the external bearing races from the bearing

forcing a pin-driver into the appropriate slots on the hub

(Item 1) [Figure 40-21-17].
NOTE: Hammer in an alternate way so as to avoid

crawling or deformation of the bearing races.

Steering Knuckle And Drive Axle Parts Identification
1
1. Snap ring
2
3 2. Snap ring
4
5 3. Ball bearing
6
4. Seal
7
5. Reduction bushing
6. O-ring
7. Joint
36
8. Thrust bushing
9. Thrust bushing
10
35 8 10. Plug
32 9
15. Cover
17. Pivot pin
18. Grease fitting
19. Grease fitting
20. Plug
15
24
21. Shim

16
19 22. Seal
25
17 23. Bushing
26
18
24. Nut
20
25. Washer
21
32 26. Stud
22 27(RIGHT)
27. Steering case
23
28(LEFT) 28. Steering case
34 29. Articulation
33 30. Pivot pin
37
31. Bolt
29 32. Articulated tie rod
32 22 33. Bushing
17 34. Nut
30
18
35. Cylinder
31 36. Bolt
20
37. Bushing assembly
S2671

Steering Knuckle Disassembly
Figure 40-21-18
1 2
1
3
2
2 S4853
1
Using two levers, remove the top tie rod (Item 1)
S2591 complete with front seal (Item 2) and shims (Item 3)
[Figure 40-21-20].
Loosen and remove the fitting bolts (Item 1) from the tie
rod (Item 2) [Figure 40-21-18]. Figure 40-21-21
Figure 40-21-19

2
1
3
UPPER TIE ROD BOTTOM TIE ROD

S1393
1
Configuration of the upper (Item 1) tie rod with shims
S2427 (Item 2) and the lower tie rod (Item 3) [Figure 40-21-21].
Using two levers, remove the bottom tie rod (Item 1)

complete with front sealing ring (Item 2) [Figure 40-21-
19].

Steering Knuckle Disassembly (Cont’d)
Figure 40-21-22
1
1
S2540
Remove the entire drive axle (Item 1) [Figure 40-21-24].

S2539
NOTE: To remove the drive axle use, if necessary, a
plastic hammer or a lever.
Remove the complete steering case (Item 1) [Figure 40-
21-22].

Figure 40-21-23
1
3
4
S1387
Use a puller to remove the centring ring (Item 1), the

sealing ring (Item 2) and the bearing (Item 3) from the
NOTE: Note down the orientation of both centring

and sealing ring.

Differential And Bevel Pinion Parts Identification

1. Cylinder bolt
2. Shim
3. Taper roller bearing 10. Differential pinion
4. Bolt 11. Washer
5. Bevel gear set 12. Differential side
gear
6. Circlip
13. Differential carrier
7. Friction washer
14. Differential
8. Snap ring
9. Pin
16. Shim
18. Shim
19. Shim
20. Spacer
21. Ring nut
22. Seal
23. Gear assembly
24. Flange
25. O-ring
26. Pinion
S2670

Differential Disassembly
Figure 40-21-25
S2543
Pull out the differential (Item 1) [Figure 40-21-27].

S2541
Figure 40-21-28
Loose the nuts (Item 1) [Figure 40-21-25].
Figure 40-21-26

1
S2544

1 S2542
Remove the complete arm (Item 1) [Figure 40-21-26].

Figure 40-21-29
1
1
2
S1415

S2545
(Item 1) and remove the crown (Item 2) [Figure 40-21-
31].
Remove the top plug (Item 1) [Figure 40-21-29]. Figure 40-21-32
Figure 40-21-30

1
1
2
S1416
S1414
Remove the shim washer (Item 1) and the planetary gear
(Item 2) [Figure 40-21-32].
Remove the fitting bolts (Item 1) from the crown (Item 2)
[Figure 40-21-30].

Figure 40-21-33 T
2 1 1 2
2
S1419
Insert a tool T between two planet wheel gears (Item 1)

S1417 [Figure 40-21-35].
NOTE: Make sure that the tool is perfectly lined up

If the bearing needs to be replaced, extract the bearing with the pins (Item 2) [Figure 40-21-35] when
(Item 1) from the differential carrier (Item 2) [Figure 40- locked.
21-33].

Figure 40-21-36
Figure 40-21-34
3
1
2
1
2
S1421
S1418
Remove the snap rings (Item 1) from the four pins Place the differential carrier (Item 1) under a press,
(Item 2) [Figure 40-21-34] of the planet wheel gears. position a bushing (Item 2) and insert a pin (Item 3)
[Figure 40-21-36]. Press the pin of the upper planet
wheel gear into the tool T [Figure 40-21-35].

Figure 40-21-37
1
2
S1424
Leave the released planet wheel gear (Item 1) [Figure

S1422 40-21-39] in position and again lock the tool.
Repeat the operations for the extraction of the pin of the

Remove the pin and bushing [Figure 40-21-37]. 2nd planet wheel gear (Item 2) [Figure 40-21-39].
NOTE: In this condition the tool contains the pin. Repeat the operations for the two remaining pins.

Figure 40-21-38 Figure 40-21-40
S1423
S1425
Remove the tool with inside the pin of the planet wheel
Remove the tool T and remove the planet wheel gears
gear [Figure 40-21-38].
(Item 1) and the relative shim washers (Item 2) from the

Bevel Pinion Disassembly
Figure 40-21-41
1
1
S2547
2
Remove the flange (Item 1) [Figure 40-21-43] complete
S2546 with guard by means of a puller.
If disassembly is awkward, heat the check nut (Item 1) of Figure 40-21-44

the flange (Item 2) [Figure 40-21-41] at 80°C.
NOTE: Heating is meant to unloose the setting of

Loctite® on the nut. Always be careful with 1
hot parts.
Figure 40-21-42
S2548
1
Remove the swinging support (Item 1) [Figure 40-21-
44].
2
S2571
Remove the nut (Item 1) and remove the O-ring (Item 2)

[Figure 40-21-42].

Figure 40-21-45
2
1
S2551
Extract the pinion (Item 1) [Figure 40-21-47] complete

S2549
with the internal bearing, the distance piece and shims.
NOTE: The bearing races remain in the central body

Remove the sealing ring (Item 1) [Figure 40-21-45]. (Item 2) [Figure 40-21-47].
Figure 40-21-46
Figure 40-21-48

T21 1
1
T22
S2550
S1564
Position wrench T22 onto the ring nut (Item 1) [Figure

40-21-46] and apply bar hold T21 to the pinion (Item 1) Remove the pinion (Item 1) [Figure 40-21-48], shims
[Figure 40-21-47]. and distance piece.
Stop wrench T22 and rotate the pinion so as to release

and remove the ring nut (Item 1) [Figure 40-21-46].
NOTE: If disassembly proves awkward, heat the ring

nut to approx. 80°C.

Figure 40-21-49
1 1
S1567
Insert a drift in the appropriate holes and remove the

S1565
bearing race (Item 1) as well as the shim washers
(Item 2) [Figure 40-21-51].
Using a puller and a press, remove the inner bearing

(Item 1) from the pinion (Item 2) [Figure 40-21-49].
Figure 40-21-50

1
S1566
Remove the bearing race of the external bearing (Item 1)

[Figure 40-21-50].

Bevel Pinion Assembly
Figure 40-21-52
DG
T25C
T24
T25A S1571
Partially insert the bearing race (Item 1) [Figure 40-21-

S1569 54].
Figure 40-21-55
Using a surface plate, reset a magnetic based dial
indicator and placing it on the measurement ring T24
(with a thickness of 30,2 mm) [Figure 40-21-52].

Preset the indicator to approx. 2mm.
T25B T24 T25C T25A
Figure 40-21-53
DG 1
S1572
Install tension rod T25C, measurement ring T24 and front

guide tool T25A on the bearing race of the external
1 bearing (Item 1) [Figure 40-21-55].
S1570
Bring the internal bearing (Item 1) [Figure 40-21-53],

complete with its bearing race, under the indicator.
Determine overall thickness “D” of the bearing checking

the discrepancy between this size and the size of the
measurement ring.
NOTE: Press the bearing race in the centre and take

several measurements while rotating the
bearing race.

Bevel Pinion Assembly (Cont’d)
Figure 40-21-56 DG1

1
GB
GB
S1575
Fit a depth gauge with long stem into a perfectly flat bar
S2556 (Item 1) [Figure 40-21-58]; when the bar rests on two
size-blocks “GB” of 57mm, reset the indicator.
Connect the tension rod to the press and move the
Preset the indicator to approx. 2 mm and reset.
bearing race (Item 1) [Figure 40-21-56] into its seat.
Disconnect the press and remove the tension rod.
Figure 40-21-59

NOTE: Before starting the next stage, make sure that
the bearing race has been completely inserted
into its seat.
Figure 40-21-57
T26 (1)
T26 (2) T24 T26 (1)

1 S1576
Lay bar (Item 1) [Figure 40-21-59] on tool T26(1) and

take the size “A” at about 57 mm corresponding to the
maximum diameter of arms centring.
S1574
Insert both parts of tool T26 complete with external

bearing (Item 1) [Figure 40-21-57], measurement ring
T24.
Tighten manually.

Figure 40-21-60
T26 (2)
T24
R115
( )S
T26 (1) D Z
C=Z+D C
S1579
A
30.2 61 Calculate size “C” which represents the second value for
(61-A)+115+30.2=B B S1577
calculating the size of the shims “S” that are to be placed
Calculate size “B” which will be the first useful value for Figure 40-21-63
calculating the size of the shims that are to be inserted
1

Figure 40-21-61
1
X
S
Y
Find shim(s) to
obtain size “S”
S1580
Calculate the difference between sizes “B” and “C” so as

to obtain the size “S” of the shim (Item 1) [Figure 40-21-
S1578
63] that will go under the bearing race.
Check the nominal size (X) marked on the pinion

(Item 1) [Figure 40-21-61] and add or subtract the
indicated variation (Y) so as to obtion size (Z).
e.g.: Z= 118 + 0,1= 118.1
Z= 118 - 0.2= 117.8

Figure 40-21-64
T26 (2)
1 2
T26 (1)
S2561
Position tools T26C and T26B complete with tapered

bearings (Items 1 and 2) [Figure 40-21-66]; manually
2 S2559 tighten until a rolling has been obtained.
Insert shim “S” (Item 1) and the bearing race of the Figure 40-21-67
internal bearing (Item 2) [Figure 40-21-64] in the central
body.

Figure 40-21-65 DDG
S2562
Insert the stem of a depth dial indicator in either side hole

T25A of tool T26C; reset the indicator with a presetting of
S2560
approx. 3 mm [Figure 40-21-67].
T25C
Position tool T25A and tension rod T25C [Figure 40-21-
65].
Connect the tension rod to the press, fasten the bearing

race and then remove the tools.
NOTE: Before going on to the next stage, make sure

that the bearing race has been completely
inserted.

Bevel Pinion Assembly (Cont’d) 1 S1

Figure 40-21-68
T25C
2 1 3
T26 (1)
S1587
The variation is to be added to a set value of 0,12-

0,13 mm, so as to obtain the size of shim “S1”
S1585 (Item 1) [Figure 40-21-70] which will be inserted
between the external bearing (Item 1) [Figure 40-21-69]
Remove the indicator and release tools and bearings and the distance piece (Item 1) [Figure 40-21-68] and
from the central body. subsequently, to determine the preload for the bearings.
Figure 40-21-71

Re-install all and insert the distance piece (Item 1)
between both bearings (Items 2 and 3) [Figure 40-21-
68]; manually tighten the whole pack.
Figure 40-21-69
H
DDG 2
T26 (2) 1
1
1
S1588
T26 (1)
Position the internal bearing (Item 1) and the pinion
(Item 2) [Figure 40-21-71] under a press. Force the
S1586 bearing onto the pinion.
Insert depth dial indicator into tool T26B-T26C and

measure variation “H” in relation to the zero setting
performed in [Figure 40-21-69].

Figure 40-21-72
4
1 3
S2564
2 Connect the pinion (Item 1) [Figure 40-21-74] to the tie

S2563 rod T28A and T28B. Connect the tie rod T28C to the
press and block.
Fit the pinion (Item 1), shim “S1” (Item 2) and the
Figure 40-21-75
distance piece (Item 3) in the main body (Item 4) [Figure
40-21-72].

NOTE: The finer shims must be placed in between
the thicker ones.
Figure 40-21-73
2 1
1
S2570
Apply Loctite® 242 to the thread of the ring nut

(Item 1) and screw the nut onto the pinion
(Item 2) [Figure 40-21-75].
S1590
Insert the external bearing (Item 1) [Figure 40-21-73] in

the central body in order to complete the pack arranged
as in the figure.

Figure 40-21-76
T19 1
T19
T22
S2566
1
Apply onto the pinion (Item 2) [Figure 40-21-77] the bar-
S2565 hold and with the help of a torque indicator, check the
torque of the pinion.
Apply special wrench T22 to the ring nut (Item 1) [Figure
Torque: 120-170 N•m.
40-21-76] and bar-hold T19 to the pinion.
NOTE: If torque exceeds the maximum value, then
Lock the wrench T22 and rotate the pinion using a

the size of shim “S1” between the bearing and
dynamometric wrench, up to a minimum required torque
the distance piece needs to be increased.
of 370 ft.-lb. (500 N•m).
NOTE: If torque does not reach the set value,
increase the torque setting of the ring nut in
different stages to obtain a maximum value of
420 ft.-lb. (570 N•m).
NOTE: If torque does not reach the minimum value,

then the size of shim “S1” needs to be
reduced.
NOTE: When calculating the increase or decrease in

size of shim “S1”, bear in mind that a variation
of shim of 0,01 mm corresponds to a variation
of 0,44 ft.-lb. (60 N•m) in the torque of the
pinion.

Figure 40-21-78
2
T27
1
1
S1597
Fit the flange (Item 1) complete with the guard

S2567 (Item 2) [Figure 40-21-80] and fasten it. For aligning the
flange, use a plastic hammer if necessary.
Lubricate the outer surface of the new sealing ring
(Item 1) and fit it onto the central body (Item 2) [Figure NOTE: Make sure that the guard is securely fastened
40-21-78] using tool T27. onto the flange and that it is not deformed.

Figure 40-21-79 Figure 40-21-81
1
3
S2548 S2571
Install the swinging support (Item 1) [Figure 40-21-79]. Apply Loctite® 242 to the threaded part of the pinion
(Item 1) [Figure 40-21-81]. Position tool T20A (or T20B)
NOTE: Check that it is properly oriented. and fasten it in order to avoid rotation.
Insert the O-ring (Item 2) and the nut (Item 3) [Figure

40-21-81] and tighten it using a dynamometric wrench.
Tighten the bolt to 207 - 229 ft.-lb. (280-310 N•m) torque.

Differential Assembly
2
Figure 40-21-82
1
2
S1534
With the help of a bar, position the second planet wheel

gear (Item 1) and the relative shim washer
S1532
(Item 2) [Figure 40-21-84].
Insert the shim washer (Item 1) and the planetary gear Figure 40-21-85
(Item 2) in the differential carrier (Item 3) [Figure 40-21-
82].

Figure 40-21-83
3
S1535
Insert a tool between the two planetary gears

S1533
(Item 1) [Figure 40-21-85]. Line up the entire unit by
pushing the bar all the way down until it is ejected.
Position the shim washer (Item 1) and the first planet

wheel gear (Item 2). Hold them in position using a bar
(Item 3) [Figure 40-21-83].

Differential Assembly (Cont’d) 2

1
Figure 40-21-86
1
1
S1538
Place the differential carrier under the press, position

bushing (Item 1) and insert the planet wheel pin
S1536 (Item 2) [Figure 40-21-88].
Lock the tool the planet wheel gears (Item 1) [Figure 40- Figure 40-21-89
21-86]. After locking, remove bar T16C.

Figure 40-21-87
2
1
S1539
Put a tool pin on top of the planet wheel pin

S1537
(Item 1) [Figure 40-21-89].
Fit the snap rings (Item 1) onto the pins (Item 2) [Figure
40-21-87].

Differential Assembly (Cont’d)
Figure 40-21-90 1
S1542
1
Position the second planetary gear (Item 1) in the
S1540
Figure 40-21-93
Press the pin all the way down (Item 1) [Figure 40-21-
90].
Figure 40-21-91 1

2
2
S1543
Position the shim washer (Item 1) on the crown

(Item 2) [Figure 40-21-93].
S1541
NOTE: In order to hold the shim washer in position,

Remove tool pin, bushing and fit the snap ring (Item 1) apply grease to it.
on the pin (Item 2) [Figure 40-21-91].
NOTE: Make sure that the snap ring centres the seat
and that it rests on the surface of the
differential carrier.
Repeat the operations on the other planet
wheel pin or planet wheel axle.

Figure 40-21-94 1
3 1 2
S1546
If the bearings are replaced, insert the external bearing

2
races (Item 1) in the central body (Item 2) [Figure 40-21-
S1544 96].
Position the crown (Item 1) on the differential carrier Figure 40-21-97

(Item 2) and lock the bolts (Item 3) [Figure 40-21-94]
with Loctite® 242.

Tighten the bolts to 94 - 105 ft.-lb. (128-142 N•m) torque.
A
NOTE: Secure the bolts using the cross tightening 2
method.
Figure 40-21-95
1
S1551
T17
2
T17
1 Introduce a dial indicator with rotary key “A” through the
top plug hole (Item 1). Position the indicator on the centre
of one of the teeth of the crown (Item 2) [Figure 40-21-
97] and pre-set it to 1 mm and reset it.
S1545
Install the bearing races (Items 1 and 2) [Figure 40-21-

95] using tool T17.

Figure 40-21-98
A 1
S2542
Re-install the complete arms (Item 1) [Figure 40-21-99].

S1552
Manually move the crown (Item 1) [Figure 40-21-98] in

both directions in order to check the existing backlash
between the pinion and the crown.

NOTE: Difference between MIN and MAX clearance
for whole circumference should not exceed
0,09 mm.

Steering Knuckle Assembly
Figure 40-21-100
T17
1
1
S1496
Lubricate the terminal of the drive axle and install the

S1447
Pay due attention not to damage the dust cover rings and
Lubricate the bushing (Item 1) and the seat of the the sealing rings.
steering case (Item 2). Install the bushing
(Item 1) [Figure 40-21-100], using tool T17. Figure 40-21-103

Figure 40-21-101 2
1 2 1
T8
S1497
S1448 Prepare a series of shims (Item 1) of 0,85 mm. To be

assembled under the upper pin (Item 2) [Figure 40-21-
103].
Lubricate the outer surface of the sealing ring
(Item 1) and centering ring (Item 2) [Figure 40-21-101].
Fit them into their seat using tool T8.

Figure 40-21-104
3
3
1
2 1 2
BOTTOM TIE ROD
S1500
UPPER TIE ROD
Fit the unit (Item 1) in the steering case (Item 2) [Figure

S1498
40-21-106]. Position the new bolts and tighten.
Check for the correct assembly side of the seal

Fit a new seal (Item 1) onto the top tie rod (Item 3). (Item 3) [Figure 40-21-106].
Lubricate and install the unit in the steering case. Insert
and tighten the 6 bolts (Item 2) [Figure 40-21-104] to Figure 40-21-107

103 ft.-lb. (140 N•m) using the cross tightening method.
Check the correct assembly side of the seal

(Item 1) [Figure 40-21-104].
Figure 40-21-105
S1501
Tighten the fitting bolts (Item 1) [Figure 40-21-107] of

the bottom tie rod in sequence using the cross tightening
method, to 103 ft.-lb. (140 N•m).
S1499
Lubricate the group with grease and mount it in the

steering case [Figure 40-21-105].

Figure 40-21-108
S2569
Check the torque of the pins, which has to be between

S2568 22 - 44 ft.-lb. (30 - 60 N•m). If the preliminary measured
value is too high, the shims have to be increased [Figure
40-21-109].
Install a magnetic based dial indicator on the steering
housing.Check by means of a lever that there is no
vertical gap. In case there is any gap, determine the
width and reduce it by removing shims [Figure 40-21-

108].

Planetary Carrier Assembly
Figure 40-21-110
T10
T9B
S2588
Position tool T10 and press the sealing ring into its seat
S1451 [Figure 40-21-112].
Figure 40-21-113
Position the upper part of tool T9B and press the bearing
races into the hub (Item 1) [Figure 40-21-110] all the
way down.

Figure 40-21-111
1
1 2
S1455
Insert the flange (Item 1) in the crown (Item 2) [Figure

40-21-113].
S2587
Fit the bearing (Item 1) [Figure 40-21-111] into the

internal bearing race (wide side up).

Planetary Carrier Assembly (Cont’d)
Figure 40-21-114
2
3
S4855
Install the four snap rings (Item 1) [Figure 40-21-116].

S1456
Figure 40-21-117
Insert the snap ring (Item 1) in order to fix the flange

(Item 2) in the crown (Item 3) [Figure 40-21-114].
2
NOTE: Carefully check that the ring is properly

inserted in the slot of the crown.
Figure 40-21-115
DOWN 1
S2539
T11
1 Fit the steering case (Item 1) onto the drive axle

(Item 2) [Figure 40-21-117] and install the tie rods.
2 Connect the steering bars.
S1457
With the help of tool T11, insert the planet wheel gears
(Item 1) into the cover (Item 2) [Figure 40-21-115].
Accurately check the orientation.

Planetary Reduction Assembly (Cont’d)
Figure 40-21-118
1
S2646
Fit the complete crown flange (Item 1) [Figure 40-21-

120].
S4857
NOTE: In order to fasten the flange, use a plastic

Install the hub (Item 1) [Figure 40-21-118]. hammer and alternatively hammer on several
equidistant points.
Figure 40-21-119
Figure 40-21-121

2
1
1
S4856
S2467
Install the external bearing (Item 1) [Figure 40-21-119].

Apply silicone based grease to the surface of the flange
NOTE: Using a plastic hammer, drive the bearing to (Item 1) which touches the crown flange (Item 2). Fit the
the limit stop by lightly hammering around the flange (Item 1) [Figure 40-21-121].
edge.

Planetary Reduction Assembly (Cont’d)
Figure 40-21-122
2
1
S1468
Lock the planetary carrier cover (Item 1) by tightening

S2647 the bolts (Item 2) [Figure 40-21-124]. Tighten the bolts to
30 - 37 ft.-lb. (40 - 50 N•m).
Cross tighten the nuts (Item 1) [Figure 40-21-122] in two

stages.

Initial torque setting: 88 ft.-lb. (120 N•m).
The final torque setting is 188 - 210 ft.-lb. (255 - 285 N•m)
torque.
Figure 40-21-123
1
S4858
Fit the planetary carrier cover (Item 1) onto the hub

(Item 2) [Figure 40-21-123].
NOTE: Check that the O-ring is in good condition and

in position.

Special Tools
TOOL
BOBCAT P/N IMAGE DESCRIPTION
NR.
6912190 WHEEL HUB SEAL T10
6912192 DIFFERENTIAL RING NUT T13
6912196 DIFFERENTIAL BEARING T17

INNER RINGS

6912197 PINION RING NUT T19
T21
T22
6912199 PINION DUMMY BEARING T24
6912201 DUMMY PINION T26
6912202 PINION TAIL SEAL T27

FRONT AXLE Figure 40-30-2
Removal
Fully retract the telescoping boom. Raise the boom and

install the boom stop. (See Installing The Approved
1
Boom Stop on Page 10-150-1.)
Figure 40-30-1
1 1
P-29281
Remove the two bolts (Item 1) from the cover (Item 2)

[Figure 40-30-2]. Remove the cover.
S1978
IMPORTANT

Rotate the battery disconnect switch (Item 1) [Figure 40-
30-1] to the right, to disconnect the power supply from When repairing hydrostatic and hydraulic systems,
the battery. clean the work area before disassembly and keep all
damage the system.
WARNING I-2003-0888
NOTE: On machines without frame leveling, the

frame leveling cylinder has been replaced by
a rigid connection (Item 1) [Figure 40-30-3].
Follow the same procedure.
Figure 40-30-3
immediately.
W-2145-0290
Drain the hydraulic reservoir. (See Replacing Hydraulic

Fluid on Page 10-100-2.)
S2066

FRONT AXLE (CONT’D) Figure 40-30-6
Removal (Cont’d)
Figure 40-30-4
1
2
1
S1960
Remove the hose (Item 1) [Figure 40-30-6] from the right

side of the drive motor.
S1986
Figure 40-30-7
Remove the hose (Item 1) and disconnect the wire
harness (Item 2) [Figure 40-30-4] from the top of the
drive motor.

Figure 40-30-5
1
1
S1966
Remove the hose (Item 1) [Figure 40-30-7] from the left

side of the drive motor.
S1975
Remove the hose (Item 1) [Figure 40-30-5] from the top

right side of the drive motor.

Removal (Cont’d)
Figure 40-30-8
S1959
2 1
S1984
bottom of the drive motor.
Figure 40-30-11
Remove the nut (Item 1) and coil (Item 2) [Figure 40-30-
8] from the right side of the drive motor.

Figure 40-30-9
S1961

S1970 bottom right side of the drive motor.
Disconnect the wire harness (Item 1) [Figure 40-30-9]

coming from the headlights on the right side.

Removal (Cont’d)
Figure 40-30-12
1
1
S1981
Remove the hose (Item 1) [Figure 40-30-14] on the right

S1975 side of the steering cylinder.
Figure 40-30-15
Remove the two four bolt flange hoses (Item 1) [Figure
40-30-12].

Mark the location of the hoses for correct installation.
Figure 40-30-13
1 S2042
1
Lift the front of the machine and place jack stands (Item
1) [Figure 40-30-15] under the frame as shown.
S1983
Place a block in front and behind one of the rear wheels.
Remove the hose (Item 1) [Figure 40-30-13] on the left

side of the steering cylinder.

Removal (Cont’d)
Figure 40-30-16
1
2
1
S1951
Remove the four bolts (Item 1) from both front fender

mount brackets (Item 2) [Figure 40-30-18].
S1850
Remove the front fenders.

Remove the four driveshaft mounting bolts (Item 1)
[Figure 40-30-16] and nuts. Figure 40-30-19

Figure 40-30-17
S2037
S1954
Using a jack, apply upward pressure to lift and support
the front axle [Figure 40-30-19].
Remove the eight lug nuts and washers (Item 1) [Figure
40-30-17] from each front tire.
Remove both front tires.

Removal (Cont’d)
Figure 40-30-20
2
2
1
S2035
Remove the bolt (Item 1) and nut from the pivot pin (Item
S2049
2) [Figure 40-30-22].
Figure 40-30-23
Remove the snap ring (Item 1) and washer (Item 2)
[Figure 40-30-20].

Figure 40-30-21
2
1
1 S2030
Use a pin removal tool (Item 1) to remove the pivot pin

S2034
(Item 2) [Figure 40-30-23].

Removal (Cont’d)
Figure 40-30-24
S1981
Remove the brake hose (Item 1) [Figure 40-30-26] from

S2017
the right side of the axle.
Figure 40-30-27
Gently lower the jack approximately 6 in. (150 mm)
[Figure 40-30-24].

Figure 40-30-25
S2022
Have an assistant balance the axle on the jack and lower

S1983 the jack slowly while rolling the axle out from under the
frame [Figure 40-30-27].
Remove the brake hose (Item 1) [Figure 40-30-25] from
the left side of the axle.

Installation
Figure 40-30-28
S1981
Install the brake hose (Item 1) [Figure 40-30-30] from the

S2022 right side of the axle.
Have an assistant balance the axle on the jack and roll Figure 40-30-31
the axle under the frame [Figure 40-30-28].

Figure 40-30-29
S2017
Gently raise the jack [Figure 40-30-31].

S1983
Install the brake hose (Item 1) [Figure 40-30-29] from the

left side of the axle.

Figure 40-30-32
1 S2034
S2017 Install the pivot pin (Item 1) [Figure 40-30-34].
Figure 40-30-35
Install the pivot pin (Item 1) [Figure 40-30-32] using a
copper hammer.

Figure 40-30-33
1
2
S2049
1
Install the washer (Item 1) and snap ring (Item 2) [Figure
S2017
40-30-35].
Install the bolt (Item 1) and nut from the pivot pin
(Item 2) [Figure 40-30-33].

Figure 40-30-36 1
S1954
Install both front tires. Install the eight lug nuts and
S2037 washers (Item 1) [Figure 40-30-38] from each front tire.
Tighten the nuts to 221 ft.-lb. (300 N•m) torque.

Lower the jack and remove it [Figure 40-30-36].
Figure 40-30-39

Figure 40-30-37
S1850
S1951
Install the four driveshaft mounting bolts (Item 1) [Figure

Install the front fenders. 40-30-39] and nuts.
Install the four bolts (Item 1) from both front fender mount
brackets (Item 2) [Figure 40-30-37].
Tighten the bolts to 90-100 ft.-lb. (125-140 N•m) torque.

Figure 40-30-40
S1983
Install the hose (Item 1) [Figure 40-30-42] on the left side

1 S2042
of the steering cylinder.
Figure 40-30-43
Lift the front of the machine and remove the jack stands
(Item 1) [Figure 40-30-40] from under the frame.

Place a block in front and behind one of the rear wheels.
Figure 40-30-41 1
S1975
1
Install the two four bolt flange hoses (Item 1) [Figure 40-
30-43].
S1981 Mark the location of the hoses for correct installation.
Install the hose (Item 1) [Figure 40-30-41] on the right

side of the steering cylinder.

Installation (Cont’d) 1
Figure 40-30-44
S1973
Reconnect the wire harness (Item 1) [Figure 40-30-46]

coming from the headlights on the left side.
S1961
Figure 40-30-47
Install the hose (Item 1) [Figure 40-30-44] from the
bottom right side of the drive motor.

Figure 40-30-45
S1970
1
Reconnect the wire harness (Item 1) [Figure 40-30-47]
coming from the headlights on the right side.
S1959
Install the hose (Item 1) [Figure 40-30-45] from the

bottom of the drive motor.

Figure 40-30-48
1
S1960
2 1
Install the hose (Item 1) [Figure 40-30-50] on the right
S1984 side of the drive motor.
Figure 40-30-51
Install the nut (Item 1) and coil (Item 2) [Figure 40-30-48]
from the right side of the drive motor.

Figure 40-30-49
1
S1975
Install the hose (Item 1) [Figure 40-30-51] on the top

S1966 right side of the drive motor.
Install the hose (Item 1) [Figure 40-30-49] on the left side

of the drive motor.

Figure 40-30-52
1 1
2
S1977
Rotate the battery switch (Item 1) [Figure 40-30-54] to

S1986 the left to reconnect the power supply from the battery.
Install the hose (Item 1) and connect the wire harness

(Item 2) [Figure 40-30-52] on the top of the drive motor.

Figure 40-30-53
2
P-29281
Install the cover (Item 1) with two bolts (Item 2) [Figure

40-30-53].
Fill the hydraulic reservoir. (See Replacing Hydraulic


AXLE TOE-IN Figure 40-40-3
Adjustment
The axle is removed from the machine for photo clarity,

1 2
but this procedure may be completed with the axle
installed in the machine.
Turn the steering wheel until the steering cylinder rod is 3

positioned in the center. Measure the exposed part of the
cylinder rod on each side of the cylinder housing making
sure they are the same length.
Figure 40-40-1
S2058
If measurement is not the same, adjust both tie rod ends

(Item 1) by loosening or tightening the track rods (Item 2)
[Figure 40-40-3] of both tie rods until the measurement
is the same.
1
Tighten the nut (Item 3) [Figure 40-40-3] to 221 ft.-lb.
(300 N•m) torque.

1
S2056
Install two identical, straight bars (Item 1) [Figure 40-40-

1] onto the wheel hub and secure them using lug nuts.
NOTE: The two bars must be perpendicular to the

ground.
Figure 40-40-2
S2057
Measure the distance between the ends of the two bars

[Figure 40-40-2]. The measurement must be equal.


PARKING BRAKE Figure 40-50-3
Releasing The Brake For Towing
Block all four wheels to prevent the machine from moving 1

once the parking brake is released.
Locate the six brake release bolts (three per side) on the
front axle.
Figure 40-50-1
Towing
Position
S6802
Locate the tow valve (Item 1) [Figure 40-50-3], turn

counterclockwise 90° to the towing position.
The machine is now ready to be towed.

S1394
Figure 40-50-2
S1395
Alternately turn the brake release bolts [Figure 40-50-1]

"IN" (clockwise) 1/2 turn each until you feel resistance.
Continue to turn each release bolt in equally 1/2 turn for a
total of approximately 5 complete turns.

PARKING BRAKE (CONT'D) Figure 40-50-6
Re-Activating The Brake

Operating
Block all four wheels to prevent the machine from Position 1
moving.
Locate the six brake release bolts (three per side) on the
front axle.
Figure 40-50-4
S6802
Locate the tow valve (Item 1) [Figure 40-50-6] under the

hood, turn clockwise 90° to the operating position.
The parking brake is now re-activated.
NOTE: Brakes will be disabled until brake screws are

returned to original position.
S1394
Figure 40-50-5
S1395
Alternately turn the brake release bolts [Figure 40-50-4]

"OUT" (counterclockwise) 1/2 turn until the torque drops
off sharply. Continue to turn each release bolt out equally
1/2 turn until the brake release bolt presses against the
bolt housing. After the brake release bolt is touching the
bolt housing turn each brake release bolt "IN" (clockwise)
a1/4 turn.

STEERING ANGLE ADJUSTMENT Figure 40-60-3
Adjustment
The axle is removed from the machine for photo clarity, 1

but this procedure may be completed with the axle
installed in the machine.
Figure 40-60-1
S2061
Adjust the stop (Item 1) [Figure 40-60-3] as needed.

Tighten the lock nut to 110 ft.-lb. (150 N•m) torque.
Figure 40-60-4
2
S2059

1
Install a straight bar (Item 1) onto the wheel hub and
secure using lug nuts. Turn the steering wheel completely
to one side. Place a straight bar (Item 2) [Figure 40-60-
1] on the pinion shaft.
Figure 40-60-2
S2062
Turn the steering wheel completely to the other side

[Figure 40-60-4] and repeat above procedure.
32-35
Degrees
S2060
Use an angle gauge, to obtain a reading of 32-35

degrees [Figure 40-60-2].


DRIVESHAFT Figure 40-70-2
Figure 40-70-1
S2047
S1850 Remove the drive shaft out the rear of the machine
[Figure 40-70-2].
Remove the four drive shaft mounting bolts (Item 1)

[Figure 40-70-1] from each end of the drive shaft.


SERVICE BRAKE Figure 40-80-3
Description
There are two bleed screws located on each side of the

front axle differential housing.
1
Air trapped in the brake lines may cause a spongy feel
and/or delayed activation of the service brake. 2
Use the following procedure to remove air from the brake

circuit.
Bleeding The Brake Circuit
Lift and block the machine. (See “Procedure” on S2013
Page 10-10-1.)
Figure 40-80-4
NOTE: Position the jack stands to allow starting the
machine and driving the wheels.
Figure 40-80-1
1
2

S2014
Remove the caps and loosen the four bleed screws

1 (Items 1 and 2) [Figure 40-80-3] and [Figure 40-80-4].
S2043
NOTE: Hydraulic fluid will be forced from the bleed

Figure 40-80-2 screws during the following procedure:
With the aid of an assistant, start the engine, lower the

restraint bar and apply the service brake until a
continuous stream of clean hydraulic fluid, with no air,
flows from the inside bleed screws (Item 1) [Figure 40-
80-3] and [Figure 40-80-4]. Stop the engine and tighten
the two inside bleed screws.
Start the machine, engage the hydro stat and turn the
wheels until a continuous stream of clean hydraulic fluid,
1 with no air, flows from the outside bleed screws (Item 2)
[Figure 40-80-3] and [Figure 40-80-4]. Stop the engine
and tighten the two outside bleed screws.
S2048 Lower the machine and test for proper brake operation.
On machines with frame leveling the bleed screws are

accessible from (Item 1) [Figure 40-80-1] and [Figure
40-80-2] on each side of the pivot frame.


REAR AXLE Figure 40-90-2
Removal
Position the machine on the work surface.
WARNING
and possible death if proper medical treatment by a S7422
immediately.
W-2145-0290 Lift the rear of the machine and place jack stands under
the frame as shown [Figure 40-90-2].
Figure 40-90-1 Place a block in front and behind the front wheel [Figure
40-90-2].

Figure 40-90-3
S1978

90-1] to the right, to disconnect the power supply from S1955
the battery.
Drain the hydraulic reservoir. (See Replacing Hydraulic Remove the eight lug nuts and washers (Item 1) [Figure
Fluid on Page 10-100-2.) 40-90-3] from each rear tire.
Remove both rear tires.

REAR AXLE (CONT’D) Figure 40-90-6
Removal (Cont’d)
Figure 40-90-4
S1947

S1951 steering cylinder.
Figure 40-90-7
remove the rear fenders.

1
Figure 40-90-5
S1949

S1850
steering cylinder.
Remove the four bolts (Item 1) [Figure 40-90-5] and nuts

from the driveshaft.
IMPORTANT
damage the system.
I-2003-0888

Removal (Cont’d)
Figure 40-90-8
S1945
Remove the two bolts (Item 1) [Figure 40-90-10] from

S1950 the front mount bracket.
Figure 40-90-11
8].

Figure 40-90-9
1 1
1
S1943
Remove the two bolts (Item 1) [Figure 40-90-11] from

S1939 the rear mount bracket.
Install two jack stands (Item 1) [Figure 40-90-9] under

the axle.

REAR AXLE (CONT’D) Installation
Removal (Cont’d) Figure 40-90-13
Figure 40-90-12
S1934
S1936
Have an assistant balance the axle on the floor jack and

roll the axle under the frame [Figure 40-90-13].
Remove the jack stands from the axle.
Figure 40-90-14
Have an assistant balance the axle on the floor jack and

lower the floor jack slowly. Roll the axle out from under
the frame [Figure 40-90-12].
S1936
Raise the floor jack, lifting the axle upward and into
position [Figure 40-90-14].

Figure 40-90-15
1 1
P-44945
S1945
Install the two bolts (Item 1) [Figure 40-90-17] in the front

S1939 mounting bracket.
Figure 40-90-18
Install jack stands (Item 1) [Figure 40-90-15] under the
axle.
1

Figure 40-90-16
S1950
1
Plug the wire connector (Item 1) [Figure 40-90-18] into
S1943
the wire harness.
Install the two bolts (Item 1) [Figure 40-90-16] in the rear

mount bracket.

Figure 40-90-19
1
S1850
Install the driveshaft (Item 1) with four bolts (Item 2)

S1949 [Figure 40-90-21]. Tighten the bolts to 87 ft.-lb. (118
N•m) torque.
Install the hose (Item 1) [Figure 40-90-19] on the
Figure 40-90-22
steering cylinder.

Figure 40-90-20
S1951
Install the rear fenders (Item 1) with four bolts (Item 2)

[Figure 40-90-22].
Install the hose (Item 1) [Figure 40-90-20] on the
steering cylinder

REAR AXLE CONT’D) Figure 40-90-25
Figure 40-90-23
1
S1977

S1955
90-25] to the left, to restore the power supply from the
battery.
Install the rear tires with eight nuts (Item 1) [Figure 40-
90-23] and washers.

Tighten the nuts to 221 ft.-lb. (300 N•m) torque.
Figure 40-90-24
S7422
Raise the machine and remove the jack stands. Lower

the machine and remove the blocks from the front tire
[Figure 40-90-24].


MAIN FRAME
OPERATOR CAB (S/N A8HL12999 & BELOW, A8HP12999 & BELOW) . . . . . . . . . . . 50-10-1
OPERATOR CAB (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE) . . . . . . . . . . . . .50-11-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-11-1
CANOPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

BOOM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1

INNER BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-3

WEAR PADS (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1
WEAR PADS (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-61-1

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-61-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-61-1
ENGINE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1
AIR INTAKE COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-90-1

QUICK-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-100-1
REAR WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50-110-1

FENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-120-1
PIVOT LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-130-1


DASH COVER / STEERING COLUMN COVER (S/N A8HL12999 & BELOW, A8HP12999 &
BELOW, A8HK11001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-140-1
DASH COVER / STEERING COLUMN COVER (S/N A8HL13000 & ABOVE, A8HP13000 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-141-1
JOYSTICK PANEL (S/N A8HL12999 & BELOW, S/N A8HP12999 & BELOW, A8HK11001 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-150-1
JOYSTICK PANEL (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE) . . . . . . . . . . 50-151-1

OPERATOR CAB (S/N A8HL12999 & BELOW, Figure 50-10-3
A8HP12999 & BELOW)
1
Figure 50-10-1
P-50821
1
Remove the three screws (Item 1) from the access cover
(Item 2) [Figure 50-10-3] located on the back of the cab.
P-29315A
Remove the access cover.
Raise the boom and install the boom stop (Item 1) NOTE: Mark all hoses and electrical connectors for
[Figure 50-10-1].

Stop the engine. Figure 50-10-4
Figure 50-10-2
P-44577

P-29253 10-4].

10-2] to the right, to disconnect the power supply from
the battery.

A8HP12999 & BELOW) (CONT’D)
Figure 50-10-5
1 P-44930

7].
P-44578

10-5]. WARNING

Figure 50-10-6 Hydraulic fluid escaping under pressure can have
2 immediately.
W-2145-0290
1 IMPORTANT
P-44925 parts clean. Always use caps and plugs on hoses,
damage the system.
Loosen the screw (Item 1) and unplug the electrical I-2003-0888


1
Figure 50-10-8
1 1
P-44933
Remove the nut (Item 1) and ground wires (Item 2)

[Figure 50-10-10].
P-44931
Figure 50-10-11
Disconnect the five hydraulic hoses (Item 1) [Figure 50-

10-8].

Figure 50-10-9
1
1
2
P-44934
Remove the two wires (Item 1) [Figure 50-10-11] from

the fuel sending unit.
P-44932
Loosen the screw (Item 1) and unplug the electrical


Removal and Installation (Cont’d)

1
Remove the travel/signal levers. (See Removal And
Remove the instrument panel. (See Removal And

Remove the switch panel. (See Removal And Installation

on Page 60-90-1.)
Remove the dash cover/steering column cover. (See

P-53570A
Drain the radiator. (See Removal And Installation on

Page 70-50-1.) Remove the fuse box cover (Item 1) [Figure 50-10-13].
Figure 50-10-12 Open the engine cover.
Figure 50-10-14

1
1
P-25592
P-53571
Remove the heater hoses (Item 1) [Figure 50-10-12]
from the heater assembly.
Remove the side cover (Item 1) [Figure 50-10-14].

Figure 50-10-15 2
P-53574
Remove the bolt (Item 1) and plate (Item 2) [Figure 50-

10-17]. Remove the A/C hoses.
P-53572
NOTE: Plug the A/C hoses to prevent contamination.
Remove the cover (Item 1) [Figure 50-10-15]. Figure 50-10-18

If machine is equipped with air conditioning, remove the
refrigerant from the A/C system. (See Reclamation
Procedure on Page 80-100-1.)
Figure 50-10-16
1
1
P-53575
Loosen the mounting bracket bolt (Item 1) [Figure 50-10-

18].
P-53573
Temporarily remove the protective covering (Item 1)

[Figure 50-10-16] from the A/C hoses and expansion
valve.

Figure 50-10-19 1
P-44924
Remove the three hoses (Item 1) [Figure 50-10-21].
P-53585 Remove any necessary nylon ties.
Figure 50-10-22
Unplug the connector (Item 1) [Figure 50-10-19] located
under the fuse box.

Figure 50-10-20
P-44919
Remove the seven hoses on the right side of the cab

P-53576 [Figure 50-10-22].

Remove the two A/C hoses, heater hoses and harness
from the rear corner of the cab [Figure 50-10-20].

Figure 50-10-23
1
2
1
1
P-44936A
Remove the two screws (Item 1) from the access panel

(Item 2) [Figure 50-10-25]. Remove the access panel.
P-53603
Figure 50-10-26
Remove the engine speed control cable (Item 1) [Figure

50-10-23].

Figure 50-10-24
P-44935A
Install a hoist to lift and support the cab [Figure 50-10-

26].
P-53604

50-10-24] from the bracket.
Remove any necessary nylon ties, carefully remove the

speed control cable from the engine compartment and
into the cab.
NOTE: Adjust the engine speed control cable during

installation. (See Removal And Installation on
Page 70-20-1.)
Close the engine cover.

OPERATOR CAB (S/N A8HL12999 & BELOW, S/N Figure 50-10-29

1
Figure 50-10-27
2 2
P-49050
Remove the two bolts (Item 1) and rubber cushions (Item

2) [Figure 50-10-29].
P-44937A
Figure 50-10-30
Remove the cab mount bolt (Item 1) [Figure 50-10-27]

from the front of the cab.

Figure 50-10-28
1 P-44938A
Lift and remove the cab [Figure 50-10-30].
P-44920
Remove the grounding strap (Item 1) and rear mounting

bolt (Item 2) [Figure 50-10-28].

OPERATOR CAB (S/N A8HL13000 & ABOVE, Figure 50-11-3
A8HP13000 & ABOVE)
1
Figure 50-11-1
P-50821
1
(Item 2) [Figure 50-11-3] located on the back of the cab.
P-29315A
Raise the boom and install the boom stop (Item 1) NOTE: Mark all hoses and electrical connectors for
[Figure 50-11-1].

Stop the engine. Figure 50-11-4
Figure 50-11-2
P-44577

P-29253 11-4].

the battery.

A8HP13000 & ABOVE) (CONT’D)
Figure 50-11-5
1 P-44930
Unplug the electrical connector (Item 1) [Figure 50-11-7].
P-44578
Unplug the two electrical connectors (Item 1) [Figure 50- WARNING

11-5].

Figure 50-11-6 sufficient force to enter a person’s body by
immediately.
2 W-2145-0290
1
IMPORTANT
P-44925 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888


1
Figure 50-11-8
1 1
P-44933

[Figure 50-11-10].
P-44931
Figure 50-11-11
Disconnect the five hydraulic hoses (Item 1) [Figure 50-

11-8].

Figure 50-11-9
1
1
2
P-44934

the fuel sending unit.
P-44932


OPERATOR CAB (S/N A8HL13000 & ABOVE, If machine is equipped with air conditioning, remove the
A8HP13000 & ABOVE) (CONT’D) refrigerant from the A/C system. (See Component
Replacement And Refrigeration Leaks on Page 80-60-3.)
Figure 50-11-14
Remove the travel / signal levers. (See Removal And
Remove the instrument panel. (See Removal And 2

1

10-70-2.)
Figure 50-11-12
S36333
1
Mark and remove both A/C hoses (Item 1) [Figure 50-11-

14].

NOTE: Plug the A/C hoses (Item 1) [Figure 50-11-14]
to prevent contamination.
Remove the heater hose (Item 2) [Figure 50-11-14] NOT

connected to the heater valve (Item 3) [Figure 50-11-15].
Figure 50-11-15
P-97028

2
3
Figure 50-11-13
S36334
Remove the heater hose (Item 1) [Figure 50-11-15].
Remove bolt, nut and clip (Item 2) [Figure 50-11-15].
S36381

Figure 50-11-16
P-53576
Remove the two A/C hoses, heater hoses and harness

from the rear corner of the cab [Figure 50-11-18].
S36344
Figure 50-11-19
Unplug the connectors (Item 1) [Figure 50-11-16]

located under the dash cover.

Figure 50-11-17 1
P-44924
1 Remove the three hoses (Item 1) [Figure 50-11-19].
P-53575 Remove any necessary nylon ties.

17].

Figure 50-11-20
P-53604

P-44919
Remove the seven hoses on the right side of the cab into the cab.
[Figure 50-11-20].

Open the engine cover. installation. (See Removal And Installation on
Page 70-20-1.)
Figure 50-11-21
Figure 50-11-23
1
P-53603

P-44936A
50-11-21].


Figure 50-11-24
2
P-44920

bolt (Item 2) [Figure 50-11-26].
P-44935A
Figure 50-11-27
Install a hoist to lift and support the cab [Figure 50-11-

24].

1
Figure 50-11-25
2 2
P-49050
Remove the two bolts (Item 1) and rubber cushions (Item

2) [Figure 50-11-27].
P-44937A
Remove the cab mount bolt (Item 1) [Figure 50-11-25]

from the front of the cab.

OPERATOR CAB (S/N A8HL13000 & ABOVE,
Figure 50-11-28
P-44938A
Lift and remove the cab [Figure 50-11-28].

CANOPY Figure 50-20-3
Figure 50-20-1
P-50821
1

P-29315A (Item 2) [Figure 50-20-3] located on the back of the
canopy.
Raise the boom and install the boom stop (Item 1) Remove the access cover.
[Figure 50-20-1].

NOTE: Mark all hoses and electrical connectors for
Relieve hydraulic pressure. correct installation.
P-29253 P-44577
Rotate the battery disconnect switch (Item 1) [Figure 50- Unplug the two electrical connectors (Item 1) [Figure 50-
20-2] to the right, to disconnect the power supply from 20-4].
the battery.

CANOPY (CONT’D) Figure 50-20-7
Figure 50-20-5
1
P-44930

P-44578 7].

20-5].
WARNING

Figure 50-20-6
2 physician familiar with this injury is not received
immediately.
W-2145-0290
1
IMPORTANT
P-44925 clean the work area before disassembly and keep all
Loosen the screw (Item 1) and unplug the electrical damage the system.
connector (Item 2) [Figure 50-20-6]. I-2003-0888

Figure 50-20-8 1
1 1
P-44933

P-44931 [Figure 50-20-10].
Figure 50-20-11
Disconnect the five hydraulic hoses (Item 1)[Figure 50-
20-8].

Figure 50-20-9
1
2 1
P-44934

P-44932 the fuel sending unit.


Figure 50-20-12
P-53603
1 Remove the engine speed control cable (Item 1) [Figure

P-44924 50-20-14].
Figure 50-20-15
Remove the three hoses (Item 1) [Figure 50-20-12].

Remove any necessary nylon ties.
Figure 50-20-13
P-53604

P-44919
Remove the seven hoses on the right side of the canopy into the cab.
[Figure 50-20-13].
Open the engine cover. installation. (See Removal And Installation on
Page 70-20-1.)

Figure 50-20-16
1
P-44937
Remove the canopy mount bolt (Item 1) [Figure 50-20-

P-44935 18] from the front of the cab.
Figure 50-20-19
Install a hoist to lift and support the canopy[Figure 50-
20-16].

Figure 50-20-17
2
1 1
1
P-44920

P-44936 bolt (Item 2) [Figure 50-20-19].


Figure 50-20-20
P-44938
Lift and remove the canopy [Figure 50-20-21].

1 P-44921

20] from the canopy spring.

OPERATOR SEAT Figure 50-30-3
Figure 50-30-1
1
P-44527
1 Remove the two seat mount bolts (Item 1) [Figure 50-30-

P-44525 3] from both sides.
Remove the seat.

Figure 50-30-2

1
P-44526
Raise the seat mount cover (Item 1) [Figure 50-30-1] by

sliding the bottom edge of the seat mount cover to the
right to remove the cover retainers (Item 1) from the seat
frame (Item 2) [Figure 50-30-2].
NOTE: There are several retainers molded into the

bottom edge of the cover.


BOOM ASSEMBLY Figure 50-40-3
Remove the bucket positioning cylinder. (See Removal

Figure 50-40-1
P-29765
Place a wood block (Item 1) [Figure 50-40-3] under the

lift cylinder.
Figure 50-40-4
P-29763

Lower the boom onto adequate stands or blocks as
shown [Figure 50-40-1].
1
Figure 50-40-2
P-29764

40-4] from the lift cylinder.
S7421
Remove the rear cover (Item 1) [Figure 50-40-2] from

the machine.

BOOM ASSEMBLY (CONT'D) Figure 50-40-7
Figure 50-40-5
1
P-29563
1
Disconnect the light harness connector (Item 1) [Figure
P-29768 50-40-7]. (If Equipped)
Remove the lift cylinder pivot pin using a pin removal tool
(Item 1) [Figure 50-40-5]. Lower the cylinder onto the
IMPORTANT

block.
NOTE: For additional information on removing the lift

cylinder. (See Removal And Installation on When repairing hydrostatic and hydraulic systems,
Page 20-20-1.) clean the work area before disassembly and keep all
Figure 50-40-6 tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
Figure 50-40-8
P-44524
Disconnect the secondary auxiliary harness connector 1 1

(Item 1) [Figure 50-40-6]. (If Equipped) P-44522
Disconnect the six hydraulic hoses (Item 1) [Figure 50-

40-8] from the tubelines.

BOOM ASSEMBLY (CONT'D) Figure 50-40-11
Figure 50-40-9
1
2
P-29769
Remove the bolt (Item 1) and washer (Item 2) [Figure

P-29772 50-40-11] from the boom pin.
Figure 50-40-12
Install a lifting chain (Item 1) [Figure 50-40-9] on the front
of the boom.

Figure 50-40-10
P-29770
Remove the boom pin [Figure 50-40-12].

P-29773
Install a lifting chain (Item 1) [Figure 50-40-10] on the

rear of the boom.
Raise the hoist until the weight of the boom is supported

by the hoist.

BOOM ASSEMBLY (CONT'D)
Figure 50-40-13
P-29771
Lift and remove the boom assembly [Figure 50-40-13].

INNER BOOM Figure 50-50-3
Removal
Figure 50-50-1
1
P-29563
Disconnect the light harness connector (Item 1) [Figure

S7421 50-50-3].(If Equipped)
IMPORTANT

Remove the front wear pads. (See Removal And
Figure 50-50-2 When repairing hydrostatic and hydraulic systems,

damage the system.
I-2003-0888
Figure 50-50-4
P-44524
Disconnect the secondary auxiliary harness connector

(Item 1) [Figure 50-50-2]. (If Equipped)
1 1
P-44522
Disconnect the six hydraulic hoses (Item 1) [Figure 50-

50-4] from the tubelines.

INNER BOOM (CONT'D) Figure 50-50-7
Removal (Cont'd)
Figure 50-50-5
1 P-23876
2
Begin sliding the inner boom from the main boom. Before
2 P-29565 the inner boom is completely removed, position a hoist
and lifting strap on the inner boom. Carefully continue to
remove the inner boom completely [Figure 50-50-7].
Remove the bolt (Item 1) [Figure 50-50-5] from the
cylinder.

Loosen the rear wear pad adjusting bolts (Item 2) [Figure
50-50-5].
Figure 50-50-6
P-32000
Remove the extension cylinder mounting block (Item 1)

[Figure 50-50-6].

Installation
Figure 50-50-8
1
P-32000
Install the extension cylinder mounting block (Item 1)

P-23877 [Figure 50-50-10].
Figure 50-50-11
Apply grease to the inside top and bottom corners of the
main boom [Figure 50-50-8].

2
Figure 50-50-9
2
1
1
2 P-29565
Apply Loctite® 242 to the bolt and install the bolt (Item 1)
P-23876 [Figure 50-50-11] through the support pin and into the
cylinder. Tighten the bolt to 221 ft.-lb. (300 N•m) torque.
Install the end of the inner boom (Item 1) [Figure 50-50- Loosen the rear wear pad adjusting bolts (Item 2) [Figure
9] into the main boom approximately 2 ft. (610 mm). 50-50-11].
Install the front wear pads. (See Removal And Installation

on Page 50-60-1.)
Remove the lifting strap and slide the inner boom fully
into the main boom (Item 2) [Figure 50-50-9].

Installation (Cont'd)
Figure 50-50-12
P-44524
1 Reconnect the front auxiliary harness connector (Item 1)

1
P-44522 [Figure 50-50-14]. (If Equipped)
Adjust the wear pads. (See Removal And Installation on

Reconnect the six hoses (Item 1) [Figure 50-50-12] to Page 50-60-1.)
the tubelines.

Figure 50-50-15
Figure 50-50-13
1 S7421
P-29563
Install the rear cover (Item 1) [Figure 50-50-15].

Reconnect the light harness connector (Item 1) [Figure
50-50-13]. (If Equipped)

WEAR PADS (FRONT) Figure 50-60-3
Figure 50-60-1
1
1 2
P-23862
Remove the wear pad (Item 1) and inner support (Item 2)

P-23861 [Figure 50-60-3].
With both upper wear pads removed, use a hoist and

Extend the inner boom approximately 2 ft. (610 mm) and lifting strap at the end of the boom, apply upwards
mark the location of the inner supports and wear pads pressure, lifting the inner boom off the bottom wear pads.

(Item 1) [Figure 50-60-1].
Figure 50-60-4
Figure 50-60-2
2
1
1
1 P-23865
P-23860
Remove the bottom wear pads (Item 1) [Figure 50-60-4].

Remove the four bolts (Item 1) and two blocks (Item 2)
[Figure 50-60-2] from the boom.
Installation: Tighten the bolts to 58 ft.-lb. (43 N•m).


WEAR PADS (REAR) Figure 50-61-3
Removal
1
Figure 50-61-1
P-23878
Install the new wear pad (Item 1) [Figure 50-61-3].

P-23878
Figure 50-61-4
Remove the inner boom. (See Removal on Page 50-50-

1.)

With the inner boom supported, remove the wear pad
(Item 1) [Figure 50-61-1].
NOTE: Grease was removed for photo clarity.
Installation
Figure 50-61-2
3 P-23880
1
Apply grease to the wear pads [Figure 50-61-4].
Install the inner boom. (See Installation on Page 50-50-

3.) DO NOT hook up the hoses at this time.
2
P-23879
Loosen the adjustment screw (Item 1) until the adjusting

plate (Item 2) is flush with the wear pad retainer (Item 3)
[Figure 50-61-2].

WEAR PADS (REAR) (CONT’D) Figure 50-61-7
Installation (Cont'd)
Figure 50-61-5
1
P-44524
1
Connect the secondary auxiliary harness (Item 1)
P-29565 [Figure 50-61-7]. (If Equipped)
Figure 50-61-8
Turn the adjusting bolts (Item 1) [Figure 50-61-5]
equally, centering the inner boom inside the main boom.

Tighten the adjusting bolts to 29 ft.-lb. (39 N•m) torque.
Figure 50-61-6
1
P-29563
Connect the front auxiliary light harness connector (Item

1 1 1) [Figure 50-61-8]. (If Equipped)
P-44522
Install the rear cover.
Reconnect the hoses (Item 1) [Figure 50-61-6] to the

tubelines.

ENGINE COVER Removal And Installation
Gas Cylinder Removal And Installation Remove the gas cylinder.

1
S6854
Figure 50-70-3

1 1
S6852
Lift the engine cover [Figure 50-70-1]. Add a support to

prevent the cover from closing when the gas cylinder is
removed.
S6853
Remove the retainer clips (Item 1) [Figure 50-70-1] at
both of the ball joints ends. Remove the ball joints from
the ends. Remove the four hinge mounting bolts (Item 1) [Figure
50-70-2] and [Figure 50-70-3].
Remove the gas cylinder.
Remove the engine cover.
WARNING
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288


AIR INTAKE COWLING Figure 50-80-2
Figure 50-80-1 1
S4596
While supporting the air intake cowling remove the two

S4594 bolts (Item 1) [Figure 50-80-2].
Remove the air intake cowling.

Remove the bolts (Items 1 and 2) [Figure 50-80-1].


FUEL TANK Figure 50-90-3
Figure 50-90-1
1
1
P-29256
Drain the fuel from the fuel tank by removing the plug
P-29315A (Item 1) [Figure 50-90-3].
Figure 50-90-4
Raise the boom and install the boom stop (Item 1)
[Figure 50-90-1].
1

Remove the battery. (See Removal And Installation on
Page 60-20-1.)
Figure 50-90-2
2
P-50821
Remove the three screws (Item 1) and remove the

access panel (Item 2) [Figure 50-90-4].
P-29280A
Install a hoist to lift and support the cab [Figure 50-90-2].

FUEL TANK (CONT’D) Figure 50-90-7
Figure 50-90-5
1
P-42457
1 1
P-29250 the fuel tank.

Remove the two bolts (Item 1) [Figure 50-90-5] from the
cab spring. Figure 50-90-8

Figure 50-90-6
P-29257
P-29251
Support the fuel tank using a forklift or jack [Figure 50-
90-8].
fuel sending unit.
NOTE: Mark the wires for correct installation.

FUEL TANK (CONT'D) Figure 50-90-11
Figure 50-90-9
P-29253
1
Figure 50-90-12
P-29281
Remove the access panel (Item 1) [Figure 50-90-9].

Figure 50-90-10
P-29254
Remove the mounting bolts (Item 1) [Figure 50-90-11]

and [Figure 50-90-12] from the rear of the fuel tank.
P-29255

10] from the front of the fuel tank.

FUEL TANK (CONT'D)
Figure 50-90-13
P-29259
Carefully lower and remove the fuel tank [Figure 50-90-

13].

QUICK-TACH Figure 50-100-3
Figure 50-100-1
P-32153
Remove the pivot pin [Figure 50-100-3].

P-32251
Figure 50-100-4
Rotate the quick-tach forward fully.

Disconnect the couplers (Item 1) [Figure 50-100-1].
Figure 50-100-2
P-32155
1
Support the link as shown [Figure 50-100-4].
P-32152

100-2].

QUICK-TACH (CONT'D) Figure 50-100-6
Figure 50-100-5
P-32156
Remove the pivot pin [Figure 50-100-6].

P-32154
Remove the quick-tach.

100-5].

REAR WEIGHTS Figure 50-110-3
Figure 50-110-1
P-32286
Position a hoist as shown to lift and support the rear

S7421 weight [Figure 50-110-3].
Figure 50-110-4
1

Figure 50-110-2
1
1
P-50986
3
P-50972 Remove the two weight mounting bolts (Item 1) [Figure
50-110-4].
Unplug the tail light connector (Item 1) [Figure 50-110-2] Remove the weight.
from the main harness.
Remove the cross bar mounting bolt (Item 2) (both sides)

and remove the cross bar (Item 3) [Figure 50-110-2].
Installation: Tighten the bar to 188 - 210 ft.-lb. (255 - 285

N•m) torque.


FENDER Figure 50-120-2
Figure 50-120-1
1
S1951
Remove the four bolts (Item 1) from the fender mount

S1954 brackets (Item 2) [Figure 50-120-2].
Remove the fender.

Remove the eight lug nuts and washers (Item 1) [Figure
50-120-1] from the tire. Remove the tire. Installation: Tighten the bolts to 90-100 ft.-lb. (125-

140 N•m) torque.


PIVOT LINK Figure 50-130-3
Rotate the quick-tach back fully.
Figure 50-130-1
P-32150
Rotate the quick-tach forward until it is on the ground

[Figure 50-130-3].
P-32006 Figure 50-130-4

130-1] from the pivot.
1
Figure 50-130-2 1
1 2 P-29719
Remove the two mounting bolts (Item 1) and cover (Item

2) [Figure 50-130-4].
P-32007
Remove the pivot pin (Item 1) and lower the link (Item 2)
[Figure 50-130-2].

PIVOT LINK (CONT'D) Figure 50-130-7
Figure 50-130-5
P-32008
Place a floor jack under the pivot link [Figure 50-130-7].

P-32001
Figure 50-130-8

130-5].

1
Figure 50-130-6
P-32004

130-8].
P-32002
Remove the pivot pin (Item 1) [Figure 50-130-6] from the

tilt cylinder.

PIVOT LINK (CONT'D) Figure 50-130-10
Figure 50-130-9
P-32009
Lower the floor jack and remove the pivot link [Figure 50-
P-32005 130-10].


DASH COVER / STEERING COLUMN COVER (S/N Figure 50-140-3
A8HK11001 & ABOVE)


on Page 60-90-1.)
Figure 50-140-1
P-52330
Remove the screw (Item 1) [Figure 50-140-3] from the

right side of the dash.
Figure 50-140-4
1 1

1
P-52328
1
Remove the two screws (Item 1) [Figure 50-140-1] from

the center of the dash cover.
Figure 50-140-2
1 1
P-52331
1
Remove the four screws (Item 1) [Figure 50-140-4] from
1 the right side of the dash cover.
P-42835
Remove the two dash cover mounting screws (Item 1)

[Figure 50-140-2].

A8HK11001 & ABOVE) (CONT'D)
Figure 50-140-5
P-42845
1
1
the right side of the column cover.
P-52332 Figure 50-140-8
Remove the five screws (Item 1) [Figure 50-140-5] from

the left side of the dash cover.
Figure 50-140-6
P-42846

left side of the column cover.
P-52335
Lift and remove the dash cover [Figure 50-140-6].

A8HK11001 & ABOVE) (CONT'D)
Figure 50-140-9
P-42848
Remove the steering column cover [Figure 50-140-9].


A8HL13000 & ABOVE, A8HP13000 & ABOVE)


on Page 60-91-1.)
Remove the steering wheel. (See Removal And 1

Remove the signal / travel levers. (See Removal And

S36366
Figure 50-141-1
Remove the louver cap (Item 1) [Figure 50-141-3].
Figure 50-141-4
1
2

S36364
1
Remove the nut (Item 1) and knob (Item 2) [Figure 50-

S36372
141-1]
Figure 50-141-2 Remove the two screws (Item 1) [Figure 50-141-4].
1
2
S36365
Remove the nut (Item 1) and washer (Item 2) [Figure 50-

141-2]

(CONT’D)
Figure 50-141-5 1
1
2
S36368
Remove the louver cap (Item 1) [Figure 50-141-7].
Figure 50-141-8
S36367
Pull out the blower hose [Figure 50-141-5].

Loosen the retainer screw (Item 1) [Figure 50-141-5] 1
Remove the cap (Item 2) [Figure 50-141-5].
Figure 50-141-6
1
S36373
Remove the two screws (Item 1) [Figure 50-141-8].
S36371
Unplug the connector (Item 1) [Figure 50-141-6].

(CONT’D) 2
Figure 50-141-9
2 1
1
S36375
Remove the seven screws (Item 1) from the dash cover

(Item 2) [Figure 50-141-11].
S36369 Lift up the dash cover (Item 2) [Figure 50-141-11].
Figure 50-141-12
Pull out the blower hose [Figure 50-141-9].

Loosen the retainer screw (Item 1) [Figure 50-141-9]
Remove the cap (Item 2) [Figure 50-141-9].

1
Figure 50-141-10
S35374
Unplug the connectors (Item 1) [Figure 50-141-12] from

the dash cover.
Remove the dash cover.

S36370
Remove the two dash cover mounting plugs (Item 1)

[Figure 50-141-10].

(CONT’D)
Figure 50-141-13
1
2
S36376
Remove the five screws (Item 1) [Figure 50-141-13]

from the column cover.
Remove the column cover (Item 2) [Figure 50-141-13].

JOYSTICK PANEL (S/N A8HL12999 & BELOW, S/N Figure 50-150-3
A8HP12999 & BELOW, A8HK11001 & ABOVE)


on Page 60-90-1.)

1
Figure 50-150-1 1
P-52338
Remove the four bolts (Item 1) [Figure 50-150-3].
Figure 50-150-4
1

P-52336
Remove the fuse box cover (Item 1) and side cover (Item
2) [Figure 50-150-1]. 1
Figure 50-150-2
P-52339
Remove the joystick panel (Item 1) [Figure 50-150-4].
P-52337
Disconnect the frame leveling connector (Item 1) [Figure

50-150-2].


JOYSTICK PANEL (S/N A8HL13000 & ABOVE, Figure 50-151-3
A8HP13000 & ABOVE)

1 2
Figure 50-151-1
1 S36359
Remove three screws (Item 1) [Figure 50-151-3].
P-97028 Remove the joystick panel (Item 2) [Figure 50-151-3]

and place on its side.
Remove the fuse box cover (Item 1) [Figure 50-151-1]. Figure 50-151-4

Figure 50-151-2
1 1
2
1 1
1
S36360
S36358
Remove the screw (Item 1) [Figure 50-151-4].
Remove the four bolts (Item 1) [Figure 50-151-2]. Remove the temperature control knob (Item 2) [Figure
50-151-4].

JOYSTICK PANEL (S/N A8HL13000 & ABOVE, Figure 50-151-6
1
Figure 50-151-5
1
S36362
1 Mark and remove the connectors from the joystick panel

(Item 1) [Figure 50-151-6].
S36361
Remove the joystick panel.

Remove the temperature control (Item 2) [Figure 50-
151-5] from the joystick panel.

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SYSTEM INFORMATION (S/N A8HL12999 & BELOW, A8HP12999 & BELOW,
A8HK11001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
Fuses, Diodes And Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10-2
ELECTRICAL SYSTEM INFORMATION (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-11-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-11-1
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-11-2
Fuses, Diodes And Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-11-2
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-1
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-2
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20-3
ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-1

Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30-2
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-1
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-2
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-11
LATERAL OPERATOR RESTRAINT SYSTEM (LORS) . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1

Restraint Bar Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-1
Sensor Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-2
Strut Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-4
Strut Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-5
Restraint Bar Bushing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
Restraint Bar Bumper Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-50-6
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Rear Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-1
Front Light Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-60-2
TRAVEL / SIGNAL LEVER (S/N A8HL12999 & BELOW, A8HP12999 & BELOW, A8HK11001 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
TRAVEL / SIGNAL LEVER (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE) . . . . 60-71-1
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-80-1


SWITCH PANEL (S/N A8HL12999 & BELOW, S/N A8HP12999 & BELOW, S/N A8HK11001 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
SWITCH PANEL (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE) . . . . . . . . . . . . 60-91-1
BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
WIPER MOTOR (FRONT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-110-1

WIPER MOTOR (TOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-111-1

WIPER MOTOR (REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-112-1


PEDAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-120-1
INCHING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
SERVICE SOFTWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1

Connecting The Laptop Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
Entering The Service Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-2
Monitor Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-3
Warnings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-5
Calibrate Inch Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-6
Calibrate Creep Potentiometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-7
Program / Update Susmic Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-9
FRAME LEVEL SPEED SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-1
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-150-2

ELECTRICAL SCHEMATIC Printable Version Click Here
V723 (S/N A8HK11001 AND ABOVE)
(en A F4)
(Printed February 2008) 38-R
V-1024
Sheet 1 of 11 + BATTERY X190A (en A F7)
+ BATTERY + BATTERY
40A
1
R
F2 E22
70 A
X190B
56-R + CONTACT
50A + CONTACT
30
1
87
F1
400-A-G 400-A-G
85
86
50A XI305
056-R
XXXXX.X
9 ---
7,5 A
7,5 A
7,5 A
7,5 A
7,5 A
F3 5
41.0-A
38-R
R
CREEP
A
+ BATTERY F14 F19 F27 F22 F21
38-R
15/54
58 1 10
R
1 0 524005+------
6 76B-H-G 400-A-G
62-N
B
1 30 400-A-G
40-L
5
11-G-R
19 76-G/R
400-A-G
FUS.F28 >>
[D]
76B-H-G
37-B 37-B 7 50a XI401
9
231-B
C
96607.7
9 --- CREEPER
17 5
37-B See Page 2 of 11 POTENTIOMETER
84A-H-R
57.A-M
D
1/86
Work
3/30
10/20A
RS232
040-A
595-V
57.B-M
57.A-M
76.A-G/N CONTACT KEY R:1K
E8 DIAGNOSTIC 1 10
38-R
1 0
37-B
524005+------
4/87a
2 3 5 9
5/87
62-N
P
XM-AB
1/86 2/85
3/30
10/20A
11
76.A-G/N
10-L
See Page
[E]
4/87a
37-B 33.A-G-R
G
5/87
E9
2 of 11 G G
R:68R
R:68R
2/85 37-B >> C-DIODE D12
400-A-G
595-V
02-S-G
62-N
76-G/R
53-B/N
62-N
START XCG252
M
V
B
1
X28B
X28B
X28B
COLOUR SWF
RESERVE DE FREIN
POSITION SUR 6V DEUTSCH
B
R
(BRAKE RESERV)
COLOUR HOBBS 42 28 20 21 13 4
COLOUR HOBBS CANOPY

37-B
X50
M/N 15
-- 15 P
10A
(53a)
57.A-M
COLOUR SWF
53-B/N
1 32 10-L
38-R
37-B
06-G-V
04-M
2 R 5 11-G-R
86 F
70 A
30 N
596-V-M
57.B-M
1 2 R N F
05-L
400-A-G
400-A-G
400-A-G
31
M
V N
V
C
L
G
M
S
L
04-M
1
6 2 5 3 4
R2 06-G-V
60A-Z-N
87 85
57.B-M
14
X50
2
>> FUS.F10
D35 D36
27-B
75-A/V 75-A/V
See Page 3 of 11
2 62-N
29
62-N
74-M/N 74-M/N 3 15
24
040-A
07-M
R
231-B
R
X50
[A]
230-M-B
400-A-G
62-N
See Page
76.A-G/N 1/86
09-A
3/30
XI305
10/20A
3 of 11
6 9 16 08-G-V
See Page
596-V-M
230-M-B 040-A 040-A
[B] 3 of 11
40-L
6
P 7 8
4/87a
84B-A/B
5/87
74-M/N
19 X87
20
X87
18
06-G-V
2/85
84A-H-R
1/86 1 2
3/30
1 7 8
(LIGHT LOAD BATTERY) [C]
0
10/20A
10
478-L/N
47-Z/B
48-V/N
04-M
+
05-L
E10
X87
R
X87
21
33H-A-B
>> 86-13
X190D
57.B-M
See Page 3 of 11
1
38-R
(TACHOMETER)
27-B
AUTO
X28A
62N
4/87a
X28A
C
B
X28A
5/87
84A-H-R
P
BATTERY 12V
E14
2/85
07-M
86
70 A
85-S-N
30
09-A
24
X87
040-A
G
1/86
D--
3/30
33M-G-B
10/20A
V
08-G-V
[F]
62-N
D--
230-M-B
X27
C
R
54-S
R:510R
R:510R
33.E C/B
R1
4/87a
R
87 85
5/87
X27
A
XM-AB
E11
62-N
2/85
23
X87
X27
B
B+
9
D+
W
CONTROL PUMP GO
478-L/N
33M-G-B
X190D
62-N
84.C-A-B
3
- T
R
V
57-M
22
X87
XM-AB
/WATER TEMP.
47-Z/B
CAPTEUR VITESSE MOTEUR

8
230-M-B
X87
14
40-L
DEMARREUR
EV2
EV1
-
ALTERNATEUR
X--
478-L/N
X--
478-L/N
(STARTER)
(SPEED SENSOR)
48-V/N
(ALTERNATOR) PPU
M G
84-A-B
1
X--
PRECHAUFFAGE
(PRE-HEATING)
1 2 2 1
M P
B- PUMP. GO EV8 INCHING
STOP G.O. AV (FW) AR (R)
24
23
22
62-N
62-N
62-N
62-N
62-N
62-N
- GROUND 0V - GROUND
49.A-V-N : FIL N?49.A VERT-NOIR

EX: B-N BLANC (WHITE) (49.A-V-N : WIRE N ° 49.A GREEN-BLACK)
62-N : FIL N?62 NOIR
A BLEU CIEL (LIGHT BLUE) M MARRON (BROWN) (62-N : WIRE N ° 62 BLACK)
68.0-R : FIL N?68.0 ROUGE
B BLANC (WHITE) N NOIR (BLACK) NOIR (BLACK) (68.0-R : WIRE N ° 68.0 RED)
C ORANGE (ORANGE) R ROUGE (RED) EX: B/N 88:N? DU CONNECTEUR V-1024 (2/1/08)
G JAUNE (YELLOW) S ROSE (PINK) X88 (88:N ° CONNECTOR)
H 603
GRIS (GREY) of 913 V VERT (GREEN) 4 4:POSITION DU FIL
BLANC (WHITE) NOIR (BLACK) (4:WIRE POSITION)
L BLEU FONCE (DARK BLUE) Z VIOLET (PURPLE)
V-1025
Sheet 2 of 11
+ BATTERY + BATTERY + BATTERY
+ CONTACT ON + CONTACT ON + CONTACT ON
10 A
10 A
7,5 A
F13 F25 F28
[J] 233-Z
See Page 6 of 11
40.A-R
FUS.F17 >>
77A-C-L
(TO P BRAKE RESERV)
See Page 4 of 11
[D]
233-Z
595-V
See Page 1 of 11
408-G
402-B/R 402-B/R
402-B/R (DASHBOARD PRINTED CIRCUIT)
[G]
[L] See Page 3 of 11
XM-CD
4-XM-AB MODULE
408-G
1/86
3/30
9
10/20A
7-X251 >>
194.0-Z/B
OPTION
XI404
See Page 6 of 11
402-B/R
96604.4
9
4/87a
5
5/87
E21 2/85
VERT
GREEN + 235-A-V
234-V-B
1
0 10
-
77A-C-L
1 524005+596650
[H]
62-N
- + P 1/2
X190D
0 1
5
96593.9
XI103
Water Oil
FUS.F32 >>
9 ---
408-G
194.0-Z/B
3
Temp Temp
235-A-V
194.0-Z/B
XM-CD
XM-CD
10
12
XM-CD
XM-CD
XM-CD
XM-CD
XM-AB
6
3
S
Fuel
1 7
234-V-B
1 2 10
0
408-G 524149+596802
50-B
54-S
404-A-G
49-V-B
77-L/B
62-N
33.B-G-R
51-H/R
235-A-V
1/86 T
78-Z-N
3/30
10/20A
190-C-N
191-L-G
XI204
XM-CD
XM-AB
2
XM-AB
7
77-L/B
INVERS.VENTIL.
96596.2
9
80 ° C
--- 5
78-Z-N
E12 49.A-V-N 49.A-V-N

4/87a
5/87
402-B/R
OPTION
2/85
402-B/R
51.A-L/G 51.A-L/G
1 2 1 XVH102
X87
12
10
X50
X87
11
7
X50
1
X50
12
0
X50
X87
524010+593290
194-Z-G
15
X87
62-N
X50
402-B/R
8
62-N
X87 13
55-Z
402-B/R
594785
10
62-N
190-C-N
402-B/R
191-L-G
510-G
XVB102
62-N
X280
X87
62-N
49.A-V-N
51.A-L/G
6
49-V-B
1
51-H/R
Tach &
80 ° C
510-G
77-L/B
Hourmeter
194-Z-G
X40
594784
FILTER ON THE TANK

X29
C
B
X22
193-C-B
1
54-S
X281
h
1
T
CAPTEUR ROUES AV EN LIGNE

CAPTEUR ROUES AR EN LIGNE
62-N
X190D
(S) N
(S) N
T
4
OIL TEMP.
+M
+M
-L
-L
X87
X197
P
4
X50
10
7
33.B-G-R
X50
X87
X281
GO
X280
N:4 (7FILS)
2
50-B
2
54-S
PONT AV
X198
234-V-B
XM-CD
8
11
XM-CD
X151
N:4 (7FILS)
1
(D+ ALTERNATOR)
X146
See Page 1 of 11
OPTION
1
OPTION P
85-S-N
VIT.LENTE
1 2
77-L/B
193-C-B
78-Z-N
(SLOW FAN)
See Page 1 of 11
(W ALTERNATOR)
33-A-R
D11
+
X50
3
EV51 REVERSE
-
[E] 85-E8 >> 33.A-G-R
[C]
62-N
62-N
See Page
See Page 6 of 11
R
G-
.A-
X146
33 P
1 of 11
2
33-A-R
[B]
>> 6-X252
NOT USED
X143
D
EV52 EV58 EV6 EV7 [RD]
X151
62-N
62-N
See Page
62-N
X198 X197
62-N
2
62-N
N:7 (7FILS)
62-N
62-N
1 of 11
[K]
62-N
7 7
62-N
MASSE 0V MASSE 0V MASSE 0V MASSE 0V

C ORANGE (ORANGE) R ROUGE (RED) EX: B/N 88:N? DU CONNECTEUR
G JAUNE (YELLOW) S ROSE (PINK) X88 (88:N ° CONNECTOR) V-1025 (2/1/08)
H 604
Printable Version Click Here
ELECTRICAL SCHEMATIC
(en A F4)
(Printed February 2008) 38-R
V-1026
3 of 11
Sheet 1 + BATTERY X190A (en A F7)
+ BATTERY + BATTERY
40A
1
R
F2 E22
70 A
X190B
56-R + CONTACT
50A + CONTACT
30
1
87
F1
400-A-G 400-A-G
85
86
50A XI305
056-R
XXXXX.X
9 ---
7,5 A
7,5 A
7,5 A
7,5 A
7,5 A
F3 5
41.0-A
38-R
R
CREEP
A
+ BATTERY F14 F19 F27 F22 F21
38-R
15/54
58 1 10
R
1 0 524005+------
6 76B-H-G 400-A-G
62-N
B
1 30 400-A-G
40-L
5
11-G-R
19 76-G/R
400-A-G
FUS.F28 >>
[D]
76B-H-G
37-B 37-B 7 50a XI401
9
231-B
C
96607.7
9 --- CREEPER
17 5
37-B See Page 2 of 11 POTENTIOMETER
84A-H-R
57.A-M
D
1/86
Work
3/30
10/20A
RS232
040-A
595-V
57.B-M
57.A-M
76.A-G/N CONTACT KEY R:1K
E8 DIAGNOSTIC 1 10
38-R
1 0
37-B
524005+------
4/87a
2 3 5 9
5/87
62-N
P
XM-AB
1/86 2/85
3/30
10/20A
11
76.A-G/N
10-L
See Page
[E]
4/87a
37-B 33.A-G-R
G
5/87
E9
2 of 11 G G
R:68R
R:68R
2/85 37-B >> C-DIODE D12
400-A-G
595-V
02-S-G
62-N
76-G/R
53-B/N
62-N
START XCG252
M
V
B
1
X28B
X28B
X28B
COLOUR SWF
RESERVE DE FREIN
POSITION SUR 6V DEUTSCH
B
R
(BRAKE RESERV)
COLOUR HOBBS 42 28 20 21 13 4
COLOUR HOBBS CANOPY

37-B
X50
M/N 15
-- 15 P
10A
(53a)
57.A-M
COLOUR SWF
53-B/N
1 32 10-L
38-R
37-B
06-G-V
04-M
2 R 5 11-G-R
86 F
70 A
30 N
596-V-M
57.B-M
1 2 R N F
05-L
400-A-G
400-A-G
400-A-G
31
M
V N
V
C
L
G
M
S
L
04-M
1
6 2 5 3 4
R2 06-G-V
60A-Z-N
87 85
57.B-M
14
X50
2
>> FUS.F10
D35 D36
27-B
75-A/V 75-A/V
See Page 3 of 11
2 62-N
29
62-N
74-M/N 74-M/N 3 15
24
040-A
07-M
R
231-B
R
X50
[A]
230-M-B
400-A-G
62-N
See Page
76.A-G/N 1/86
09-A
3/30
XI305
10/20A
3 of 11
6 9 16 08-G-V
See Page
596-V-M
230-M-B 040-A 040-A
[B] 3 of 11
40-L
6
P 7 8
4/87a
84B-A/B
5/87
74-M/N
19 X87
20
X87
18
06-G-V
2/85
84A-H-R
1/86 1 2
3/30
1 7 8
(LIGHT LOAD BATTERY) [C]
0
10/20A
10
478-L/N
47-Z/B
48-V/N
04-M
+
05-L
E10
X87
R
X87
21
33H-A-B
>> 86-13
X190D
57.B-M
See Page 3 of 11
1
38-R
(TACHOMETER)
27-B
AUTO
X28A
62N
4/87a
X28A
C
B
X28A
5/87
84A-H-R
P
BATTERY 12V
E14
2/85
07-M
86
70 A
85-S-N
30
09-A
24
X87
040-A
G
1/86
D--
3/30
33M-G-B
10/20A
V
08-G-V
[F]
62-N
D--
230-M-B
X27
C
R
54-S
R:510R
R:510R
33.E C/B
R1
4/87a
R
87 85
5/87
X27
A
XM-AB
E11
62-N
2/85
23
X87
X27
B
B+
9
D+
W
CONTROL PUMP GO
478-L/N
33M-G-B
X190D
62-N
84.C-A-B
3
- T
R
V
57-M
22
X87
XM-AB
/WATER TEMP.
47-Z/B
CAPTEUR VITESSE MOTEUR

8
230-M-B
X87
14
40-L
DEMARREUR
EV2
EV1
-
ALTERNATEUR
X--
478-L/N
X--
478-L/N
(STARTER)
(SPEED SENSOR)
48-V/N
(ALTERNATOR) PPU
M G
84-A-B
1
X--
PRECHAUFFAGE
(PRE-HEATING)
1 2 2 1
M P
B- PUMP. GO EV8 INCHING
STOP G.O. AV (FW) AR (R)
24
23
22
62-N
62-N
62-N
62-N
62-N
62-N
- GROUND 0V - GROUND

C ORANGE (ORANGE) R ROUGE (RED) EX: B/N 88:N? DU CONNECTEUR V-1026 (2/1/08)
H 605
V-1027
Sheet 4 of 11
+ BATTERY + BATTERY
+ CONTACT + CONTACT
64.A-G
[N] 9-XI201 >> STOP
15 A
15 A
10 A
10 A
10 A
7,5 A
7,5 A
XI202
See Page 3 of 11 96601.0
5 9
F2 F1 F17 F7 F18 F29 F30

R
79.A-S-N
8 1 ---
721.T-H-N
10
1 029-R
SWITCH WITH BLUE LIGHT

0
721AR-A
038-R
[R]
>> 30-E13
524005+596473
25.0-G-R
022-B
>> 1-XSTOP
62-N
409-G 409-G 409-G

ORIGINAL SWITCH
OU (OR) See Page 3 of 11
See Page 3 of 11
233-Z
192-A/N
>> 30-E21
25.1-G-V
64.A-G
XI504
25.1-G-V
OPTION LIBRE
FREE OPTION
96591.3
5 9
2501-G-R
[Q]
192-A/N 192-A/N
721.T-H-N
See Page 2 of 11
192-A/N 192-A/N 1 10 66500.0
XI202B 1 0
524005+596426
79923.9
3 9 66501.8
721AR-A
72.AR-V
XI304 XI303
410-A-B
[J]
96598.8 96599.6
9 --- --- 9
3 4 4 3
0 1 5 10
2 1 511031+596473
72T-L-G
62-N
721T-H-N
524115+594769
25.5-B 1 7 2 8 8 2 7 1 2 1 0
1 2 10 10 2 1 2 7 9
0 524058+596301 524058+596154
0 ---
721T-H-N
25.1-G-V
187-H-N
188-S-G
189-R-V
186-R-N
62-N
62-N
25.0-G-R
79.A-S-N
25.1-G-V 5 10
96602.8 4
2501-G-R 176-L/B XI301
524024+596307
2501-G-R
0 1
73AR-L
9 7 1
XI002 176-L/B
X87
96591.3
2501-G-R
5 9
3
X87
721AR-A
72.AR-V
4
X87
X87
X87
X276
1
2
1
5
25.5-B
25.1-G-V
---
10 5 96603.6
89AR-Z-B
XI302
(IN RESERVE)
1 10 66500.0
62-N
0
176-L/B
1
187-H-N
186-R-N
188-S-G
524005+596426
1/86 1/86 1/86

3/30
3/30
3/30
10/20A
10/20A
10/20A
72T-L-G
189-R-V
62-N
71T-L-B
79-Z
E4 OPTION
E2 E1
4/87a
4/87a
4/87a
BLEU (BLUE)
5/87
5/87
5/87
038-R
2/85 2/85 2/85
X150
X150
X150
X150
X150
3
1
62-N
62-N
62-N
721AR-A
89AR-Z-B
25.C-G-V
72.AR-V
73AR-L
62-N
176-L/B
25-G-V
72T-L-G
(EX: VISUAL RADIO)
71T-L-B
25.6-B
25.B-G
25.6-B
721T-H-N
62-N
XALCIG
XALCIG
X--
79-Z
1
62-N
2
X89
10
(REAR OPTION)
X90
10
X90
3
X89
X90
9
13
X89
XLAVEG1
14
00-B
XLAVEG1
X90
X90
X90
11
5
2
X90
6
X90
2
X90
X30
40-A
X90
721-H-N
71-L-B
62-N
X106
62-N
72-L
1
X107
REAR AUX. WASHER

25-G-V
25.C-G-V
M
25.B-G
00-B
25.6-B
( EV13 )
25.6-B
X21
X21
3
X20
X20
-
25-G-V
-
79-Z
X20
-
X21
X20
187-H-N
X21
1
2
-
188-S-G
186-R-N
189-R-V
N
G
V
R
(-)
N
(+)
WIPER WIPER
FRONT RIGHT CAB
ROOF REAR
FRONT LEFT CAB
M
FLASHING LIGHT
REAR LEFT CAB
REAR LEFT CAB
M M
BLUE LIGHT
BLUE LIGHT
RESERVE
62-N
EV11 EV12 EV10 EV9
62-N
62-N
62-N
62-N
62-N
62-N
62-N
X30
X107
X106
X150
X150
X150
X150
X150
2
2
10
8
6
- GROUND - GROUND

G JAUNE (YELLOW) S ROSE (PINK) X88 (88:N ° CONNECTOR) V-1027 (2/1/08)
H GRIS (GREY)
606 of 913 V VERT (GREEN) 4 4:POSITION DU FIL
V-1028
Sheet 5 of 11
+ BATTERY + BATTERY
+ CONTACT + CONTACT
See Page
Not used for this

[T]
[S]
6 of 11
056-R
machine
NOT USED FUS.F31 >>
20 A
7,5 A
-
X221
1
[P] 600-M-B
1-1-X198 >>
FUS. F24 >>
See Page 3 of 11
537-S
X87B
X87B
F26 F15
1
537-S
94-H-R 94-H-R
900-R-C
X147
COMPRESSEUR
[U]
2
405-B-G
+NACELLE=AMA+SECU AVAR
VENTIL.CLIM.
602-H-L
X270
>> 16-X87
600-M-B
+TREUIL=AMA(RADIO)
20 A
10
7,5 A
X221
See Page 8 of 11
X147
1
F02 F01
X193
X193
900-R-C
INFO STAB 2 SEUILS
1
-R-
-R-
X197
X197
<25 ° =+12V(X193-2)
-H-R-
8
9
X270
10
XI253
- B
X87B
X87B
2 1
8
9
405-B-G
30 86
NOT USED
-
E17 VENTIL.CLIM.
568-A-V
See Page 3 of 11
20/30 A
NOT USED
NOT USED
>> 86-E20
+ [V] 4 3
560-Z-B
561-A-V
3 C H
M L
2 1 0 See Page
X193
X193
4
2
87a 87 85
8 of 11 and 9 of 11
XCEC
XCEC
XCEC
XCEC
90-L-R
7
9
2
91-C-B
603-B-N
-N-
911-C
601-R-G
[M]
*-*-*
>> DIODE D33
[W]
-H-
See Page
601-R-G
X87B
FUS.F20 >>
603-B-N
*-*-*
- B
8 of 11 and 9 of 11 4
XCEC X87B
601-R-G 601-R-G
Dealer Copy -- Not for Resale 5 2
3
1 0
C H
M L Wiring is on machine, but option
543-R-C
2
NOT USED
not available for this model.
-R-
XCEC >> 5-X252

[Z] See Page 6 of 11
-C-
532-L/G
-B-
-G-
4 NOT USED
-G-V- -G-V-
XCEC >> 4-X252
86 3
518-R/N OK CEC
[AA] See Page 6 of 11
E16 COMPRES.
30
20/30 A
XCEC >> DIODE D34

565-M SHUNT CEC 565-M
8 565-M [X] See Page 8 of 11 and 9 of 11
-B-
E19
-C-
-G-
87a 87 85
X222
X222
-L-
-V-
911-C
323-G
1
90-L-R
XCEC
XCEC
See Page
XCEC2
X222
10
XCEC2
X222
1
6 of 11
1
5
2
2
[R]
91-C-B
565-M
[Y] See Page 8 of 11 and 9 of 11
BUZZER RADIO
11
X50
-L-
>> 11-X252
403-R-C
62-N
X55
THERMOSTAT
NOT USED
323-G
4
X55
X55
X87C
4
T(x ° )
FUS.F23 >>
(FOR RADIO)
X55
2
C
X87B
403-R-C
10
X87B
518-R/N
-V-
11
N
R
3C
G
X152
1
X220
ACCELERATEUR RADIO
NOT USED
2
540-V-B
541-C-L
NOT USED
HVAC
MOTOR
-V-N-
M
COMPRESSOR
M
X222
519-B/N
X197
4
X197
6
5
-V-N-
N.6 7FILS N.5 7FILS

X220
X198
X198
-N-
1
PRESSURE
5
X87C
SWITCH
BUZZER RADIO
1 3
N.6 7FILS N.5 7FILS
P
X87C
534-V/B
X147
X147
3
3
X152
2 (FOR RADIO)
4
535-A/N
X220
-N-
3
62-N
X87C
519-B/N 519-B/N
-N-
1
- GROUND - GROUND

G S X88 (88:N ° CONNECTOR)
V-1028 (2/1/08)
JAUNE (YELLOW) ROSE (PINK)
H 607 of
GRIS (GREY) 913 V VERT (GREEN) 4 4:POSITION DU FIL
88:N? DU CONNECTEUR
49.A-V-N : FIL N?49.A VERT-NOIR X88 (88:N ° CONNECTOR)
V723 (S/N A8HL11001 AND ABOVE) EX: B-N BLANC (WHITE) (49.A-V-N : WIRE N ° 49.A GREEN-BLACK)
4 4:POSITION DU FIL
V723 (S/N A8HP11001 AND ABOVE) A M (62-N : WIRE N ° 62 BLACK)
(4:WIRE POSITION)
BLEU CIEL (LIGHT BLUE) MARRON (BROWN)
V723 (S/N A8HK11001 AND ABOVE) B BLANC (WHITE) N NOIR (BLACK) NOIR (BLACK)
(68.0-R : WIRE N ° 68.0 RED)
(Printed February 2008) C ORANGE (ORANGE) R ROUGE (RED) EX: B/N
V-1029 G JAUNE (YELLOW) S ROSE (PINK)
Sheet 6 of 11 H GRIS (GREY) V VERT (GREEN)
Printable Version Click Here L BLEU FONCE (DARK BLUE) Z VIOLET (PURPLE)
BLANC (WHITE) NOIR (BLACK)
43.E-V-B 43.E-V-B
**--**--** **--**--** **--**--**

X197 X87B
F31 + CONTACT + CONTACT
537-S 537-S
10 A
7
>> 5-XI502
517A-C-B 517A-C-B
[AD]

537-S >> 10-X270
[S]
F16
NOT USED A-F16
43.E-V-B
See Page 8 of 11
See Page 8 of 11
3A 43A-B-N
15 A
7,5 A
See Page 5 of 11 >> 86-E12
and 9 of 12
[G]

[AC] See Page 8 of 1
524063+594411
and 9 of 11
9
6911728
CONTROL
STOP See Page 2 of 11 F23 F32
4 3 43.B-M-B
177-B-N
194.0 Z/B
404-A-G
[H]
43.E-V-B
5-XI204 >>
3-TELESCOPE 4-TOOL 1/86
8 2 7 1
3/30
403-R-C
[AA] See Page 5 of 11
10/20A
HALL See Page 2 of 11
XI104 XI402
10 2
0
1
730-L-B
E5
511238+596653
62-N
[AB]
403-R-C
78892.7
536-R-G
43.B-M-B 43.B-M-B
4/87a
5/87
517-C
2/85
**--**--**
10
PNP
NPN
POUSSOIR 7
POUSSOIR 8
9
(BAS)
43.E-V-B
8
11-X272 >>
HALL
G
R
See Page 5 of 11
2
6
4-X87C >>
XI403
(WHITE)
ROUGE 5V
ROUGE 5V
3 0V GROUND
730-L-B
(WHITE)
See Page 5 of 11
9
(8-XCEC >>)
82077.9
177-B-N
(BLUE)
(BLUE)
SIGNAL
(BLUE)
4 3
(BLUE)
7
403-R-C
(RED)
(RED)
177-B-N
1
518-R/N 3-XCEC >>
X231
X231
X231
X231
X231
X231
[Z]
X231
X231
[R]
OK=+12V
>> 5-X285
7
1
9
10 8 2 7 1 2 1
0
X241
0
X241
565-M DIODE D34 >>
532-L/G 4-XCEC >>
X231
2
1
511053+596230
79924.7
8
730-L-B
584-A-N
OK TELESCOP.
43.E-V-B
195-H/N
1
NOT USED
43.B-M-B
194.0 Z/B
de 0.5V a 4.5V
SHUNT CEC
de 0.5V a 4.5V
536-R-G
XM-CD
62-N
33-A-R
1220-R
177-B-N
1210-L
[K]
1
**--**--**
-DIODE D12 >>

BLEU
See Page 2 of 11
X252
X252
X252
X252
X252
X252
**--**--**
X252
X87B
11
2
6
8
1
X251
X251
X251
X251
X251
X251
X251
12
2
3
7
1
**--**--** **--**--** **--**--** Dealer Copy -- Not for Resale
X197
X197
3
2
OK CEC
B M
730-L-B
**--**--**
SHUNT (LORS)
D33
6
1
2
AMA
530-G/N
883-Z-N
ON Position 2 or OFF Position 1
(X251)
(X233)
D32
X87B
6
**--**--**
X87B
D27 12V
531-V-N
**--**--**
530-G/N
K16
K15
X252
OFF
ON
5
10
E2 E1
B0 B1 B2
390 OHMS
390 OHMS
390 OHMS
2
D28 D2
390 OHMS
3 1
OK MONTEE MANIP
K10
(OK LIFT)
CONTACTS"OR"
1 3
K23 5 4 1
5 4 2
K12
5 4 1
OFF
K11 BIS
730-L-B
ON
**--**--**
1000 OHMS
**--**--**
K1
X252
3 2 1000 OHMS
OFF
9
ON
2 4 5 F2 F1
OFF
3 2
AXE5 AUXILIARY
4.5V 0.5V
ON
Also See Page 7 of 11 OU

RELIEF
D26
C1 C2 D2 D1
K20
TREUIL
D31
OK DESC.(DOWN)
(WINCH) TEST
18
16
17
**--**--** **--**--**
3
(X184)
CONTACTS"OR"
CONTACTS"OR"
CONTACTS"OR"
OK MONTEE
1 4 5 1 4 5 5 4 1
SORT.TEL.
K21
(OK LIFT)
X184
X184
X184
X184
16
17
18
EV85
3
K22
2 3 2 3 3 2
K--
(TELESCOP OUT)
16
17
18
AXE3 AXE4
D23
D24
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
X184
10
11
12
13
14
15
4
PIN LOCATIONS
See Page 7 of 11
4
X252
10
11
12
14
15
3
ROUTE
511-M
XVH101
SECU MANIP
4 3 4 3
S (+) 5V (+)
5V S
1 1
(-) 2 (-) 2
V-1029 (2/1/08)
608 of 913 (EV14) ELECT/SX14/RR ELECT/SX14/RR
EVP4
EV3
EVP3
TELESCOPE. TOOL
V-1030
Sheet 7 of 11
F1
X251
K11BIS
K1
K21
K22
K20
L1
K15
F2 F1
OFF
ON
12345678 C2 C1 D2 D1 B0 B1 B2
OFF
OFF
K16
ON
ON
P1
1 2
X184 X184
P2 X241
X252
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X233
POSITION-1
POSITION-2
1 2 3 4
987654321
MESURE
K12
1 2 3 4
K23 K10 K3
OFF
SHUNT AMA
E2 E1
ON
X231
OK MONT
OK DESC
GND-K10
OK CEC
X252-6
MANIP
AXE5
AXE4
4-GND
AXE3
JP1
12V
JP2
3-AXE5
2-AXE4
1-AXE3
CONNECTOR LOCATIONS

H GRIS (GREY) V VERT (GREEN) 4 4:POSITION DU FIL V-1030 (2/1/08)
609 of L BLEU FONCE (DARK BLUE)
913 Z VIOLET (PURPLE)
V723 (S/N 367812001 AND ABOVE)
V723 (S/N 368012001 AND ABOVE)
V723 (S/N 368112001 AND ABOVE)
V-1031 + BATTERY + BATTERY
Sheet 98 of 11
+ CONTACT + CONTACT
-**- -**- -**- -**- -**-
<25 ° =+12V
***
-**-
3-XCEC >>
***
2-XI104 >> 518-R/N
See Page
[AD]
517A-C-B
[AC] OK=+12V 565-M SHUNT CEC 565-M
[Y] See Page 5 of 11, 6 of 11,
5 of 11
-**-
>> 11-X252
See Page 6 of 11 D34 565-M SHUNT CEC 7 of 11 and 8 of 11
>> 4-X252
See Page 6 of 11 X285 X285
[U] See Page 5 of 11

XI502
-- 9 6 5 --
6 5
518-R/N
[AE]
8-XCEC >>
[X] See Page 5 of 11, 6 of 11,
7 of 11 and 8 of 11
[Y]
See Page 7 of 11 605-H
610-V/B
D33 601-R-G
10 8 2 7 1 0 1 X285
>> 5-XCEC [W] See Page 5 of 11
2-X87B >>
601-R-G 601-R-G 601-R-G 601-R-G
601-R-G
4
** ** **
516A-A 516-A-B 516-A-B
-**-
516A-A
516-A-B 516-A-B 516-A-B
X522
517A-C-B
NO SHUNT E15
1
605-H
X272
X272
7
1
FUS.F15 >>
X522
-**-
516-A-B 516-A-B
***
516A-A
2 *** -**- -**-
X87
516A-A
516A-A 1/86
3/30
X272
10/20A
X285 606-B
8
1
610-V/B
512-M-N 512-M-N
SHUNT
405-B-G
4/87a
5/87
X285
-**-
606-B 2/85
513-G-R 513-G-R E20
2
512-M-N 512-M-N
X272 -
516A-A
-**- -**- -**- 2 -**- + -**-
512-M-N
X196
2
Without Frame Leveling
590-B-R
513-G-R 513-G-R
516A-A X272
512-M-N
516A-A 513-G-R 513-G-R

3
For Models With Frame X265 X196
--
3 4 9
XI501
--
--
3 4 9
XI503
-- Dealer Copy -- Not for Resale
Leveling - See Page 8 of 11. 2
88-Z/N
X272
1 2 1 2 583-G/R
0 1 7 2 8 10 0 1 7 2 8 10
62-N 4
62-N
610-V/B
508-B-M
502-V-M 505-V
516A-A
504-S
508-B-M
516A-A
X272
516A-A
610-V/B 610-V/B 582-B-M
583-G/R
503-H-G
582-B-M
5
508-B-M
502-V-M
610-V/B 610-V/B
XI601
3/30
20/30A
1/86 9 --
-- 4 3 X265
887-L-R
3/30
3/30
10/20A
10/20A
590-B-R
1/86 1/86 1
4/87a
E16 E17 E18

5/87
X272
887-L-R
887-L-R
10 8 2 7 1 2 1
2/85 6
4/87a
4/87a
0 X272
5/87
5/87
--
62-N
2/85 2/85 11
887-L-R
OK TELESCOP.
X271
3
X266
504A-S-N
503-H-G
1
502A-V-B
501-V-N
505-V
584-A-N
590-B-R
86-C X272
87-G
10
See Page 6 of 11
4-X252 >>
X270
X270
X270
X270
X270
X271
2
and 8 of 11
3
5
X271
534-V/B
X272
12
[AB]
EV17 EV21 EV72 XM-AB -
X266
10
2
3,5%
62-N
X270
EV71
X270
X270
X271
62-N 62-N
6
62-N
8
7
EV73
X271
4
EV19 EV18 EV22
62-N 62-N 62-N 62-N
- GROUND - GROUND

H 610
GRIS of 913
(GREY) V VERT (GREEN) 4 4:POSITION DU FIL
V-1031 (2/1/08)
V-1032
9 of 11
Sheet 7
F1
X251
K11BIS
K1
K21
K22
K20
L1
K15
F2 F1
OFF
ON
12345678 C2 C1 D2 D1 B0 B1 B2
OFF
OFF
K16
ON
ON
P1
1 2
X184 X184
P2 X241
X252
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
X233
POSITION-1
POSITION-2
1 2 3 4
987654321 Dealer Copy -- Not for Resale

MESURE
K12
1 2 3 4
K23 K10 K3
OFF
SHUNT AMA
E2 E1
ON
X231
OK MONT
OK DESC
GND-K10
OK CEC
X252-6
MANIP
AXE5
AXE4
4-GND
AXE3
JP1
12V
JP2
3-AXE5
2-AXE4
1-AXE3
CONNECTOR LOCATIONS

H GRIS (GREY) V VERT (GREEN) 4 4:POSITION DU FIL V-1032 (2/1/08)
611 of 913
V-1033
Sheet 10 of 11
Ex: XI104
XI1-- XI2-- XI3-- XI4-- XI5-- 6912479
7,5 A 28 1A 12
GREEN
XI--4
32
16
VERT
XI601 17 16
7,5 A 27 21 14 7 1A 11 P
02
01
15 A
3A
R
20 A
20 A 26 7,5 A 10
7,5 A
XVH102
XI--3 20 13 6
10 A 25 7,5 A 9
OPTION
!
1 2
31
15
7,5 A 24 7,5 A 8
XI--2
19 12 5
10 A
7,5 A
10 A 23 OPTION 10 A 7
BLUE
BLEU
XI--1
Work
7,5 A 22 15 A 6
18 11 4
15
OPTION
7,5 A 21 7,5 A 5
30
14
AUTO
XVB101
Ex: XI501
7,5 A
7.5 A
15 A 20 17 10 3 15 A 4
RADIO
7,5 A 19 10 A 3
START KEY
START
YELLOW-GREEN C B GREY
R STOP
16 9 2
10 A 18 15 A 2
29
13
ORANGE H L WHITE
X273
M
7,5 A 17 P 15 A 1
10 A
10 A
YELLOW
XCEC (12V) + XCEC2 (2V)
15 8 1
Connector Number
No. of pins CONNECTIONS XX YY LOCATION
X20 4V 11/REAR WIPER CAB ROOF

X21 4V 11/ROOF WIPER CAB ROOFT
71 X28A 3V 1/14 CAB.AXE PEDAL
X28B 3V 1/CREEP OPTION CONSOLE
X50 12V 1/6 BELOW FUSE BOX **
Dealer Copy -- Not for 73

Resale X55 4V 1/HEATER BELOW FRONT CONSOLE
70 X56 6V 1/WINDSHIELD WIPER BELOW FRONT CONSOLE
X222
X87B 12V 1/5 BELOW FUSE BOX **
6V 4V 1/5 BELOW FUSE BOX
X87C **
X89 24V 1/4 BELOW FUSE BOX
X90 **
X241 2V 11V 1/11
11V X90 CAB SIDE FUSE BOXE
P
X2 X190A 1V 1/6 BELOW FUSE BOX **

72
B X2 X190B 1V 1/6 BELOW FUSE BOX **
TA 70
TS 12V
XCD251+XCD254
X2 X190D
SH
UN X285 1 71
6V 1/6 BELOW FUSE BOX **
Water
Temp
X252 12V 6V X220 3V 71/72 SIDE FUSE BOX **

12V
1
X231 X8 X1 SH X221 2V 1/71 SIDE FUSE BOX

84
12V X251 X8
7 C 6V UN
T 11
7B 92 X222 6V 71/73 REAR OF CAB
Fuel
1/2
OPTION CREEPER 8V TO
3 X8 4V 18V 93 ST
X231 12V 70/JOYSTICK SIDE FUSE BOX
X28B 7
S
TOAB X241 2V 70/LORS LEFT SIDE OF CAB

0
12V L .H
3V X8 62 EVE AR
NE X251 8V 1/70 CAB CENTER
X2 9 24V LH SS
2 1 A
(TO DISTRIBUTOR) RN X252 12V 1/70 CAB CENTER
Hourmeter
ES
2V 5
Tach &
24V S X270 12V 1/.. BELOW FUSE BOX

IC
h
ST X1
NO X1 90A X5 (TO MACHINE HARNESS) X271 6V 1/.. BELOW FUSE BOX
3,5%
AG 1V X1 90D 0
DI 90
B
1V 4 X272 12V 1/.. BELOW FUSE BOX
X276 6V 12V
X276 1V 1/..OPTION (NOT USED) SIDE FUSE BOX
X2 1V (TO LIGHTING HARNESS)
20 X285 6V 1/SHUNT STAB. SIDE FUSE BOX
6
3V
X28A
P (TO ENGINE HARNESS)
72 X20
3V 4V
XCG252
14 (TO CLIMATE HARNESS)

Temp
X21
Oil
4V
+
-
XI002 73
X56
6V
X241
XI001 2V
CANOPY MODELS ONLY

AUTO
(TO CLIMATE HARNESS)
X55
4V
CAB ELECTRICAL CONNECTIONS
612 of 913
V-1033 (2/1/08)
V-1034 12V FRAME LEVELING
Sheet 11 of 11 ) X197
SPEED SWITCH
OM
BO X322
G 3V
IN
IR
Printable Version Click Here (W
82
Connector Number
CONNECTION XX YY LOCATION
Number Of Pins
X001 4V UNDER FUSE BOX 81

X22 2V 6/HYD. OIL PRESSURE HYDRAULIC RESERVOIR
X27 3V 5/SPEED SENSOR MOTOR **
X29 3V 5/REAR AXLE SENSOR REAR AXLE **
X30 2V 4/15 LEFT REAR EXTERIOR ** X39
X193 6V
X33 6V 4/7 FRONT OF MACHINE BY AXLE **
4V
X34 6V 4/8 FRONT OF MACHINE BY AXLE **
X196
X35 6V 4/LEFT REAR LIGHT LEFT REAR OF MACHINE
2V
X36 2V 4/9 LEFT REAR OF MACHINE
X38 2V 4/BACK UP ALARM RIGHT REAR OF MACHINE
X39 6V 4/RIGHT REAR LIGHT RIGHT REAR OF MACHINE
X40 3V 5/FRONT AXLE SENSOR FRONT OF MACHINE BY AXLE
X38 2V
X50 12V 1/6 UNDER FUSE BOX
X87 24V 1/5 UNDER FUSE BOX
X87B 12V 1/5 UNDER FUSE BOX
9
X87C 4V 1/5 UNDER FUSE BOX X30
2V
X89 24V 1/4 UNDER FUSE BOX 4
X106 2V 4/56 FRONT OF MACHINE BY AXLE ** X35
X107 2V 4/57 FRONT OF MACHINE BY AXLE ** 6V
X143 4V 90/30 ** X36 2V
X144 6V 90/..NOT USED **
X146 2V 90/91 GL
OW
PL
X147 4V 90/..NOT USED UG
X150 12V 5/16 REAR OF MACHINE
S 15
X151 2V 6/53 (IF EQUIPPED)
X152 3V 6/..NOT USED NOT USED
X153 2V 5/8 FRONT OF MACHINE BY AXLE
X184 18V 70/62 CENTER OF CAB ** EV3
X190A 1V 1/6 EV
X190B 1V 1/6
CENTER OF CAB
CENTER OF CAB
72 X29
Dealer Copy -- Not for Resale 6
X190D 6V 1/6 CENTER OF CAB **
3V
X193 4V 5/74 NOT USED FOR THIS MODEL EV52
X196 NOT USED FOR THIS MODEL
**
OP
TIO
6 X150
2V 5/73 **
N X266
X197 12V 5/29 X152
BOOM 12V
P4
3V 2V
X198 12V 29/90 BOOM
EV
NO
N
X199 6V ../5 NOT USED BOOM US
ED
X151
X200 6V 39/90 NOT USED BOOM
P3 EV7 EV12
EV
2V 3V X280
X220 3V 71/72 SIDE OF FUSE BOX X27
X265 2V 5/INCLINOMETER CENTER OF CAB

53 EV2-AR
2V
EV85
X266 2V 5/92 AR MACH.
X22
X270 12V 1/92 CENTER OF CAB
2V 62
X271 6V 1/93 CENTER OF CAB EV10
X272 12V 1/INCLINOMETER CENTER OF CAB
EV1-AV EV11
EV14
X280 2V 5/FUEL SENDER REAR OF MACHINE X281
EV8
X281 2V 6/OIL FILTER HYDRAULIC RESERVOIR 2V 5
X321 3V SHUNT STAB/81 SIDE OF FUSE BOX EV71
EV
X322 3V 81/82 OPT.DETECT.TELESCOP. BOOM 73 EV9
OIL FILTER
16
8
X40 EV72
57 3V
** CAB CONNECTIONS
93 SEE PAGE 10 OF 11
X321 3V
2V X2
72
X107
X2
6V 70
70 X2
71
12V
1 12V
X34 X285
2V X8 X1
X106 6V 7C 84 6V
X153 X8
7B 18V
X33 4V
2V X8 X265
6V 7 12V 2V
7 56 1V
X8
9 24V
X1
90 24V
A
X1 X5
X1 90 0
90 D 12V
B
1V 6V
X2
71 20
3V
V-1034 (2/1/08)
613 of 913
614 of 913
615 of 913
616 of 913
617 of 913
618 of 913
619 of 913
620 of 913
621 of 913

622 of 913
623 of 913
624 of 913
625 of 913
ELECTRICAL SYSTEM INFORMATION (S/N
A8HK11001 & ABOVE)
WARNING
The following troubleshooting chart is provided for Instructions are necessary before operating or
assistance in locating and correcting problems which are servicing machine. Read and understand the
most common. Many of the recommended procedures Operation & Maintenance Manual, Operator’s
must be done by authorized Bobcat Service Personnel Handbook and signs (decals) on machine. Follow
only. warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5

Alternator will not charge. 1, 2, 5
Starter will not turn 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 the solenoid is damaged.
9. Check the fuses.

ELECTRICAL SYSTEM INFORMATION (S/N Fuses, Diodes And Relays
A8HK11001 & ABOVE) (CONT’D) Figure 60-10-2
Description
1 1
Figure 60-10-1
P-52172
The electrical system is protected by fuses, diodes and

P-24156 relays.
Remove the console cover (Item 1) [Figure 60-10-1].

The VersaHANDLER has a 12 volt, negative ground

alternator charging system. The electrical system is
Remove the cover(s) from the rows of fuses/relays/
protected by fuses located in the cab in the right console
diodes (Item 1) [Figure 60-10-2] to check or replace
(Item 1) [Figure 60-10-1].
fuses, diodes or relays.
The fuses will protect the electrical system when there is
Two relays and two fuses are located in the rear of the
an electrical overload. The reason of the overload must
engine compartment.
be found before starting the engine again.

ELECTRICAL SYSTEM INFORMATION (S/N A8HL12999 & BELOW, A8HP12999 & BELOW, A8HK11001 & ABOVE)
(CONT’D)
Fuses, Diodes And Relays (Cont’d)
Figure 60-10-3
28 12 * 11 12
U N G
27 11
32 16
26 T M 10
01 F
25
9
02 31 E 15
24 L 8
S
23 7
K
22 R D
W 6
21 J 5
30 Q C X
20 14 4
P I B
19 3
V
29 18 2
O H A 13
17
1

P-52173A
The location and description are shown below and [Figure 60-10-3]
FUSES AND DIODES RELAYS

Ref Description. Amps Ref. Description Amps Ref Description
1 Rear Work Lights 15 21 Travel Controller 7.5 A Rear Work Lights
2 Front Work Lights 15 22 Fuel Pump 7.5 B Front Work Lights
3 Headlights 10 23 Joystick 10 C Horn
4 Low Beam Headlights 15 24 Direction Signal 7.5 D NOT USED
5 Horn and Cab Light 7.5 25 Steering Mode Valve 10 E Front Auxiliary Hydraulic
6 High Beam Headlights 15 26 [2]Heater Fan 20 F Low Beam Headlights
7 12V Accessory Plug 10 27 Travel Direction 7.5 G High Beam Headlights
8 Left Park Lights 7.5 28 Control Panel 7.5 H Parking Brake
9 Right Park Lights 7.5 29 Top Wiper and Rear Travel Light 10 I Neutral Start
10 Hazard Lights 7.5 30 [2]Rear Wiper, Rear and Top 7.5 J0 Brake Control System
Washer
11 Parking Brake [1] 31 Spare Fuse 10 K Low Travel Speed
12 Transmission/Parking Brake [1] 32 Reverse Cooling Fan (Option) 7.5 L Option
13 2nd Auxiliary Hyd 10 M Backup Lights/Backup Alarm
14 Fuel 7.5 02 Air Cond. Compressor 7.5 N Fuel Pump
15 7.5 01 Air Cond. Fan 20 O Optional
16 Front Auxiliary Hyd 3 P Optional
17 Rotating Beacon 7.5 Q Optional
18 Brake Lights 10 R Not Used
19 Low Travel Speed 7.5 S Radio (Optional)
20 [2]Front Wiper 15 T Frame Leveling (Optional)
U Reverse Cooling Fan
V [2]Air Condition Fan
W [2]Air Condition Compressor
X Switched Power Relay
[1] - Diodes (Items 11 and 12) inserted with the tab toward the front of the machine (Inset) [Figure 60-10-3].
[2]- Not used on Canopy models.

A8HL12999 & BELOW, S/N A8HP12999 & BELOW, S/
N A8HK11001 & ABOVE) (CONT’D)
Figure 60-10-4
S3531
3 5

4
1
S3533
Remove the access panel at the rear of the engine

compartment. The relay/fuse receptacles are located
under the air conditioning compressor [Figure 60-10-4].
FUSES
Ref. Description Amps

1 Switched Power Fuse 50
2 Unswitched Power Fuse 40
3 Preheat Fuse 50
RELAYS
Ref. Description
4 Starting Motor Relay
5 Preheat Relay

Troubleshooting Chart WARNING

The following troubleshooting chart is provided for AVOID INJURY OR DEATH
assistance in locating and correcting problems which are Instructions are necessary before operating or
most common. Many of the recommended procedures servicing machine. Read and understand the
must be done by authorized Bobcat Service Personnel Operation & Maintenance Manual, Operator’s
only. Handbook and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing. Check for
Untrained operators and failure to follow instructions
can cause injury or death.
W-2003-0807
PROBLEM CAUSE
Battery will not take charge. 1, 2, 3, 4, 5

Alternator will not charge. 1, 2, 5
Starter will not turn 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 the solenoid is damaged.
9. Check the fuses.

ELECTRICAL SYSTEM INFORMATION (S/N Fuses, Diodes And Relays
(CONT’D) Figure 60-11-2
Description
Figure 60-11-1 1 1
P-97029
The electrical system is protected by fuses, diodes and

P-97028 relays.
Remove the console cover (Item 1) [Figure 60-11-1].

The VersaHANDLER has a 12 volt, negative earth

alternator charging system. The electrical system is
Remove the cover(s) from the rows of fuses / relays /
protected by fuses located in the cab in the right console
diodes (Item 1) [Figure 60-11-2] to check or replace
(Item 1) [Figure 60-11-1].
fuses, diodes or relays.
The fuses will protect the electrical system when there is
Two relays and two fuses are located in the rear of the
an electrical overload. The reason of the overload must
engine compartment.
be found before starting the engine again.

ELECTRICAL SYSTEM INFORMATION (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE) (CONT’D)
Fuses, Diodes And Relay Location / Identification (Cont’d)
Figure 60-11-3
28
12 *
32 21 14 7
27
11
26 16
20 13 6 10
31 25
9
24 12 5 15
8
19
23
4 7
11
22 6
18
21 5
3
30 10 14
20 17 4
19 9 2 3
16
13
29 18 2
8 1
17

15 1
S36267
The location and description are shown below and [Figure 60-11-3].
FUSES AND DIODES RELAYS
Ref Description. Amps Ref. Description Amps Ref Description

1 Rear Work Lights 15 21 Travel Controller 15 1 Rear Work Lights
2 Front Work Lights 15 22 Fuel Pump / Brake Fail Pressure 7.5 2 Front Work Lights
Switch (If Equipped)
3 Headlights 10 23 Joystick 10 3 Horn
4 Low Beam Headlights 15 24 Direction Signal 7.5 4 Blue Work Lights (If Equipped)
5 Horn, Cab Light 7.5 25 Steering Mode Valve 10 5 Front Auxiliary Hydraulic
6 High Beam Headlights 15 26 Heater and HVAC 30 6 Low Beam Headlights
7 12V Accessory Plug 10 27 Travel Direction 7.5 7 High Beam Headlights
8 Left Park Lights 7.5 28 Instrument Panel 7.5 8 Transmission/Parking Brake
9 Right Park Lights 7.5 29 Top Wiper, Rear Travel Light 10 9 Neutral Start
10 Hazard Lights 7.5 30 Rear Wiper, Rear and Top Washer 7.5 10 Not Used
11 Parking Brake [1] 31 Boom Angle Sensor 10 11 Low Travel Speed
12 Transmission/Parking Brake [1] 32 Reverse Cooling Fan / Frame Level- 7.5 12 2nd Auxiliary Hyd
ling
13 2nd Auxiliary Hyd 10 13 Backup Lights/Backup Alarm
14 Fuel 7.5 14 Fuel Pump
15 Longitudinal Stability 7.5 15 Not Used
Indicator / AMA
16 Front Auxiliary Hyd 3 16 Not Used
17 Rotating Beacon 7.5 17 Not Used
18 Stop Lights / Rear Aux hyd 10 18 Not Used
19 Low Travel Speed 7.5 19 Not Used
20 Front Wiper 15 20 Frame Levelling
21 Reverse Cooling Fan
[1] - Diodes (Items 11 and 12) inserted with the tab toward the front of the machine.

A8HL13000 & ABOVE, S/N A8HP13000 & ABOVE)
(CONT’D)
Figure 60-11-4
S3531
3 5

4
1
S3533
Remove the access panel at the rear of the engine

compartment. The relay/fuse receptacles are located
under the air conditioning compressor [Figure 60-11-4].
FUSES
Ref. Description Amps

1 Switched Power Fuse 50
2 Unswitched Power Fuse 40
3 Preheat Fuse 50
RELAYS
Ref. Description
4 Starting Motor Relay
5 Preheat Relay

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.
1
In case of acid contact, wash immediately with water.
In case of eye contact get prompt medical attention P-42338
and wash eye with clean, cool water for at least 15
minutes.
Remove the battery hold down clamp (Item 1) [Figure
If electrolyte is taken internally drink large quantities 60-20-2].
of water or milk! DO NOT induce vomiting. Get
prompt medical attention. Figure 60-20-3
W-2065-0807

Figure 60-20-1
2 1
P-42341
Always disconnect the negative cable (Item 1) [Figure

P-50821 60-20-3] first to prevent sparks.
Remove the positive battery cable (Item 2) [Figure 60-

Remove the battery access door (Item 1) [Figure 60-20-
20-3].
1].
Remove the battery.

BATTERY (CONT'D)
Servicing
Figure 60-20-4
WARNING
Batteries contain acid which burns eyes and skin on
contact. Wear goggles, protective clothing and
rubber gloves to keep acid off body.
In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention
and wash eye with clean, cool water for at least 15
minutes.
If electrolyte is taken internally drink large quantities

of water or milk! DO NOT induce vomiting. Get
prompt medical attention.
W-2065-0807
P-29246
Figure 60-20-6
Figure 60-20-5

P-09588
P-09590
The battery cables must be clean and the connections

Always clean the terminals and cable ends when tight. Remove acid or corrosion from the battery and
installing a new battery [Figure 60-20-4] and [Figure 60- cables with a sodium bicarbonate (baking soda) and
20-5]. water solution [Figure 60-20-6].
When installing the battery in the machine, do not touch Check the electrolyte level in the battery. Add distilled
any metal parts with the battery terminal posts. water as needed.
Connect and tighten the battery cables. Connect the Put Battery Saver (P/N 6664458) or grease on the
negative (-) cable last to prevent sparks. battery terminals and cable ends to prevent corrosion.

BATTERY (CONT'D)
Using A Booster Battery (Jump Starting)

IMPORTANT
If it is necessary to use a booster battery to start the
engine, BE CAREFUL! There must be one person in the Damage to the alternator can occur if:
operator's seat and one person to connect and • Engine is operated with battery cables
disconnect the battery cables. (Booster Cables) disconnected.
• Battery cables are connected when using a fast
The key switch must be OFF. The booster battery must charger or when welding on the VersaHANDLER.
be 12 volt. (Remove both cables from the battery.)
• Extra battery cables (booster cables) are
Figure 60-20-7 connected wrong.
I-2228-0304
Figure 60-20-8
1
2
1

P-50821
Remove the battery access door (Item 1) [Figure 60-20-

P-42339
7].
NOTE: The battery compartment is located in front of Connect the end of the first cable to the positive (+)
the left rear tire, on the back side of the cab. terminal of the booster battery. Connect the other end of
the same cable to the positive terminal (Item 1) [Figure
60-20-8] on the VersaHANDLER battery.
WARNING Connect the end of the second cable to the negative (-)
terminal of the booster battery. Connect the other end of
the same cable to the negative terminal (Item 2) [Figure
AVOID INJURY OR DEATH 60-20-8] on the VersaHANDLER battery.
Keep arcs, sparks flames and lighted tobacco away
from batteries. When jumping from booster battery Keep cables away from moving parts. Start the engine.
make final connection (negative) at machine frame.
After the engine has started, remove the ground (-) cable
Do not jump start or charge a frozen or damaged (Item 2) [Figure 60-20-8] first.
battery. Warm battery to 60°F (16°C) before
connecting to a charger. Unplug charger before Remove the cable from the positive terminal (Item 1)
connecting or disconnecting cables to battery. Never [Figure 60-20-8].
lean over battery while boosting, testing or charging.
Battery gas can explode and cause serious injury.

W-2066-0705


ALTERNATOR Figure 60-30-3
Figure 60-30-1
1 S6841
Loosen and remove the alternator adjusting bolt (Item 1)

S6840 [Figure 60-30-3].
Figure 60-30-4

Remove the four bolts (Item 1) and belt shield (Item 2)
[Figure 60-30-1].
1
Figure 60-30-2
S6842
Loosen and remove both mounting bolts (Item 1) [Figure

60-30-4].
1
S6851 Remove the alternator.
Remove the three connectors (Item 1) [Figure 60-30-2]

from the back of the alternator.

ALTERNATOR (CONT’D) Figure 60-30-7
Adjusting The Alternator Belt
Stop the engine.
Open the engine cover. 1
Figure 60-30-5
S6844
Move the alternator until the belt has 5/16 in. (8,0 mm)
1 movement at the middle of the belt span (Item 1) [Figure
60-30-7] with 15 lb. (20 N•m) of force.
Tighten the adjustment and mounting bolts.

S6840

Install the belt shield.
Remove the two bolts (Item 1) and the belt shield (Item 2) Close the engine cover.
[Figure 60-30-5].
Figure 60-30-6
2
S6843
Loosen the two alternator mounting bolts (Item 1)

[Figure 60-30-6].
Loosen the adjustment bolt (Item 2) [Figure 60-30-6].

STARTER Figure 60-40-3

1
Figure 60-40-1
S6849
Remove the three wires (Item 1) [Figure 60-40-3] from

P18440 the starter.
Figure 60-40-4
40-1] to the right, to disconnect the power supply from 1

the battery.
Figure 60-40-2
2 1
1
S6850
Remove the three nuts and bolts (Item 1) [Figure 60-40-

4] and remove the starter.
P-53364
Installation: Tighten to 40-45 ft.-lb. (54-61 N•m) torque.
Remove the access cover mounting bolt (Item 1) and

remove the access cover (Item 2) [Figure 60-40-2].

STARTER (CONT’D) Figure 60-40-7
Disassembly
2
Mark the frame, magnetic switch and housing for ease of
assembly. 1
Figure 60-40-5
P-53957
Remove the frame (Item 1) from the housing (Item 2)

[Figure 60-40-7].
1
Figure 60-40-8
P-53955

Remove the cable (Item 1) [Figure 60-40-5] from the
magnetic switch.
2
Figure 60-40-6
1
P-53958
1 Remove the two screws (Item 1) and remove the brush

cover (Item 2) [Figure 60-40-8].
P-53956
Remove the two bolts (Item 1) [Figure 60-40-6].

Figure 60-40-9
1
1
2
P-53961
Remove the armature (Item 1) from the frame (Item 2)

P-53960 [Figure 60-40-11].
Figure 60-40-12
Using a needle nose pliers, pull the brush springs (Item
1) back and remove the brushes (Item 2) [Figure 60-40-

9].
NOTE: The brushes are non-replaceable. If the

brushes are worn order a new brush holder 1
(for the negative brushes) and yolk (for the
positive brushes). 1
Figure 60-40-10
P-53964
Remove the three nuts and washers (Item 1)[Figure 60-

40-12] from the magnetic switch.
1
P-53962
Remove the plate (Item 1) [Figure 60-40-10] from the

frame.

1
Figure 60-40-13
P-53967
2
Pull the clutch assembly (Item 1) out of the housing
P-53965 slightly and remove the rubber gasket (Item 2) [Figure
60-40-15].
Remove the magnetic switch assembly (Item 1) from the Figure 60-40-16

Figure 60-40-14
P-53968
P-53966 Remove the pinion/clutch assembly (Item 1) from the

Remove the gasket (Item 1) [Figure 60-40-14] from the

housing.

2
Figure 60-40-17
3 1
1
P-53973
Remove the collar (Item 1) and pinion/clutch assembly

P-53971 (Item 2) from the shaft (Item 3) [Figure 60-40-19].
Figure 60-40-20
Press the collar (Item 1) down to gain access to the snap
ring (Item 2) [Figure 60-40-17].

Figure 60-40-18
1
1
P-53974

P-53972

1
Figure 60-40-21
2
1
P-53976
Remove the bushing (Item 1) [Figure 60-40-23].

P-53975
Figure 60-40-24
Remove the housing cover (Item 1) from the shaft


Figure 60-40-22
1
2
1
P-53980
Compress the spring and remove the snap ring (Item 1)

[Figure 60-40-24].
P-53977
Remove the ring gear (Item 1) from the housing cover

(Item 2) [Figure 60-40-22].

STARTER (CONT’D) Inspection And Repair
Disassembly (Cont’d) Figure 60-40-26
Figure 60-40-25
6
3 4 1
1
5
2
P-53970
P-53988
Check the bearing (Item 1) [Figure 60-40-26].
Remove the washer (Item 1), linkage assembly (Item 2), Figure 60-40-27
spring seat (Item 3), spring (Item 4) and spring seat (Item

5) from the pinion assembly (Item 6) [Figure 60-40-25].
1
P-53981
Check the pinion gear teeth (Item 1) and shaft splines

(Item 2) [Figure 60-40-27] for wear or damage.

Inspection And Repair (Cont’d)
Figure 60-40-28
B-14455
Armature Short-Circuit Test: Use a growler tester, put the

P-53979 armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-40-30]. A short circuited armature
Check the shaft splines (Item 1) and gears (Item 2) causes the blade to vibrate and be attracted to the core.
[Figure 60-40-28] for wear or damage. An armature which is short-circuited must be replaced.

Figure 60-40-29 Figure 60-40-31
P-53989 P-53982
Check the frame seals (Item 1) [Figure 60-40-29]. Armature Winding Ground Test: Use a circuit tester,
Replace as needed. touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-40-31]. There
should be no continuity. If there is continuity, the
armature is grounded and must be replaced.

Figure 60-40-32
P-53984
Check all the connections for clean and tight solder

P-53983 joints. Field Winding Ground Test: Use a circuit tester,
touch one probe to the field winding end of the brush and
the other probe to the surface of the frame [Figure 60-
Armature Winding Continuity Test: Use a circuit tester, 40-34]. There should be no continuity. If there is
touch the probes to two commutator segments [Figure continuity, the field windings are grounded.

60-40-32]. There must be continuity at any point. If there
is no continuity, the winding is open-circuited, replace the Replace the field windings.
armature.
Figure 60-40-35
Figure 60-40-33
P-53985
B-14458
Field Windings Continuity Test: Use a circuit tester, touch

Commutator Run-Out Test: Check the commutator run- one probe to the wire and the other probe to the brush
out as shown in [Figure 60-40-33]. [Figure 60-40-35]. There must be continuity. If there is
no continuity, the field windings are open-circuited.
If the commutator exceeds the service limit, repair as Replace the yoke if the field windings have an open
needed. circuit.
Check the field windings for wear and damage. Inspect the brushes for wear and damage.
Replace the brush holder or yoke assembly if the

brushes are worn or damaged.
Check brush springs, for damage or rust. Replace as

needed.

Figure 60-40-36
P-53987
Pull the pinion out (to the engaged position [Figure 60-
P-53986 40-37] and allow it to snap back to the retracted position.
The pinion must fully return to the retracted position.
Brush Holder Insulation Test: Use a circuit tester, touch The following tests should be done without the armature
one probe to the positive brush holder plate and the other assembly. Install the magnetic switch in the switch

probe to the holder plate [Figure 60-40-36]. There housing.
should be no continuity. If there is continuity, replace or
repair. NOTE: Each test should be performed a short time (3
to 5 seconds) to prevent the magnetic switch
NOTE: Assemble the over running clutch, pinion winding from burning. Each test should be
shaft, springs and pinion for this test. performed with 12 volts.
Inspect the pinion, it must rotate freely in the direction of

the starter rotation and locked in the opposite rotation.

Assembly
Figure 60-40-38
3 2 1
5
4 6 P-53978
Install the bushing (Item 1) [Figure 60-40-40].

P-53988
Figure 60-40-41
Install the spring seat (Item 1), spring (Item 2), spring
seat (Item 3), linkage assembly (Item 4) and washer 2
1

(Item 5) onto the pinion assembly (Item 6) [Figure 60-40-
38].
Figure 60-40-39
P-53977
Install the ring gear (Item 1) into the housing cover (Item
2) [Figure 60-40-41].
P-53980
Compress the spring and install the snap ring (Item 1)

[Figure 60-40-39].

Assembly (Cont’d)
Figure 60-40-42
1
P-53972
Install the snap ring (Item 1) [Figure 60-40-44].

P-53974
Figure 60-40-45
Install the housing cover assembly (Item 1) over the shaft

(Item 2) [Figure 60-40-42].

Install the snap ring (Item 3) [Figure 60-40-42] onto the
shaft.
1
Figure 60-40-43
P-53971
Pull the collar (Item 1) [Figure 60-40-45] over the snap

ring.
3 2
1
P-53973
Install the pinion/clutch assembly (Item 1) and collar

(Item 2) onto the shaft (Item 3) [Figure 60-40-43].

Assembly (Cont’d)
Figure 60-40-46 2
2
1
1
P-53966
Install the gasket (Item 1) onto the housing (Item 2)

P-53968 [Figure 60-40-48].
Figure 60-40-49
Install the pinion/clutch assembly (Item 1) into the

Figure 60-40-47
1 1
2
P-53965
Install the magnetic switch assembly (Item 1) into the

P-53967 housing (Item 2) [Figure 60-40-49].
With the clutch assembly (Item 1) out of the housing

slightly, install the rubber gasket (Item 2) [Figure 60-40-
47].

Assembly (Cont’d)
Figure 60-40-50
1
P-53962
Install the plate (Item 1) [Figure 60-40-52] onto the

P-53964 frame.
Figure 60-40-53
Install the three washers and nuts (Item 1) [Figure 60-
40-50].

3
Figure 60-40-51
1
2
P-53959
2 Install the brush holder (Item 1) [Figure 60-40-53] over

P-53961 the armature.
Use a needle nose plier, pull the spring (Item 2) back and
Install the armature (Item 1) into the frame (Item 2) install the brushes (Item 3) [Figure 60-40-53].
[Figure 60-40-51].

Assembly (Cont’d)
Figure 60-40-54
1
P-53956
2
Install the two bolts (Item 1) [Figure 60-40-56].
P-53958
Do not over tighten.
Install the brush cover (Item 1) and two screws (Item 2) Figure 60-40-57
[Figure 60-40-54].

Figure 60-40-55
2
1
P-53955
P-53957 Install the cable (Item 1) [Figure 60-40-57] onto the

magnetic switch.
Install the frame (Item 1) onto the housing (Item 2)

[Figure 60-40-55].


Restraint Bar Removal And Installation
Fully lower the restraint bar.
Figure 60-50-1
1
1
P-44453
Remove the lock nut (Item 1) [Figure 60-50-3].
Figure 60-50-4
P-44449

Remove the bolt and nut (Item 1) [Figure 60-50-1] from
the strut. Remove the strut from the restraint bar.
NOTE: The strut is under spring tension. Use care

during removal.
Figure 60-50-2
P-44518
Fully raise and remove the restraint bar [Figure 60-50-4].
P-44519
Position the seat fully forward with the seat back forward
and the restraint bar lowered [Figure 60-50-2].

(CONT’D)
Sensor Removal And Installation
Remove the restraint bar. (See Restraint Bar Removal

Figure 60-50-5
1
2
1
3
1 P-44521
Loosen the four screws (Item 1) on the control box cover

(Item 2) [Figure 60-50-7]. Open the cover.
2
Figure 60-50-8
P-44456

Remove the two screws (Item 1) and sensor (Item 2)
from the restraint bar (Item 3) [Figure 60-50-5].
Figure 60-50-6
1
1
P-44463
2
Unplug the restraint bar electrical connector (Item 1)

[Figure 60-50-8].
P-42889
Remove the fuse box cover (Item 1) and side cover (Item
2) [Figure 60-50-6].

(CONT’D)
Sensor Removal And Installation (Cont’d) 1
Figure 60-50-9
1 1
P-50821
Remove the three screws (Item 1) from the access panel

P-44464
Figure 60-50-12

connector.

Figure 60-50-10
P-44466
Remove the tiestrap (Item 1) [Figure 60-50-12] and pull

the wire harness from the right console.
P-44465
Remove the retainer (Item 1) [Figure 60-50-10] from the

side of the control box. Pull the wire harness through the
retainer.

LATERAL OPERATOR RESTRAINT SYSTEM (LORS) Strut Removal And Installation
(CONT’D)
Figure 60-50-15
Sensor Removal And Installation (Cont’d)
Figure 60-50-13
P-44520
P-44467 Fully lower the restraint bar (Item 1) [Figure 60-50-15].
Figure 60-50-16
Pull the wire harness (Item 1) [Figure 60-50-13] through
the bottom of the cab.

Figure 60-50-14
P-44450
1
Remove the bolt (Item 1) [Figure 60-50-16] and washer
2
P-44455 from the strut.
NOTE: The strut is under spring tension. Use care

Remove the two screws (Item 1) from the sensor. during removal.
harness clamp.
Pull the wire harness through the hole (Item 3) [Figure

60-50-14] in the mount plate and remove the sensor and
wire harness assembly.

(CONT’D)
Strut Removal And Installation (Cont’d)

1
Figure 60-50-17
P-44459
Remove the mount block (Item 1) [Figure 60-50-19].
P-44449 Figure 60-50-20
Remove the nut (Item 1) [Figure 60-50-17] and bolt from

the strut.

1
2
Remove the strut.
1
Strut Disassembly And Assembly
Figure 60-50-18
2 P-44460
Remove the two spring retainers (Item 1) and spring

(Item 2) [Figure 60-50-20].
P-44458
Compress the spring (Item 1) and remove the lock nut

(Item 2) [Figure 60-50-18].

LATERAL OPERATOR RESTRAINT SYSTEM (LORS) Restraint Bar Bumper Removal And Installation
(CONT’D)
Figure 60-50-22
Restraint Bar Bushing Removal And Installation
Figure 60-50-21
2
1
P-44516
P-44515 Remove the bumper (Item 1) from the restraint bar (Item
2) [Figure 60-50-22].
Remove the bushing (Item 1) [Figure 60-50-21] from the

mounting plate (both sides).

LIGHTS Figure 60-60-3
Rear Light Removal And Installation
Figure 60-60-1
1
1
P-29537
1 Remove the two lens retainer screws (Item 1) [Figure

60-60-3].
1
S7421
Figure 60-60-4
Remove the two rear cover mounting bolts (Item 1)

[Figure 60-60-1]. Remove the cover.

Figure 60-60-2
1
1
1
P-27804
Remove the two light mounting bolts (Item 1) [Figure 60-

60-4].
P-50973 Remove the light assembly.
Unplug the light harness connector (Item 1) [Figure 60-

60-2] from the main harness.

LIGHTS (CONT'D) Figure 60-60-6
Front Light Removal And Installation

Figure 60-60-5
1
P-27806
Remove the two bolts (Item 1) [Figure 60-60-6] and

1
remove the light.
P-27805

Unplug the harness (Item 1) [Figure 60-60-5] from the
light.

LIGHTS (CONT'D) Figure 60-60-9
Front Light Removal And Installation (Cont’d)
For V723 Models With S/N A8HL13000 & Above,

A8HP13000 & Above: 3
1
Figure 60-60-7
1 2
S36331
Unplug the connectors (Item 1) and remove the light

(Item 2) [Figure 60-60-9].
Loosen the indicator light (Item 3) [Figure 60-60-9].

1
S36329
Figure 60-60-10

Remove six screws (Item 1) [Figure 60-60-7] from the
light.
2
Figure 60-60-8
1
S36332
Unplug the connector (Item 1) and remove the indicator

light (Item 2) [Figure 60-60-10].
S36330
Loosen the front light (Item 1) [Figure 60-60-8].


TRAVEL / SIGNAL LEVER (S/N A8HL12999 & BELOW, Figure 60-70-3

1
Figure 60-70-1
1 P-52344
Disconnect the two signal control wire connectors (Item

1) [Figure 60-70-3].
Figure 60-70-4
P-52340

the battery.
1
Figure 60-70-2
1 1
P-52345

the travel/signal levers.
P-52343
Disconnect the travel control wire harness connector

(Item 1) [Figure 60-70-2].

TRAVEL / SIGNAL LEVER (S/N A8HL12999 & BELOW, Figure 60-70-7
(CONT’D)
Figure 60-70-5
1
1
P-52349
Installation: Align the pin (Item 1) in the travel lever with

the top hole (Item 2) [Figure 60-70-7] in the steering
column.
P-52347
Remove the signal lever (Item 1) [Figure 60-70-5].

Figure 60-70-6
P-52348
Remove the travel lever (Item 1) [Figure 60-70-6].

TRAVEL / SIGNAL LEVER (S/N A8HL13000 & ABOVE, Figure 60-71-3
A8HP13000 & ABOVE)
Figure 60-71-1
P-52340

S36377 the battery.

Remove the cover (Item 1) [Figure 60-71-1]. Installation on Page 60-80-1.)

2
1
S36378
S36379
Remove the nut (Item 1) [Figure 60-71-2]. Disconnect the signal and travel control wire harness
connectors (Item 1) [Figure 60-71-4].
Remove the steering wheel (Item 2) [Figure 60-71-2].

TRAVEL / SIGNAL LEVER (S/N A8HL13000 & ABOVE, Figure 60-71-7
Figure 60-71-5
1 1
P-52348
Remove the travel lever (Item 1) [Figure 60-71-7].

1
S36380 Figure 60-71-8

the travel / signal levers.

Figure 60-71-6
1
1
P-52349
Installation: Align the pin (Item 1) in the travel lever with

the top hole (Item 2) [Figure 60-71-8] in the steering
column.
P-52347
Remove the signal lever (Item 1) [Figure 60-71-6].

INSTRUMENT PANEL Figure 60-80-3

1
For V723 Models With S/N A8HL12999 & Below,
A8HPN12999 & Below, S/N A8HK11001 & Above:
Figure 60-80-1
1
1 1
P-52323
Remove the five instrument panel mounting bolts (Item 1)

[Figure 60-80-3].
P-25486
Figure 60-80-4

Remove the temperature control knob (Item 1) [Figure
60-80-1]. (If Equipped)
Figure 60-80-2
1
P-25580
Tilt the instrument panel forward and unplug all

connectors [Figure 60-80-4]. Remove the instrument
panel.
P-25487
NOTE: Mark the connectors for correct installation.
Remove the nut (Item 1) [Figure 60-80-2] letting the

temperature controller fall inward.

INSTRUMENT PANEL (CONT’D) Figure 60-80-6
For V723 Models With S/N A8HL13000 & Above,

2
A8HP13000 & Above:
1
Figure 60-80-5
S36323
1 1
Unplug the two connectors (Item 1) [Figure 60-80-6].
Remove the instrument panel (Item 2) [Figure 60-80-6].
S36324 NOTE: Steering wheel is removed for photo clarity.

Pry a sharp flat tool under the rim on both sides (Item 1)
of the instrument panel (Item 2) [Figure 60-80-5].
Push in on both sides (Item 1) and pull out the instrument

panel (Item 2) [Figure 60-80-5].
NOTE: Steering wheel is removed for photo clarity.

SWITCH PANEL (S/N A8HL12999 & BELOW, S/N Figure 60-90-3
A8HP12999 & BELOW, S/N A8HK11001 & ABOVE)
Figure 60-90-1
P-52326
1
Remove the switch panel [Figure 60-90-3].
1
P-52324
Remove the five screws (Item 1) [Figure 60-90-1].

Figure 60-90-2
P-52325
Unplug the harness connectors from the back of the

switch panel [Figure 60-90-2].
NOTE: Mark all connectors for ease of installation.


SWITCH PANEL (S/N A8HL13000 & ABOVE, Figure 60-91-2
A8HP13000 & ABOVE)

2
Figure 60-91-1
S36354
1
Unplug the connectors (Item 1) [Figure 60-91-2].
1 S36355 Unplug the harness connectors from the back of the

switch panel [Figure 60-91-2].
Remove the six screws (Item 1) [Figure 60-91-1]. NOTE: Mark all connectors for ease of installation.

Remove the switch panel (Item 2) [Figure 60-91-2].

SWITCH PANEL (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE) (CONT’D)
EM6701

SWITCH PANEL (S/N A8HL13000 & ABOVE, S/N
1. Control panel plate

2. Instrument panel
3. Screw
4. Ignition switch
5. Set of keys
6. Switch, beacon light
7. Warning Switch
8. Heating Control Valve
9. Fan Speed Switch
10. Bezel for outer left and right positions
11. Bezel for middle positions
12. Winch and trailer turn indicator
13. Steering mode indicator
14. Steering mode switch
15. Joystick Switch
16. Switch, head lamp
17. Working light switch
18. Fog light switch
19. Blank Plug

20. Switch, rear wiper / washer
21. Screw
22. Switch, transmission mode
23. Locking switch
24. Switch, aux. hydr.
27. Stability indicator and wire harness
28. Washer
29. Nut
30. Support for frame levelling knob
31. Screw
32. Switch (proportional)
33. Spacer
34. Screw
35. Plate


BRAKE LIGHT SWITCH Adjustment
Removal And Installation Figure 60-100-3
Figure 60-100-1
P-27150
P-52341
Remove the dash cover/column cover. (See DASH A8HL12999 & BELOW, A8HP12999 & BELOW,
COVER / STEERING COLUMN COVER (S/N A8HK11001 & ABOVE) on Page 50-140-1.) or (See

A8HL12999 & BELOW, A8HP12999 & BELOW, DASH COVER / STEERING COLUMN COVER (S/N
A8HK11001 & ABOVE) on Page 50-140-1.) or (See A8HL13000 & ABOVE, A8HP13000 & ABOVE) on Page
DASH COVER / STEERING COLUMN COVER (S/N 50-141-1.)
50-141-1.) Loosen the nut (Item 1) [Figure 60-100-3].
Unplug the switch connector (Item 1) [Figure 60-100-1] With the brake pedal at rest, turn the adjustment bolt
from the wiring harness. (Item 2) [Figure 60-100-3] until it touches the brake light
switch plug.
Figure 60-100-2
Tighten the nut (Item 1) [Figure 60-100-3].
P-27149
Loosen the nut (Item 1) [Figure 60-100-2].
Remove the switch.


WIPER MOTOR (FRONT) Figure 60-110-3
Figure 60-110-1
1 1 1
1 1
P-25646
Remove the two mounting bracket bolts (Item 1) [Figure

P-25644 60-110-3].
Figure 60-110-4

50-141-1.)
Remove the four lower mounting bracket bolts (Item 1)

[Figure 60-110-1].
Figure 60-110-2
P-25920
1
Reposition the steering column assembly (as shown)

[Figure 60-110-4].
P-25645
Disconnect the front wiper connector (Item 1) [Figure 60-

110-2] from the main harness.
Reposition the main wire harness to the right side of the

cab.

WIPER MOTOR (FRONT) (CONT'D) Figure 60-110-7
Removal and Installation (Cont'd)
Figure 60-110-5
P-25641
Remove the wiper arms from the wiper motor shafts

P-25639 [Figure 60-110-7].
Figure 60-110-8
Remove the spray tube (Item 1) [Figure 60-110-5].

Figure 60-110-6
1
1 1
P-25642
P-25640
Remove both outer nuts (Item 1) [Figure 60-110-8].
Flip the wiper covers and remove the two nuts (Item 1)
[Figure 60-110-6].

WIPER MOTOR (FRONT) (CONT'D) Figure 60-110-10
Figure 60-110-9 1
1 1
P-25647
Remove the wiper motor from inside the cab [Figure 60-
P-25643 110-10].
Remove both inner nuts and washers (Item 1) [Figure

60-110-9].


WIPER MOTOR (TOP) Figure 60-111-3
Figure 60-111-1
P-25655
1
Unplug the wiper motor connector (Item 1) [Figure 60-
111-3] from the harness.
P-52342
Figure 60-111-4
Remove the three screws (Item 1) [Figure 60-111-1]
from the upper panel.

Figure 60-111-2
P-25649
Remove the squirter tube (Item 1) [Figure 60-111-4].
P-25654
Slide the upper panel forward on the support rails[Figure

60-111-2].
Lower the panel.

WIPER MOTOR (TOP) (CONT'D) Figure 60-111-7

1
Figure 60-111-5
2
P-25651
2
Remove the plastic nut (Item 1) and extension post (Item
P-25648 2) [Figure 60-111-7].
Figure 60-111-8
Flip open the wiper covers and remove the nut (Item 1)
and clip (Item 2) [Figure 60-111-5].
1

Figure 60-111-6
P-25652
While supporting the wiper motor inside the cab, have an

P-25650 assistant remove the two nuts (Item 1) [Figure 60-111-8].
Remove the wiper motor.

Remove the wiper arms from the wiper shafts [Figure
60-111-6].

WIPER MOTOR (REAR) Figure 60-112-3
Figure 60-112-1
P-25658
1
1 Flip open the wiper cover and remove the nut (Item 1)
P-52342 [Figure 60-112-3].
Figure 60-112-4
Remove the three screws (Item 1) [Figure 60-112-1]
from the upper panel and slide the upper panel forward.

Figure 60-112-2
P-25659
1
Remove the wiper arm [Figure 60-112-4].
P-25656
Unplug the rear wiper motor connector (Item 1) [Figure

60-112-2] from the harness.

WIPER MOTOR (REAR) (CONT'D) Figure 60-112-6
Figure 60-112-5
1
2
P-25660
Remove the plastic cover (Item 1) and two nuts (Item 2)

P-25662 [Figure 60-112-6].
Remove the wiper motor.

Have an assistant support the wiper motor [Figure 60-
112-5].

PEDAL ASSEMBLY Figure 60-120-3
Figure 60-120-1
1
P-25249
Remove the accelerator cable (Item 1) from the pedal

P-52341 and mounting bracket (Item 2) [Figure 60-120-3].
Figure 60-120-4

50-141-1.)

the brake light switch.
Figure 60-120-2 1
1 P-25638

the brake valve.
IMPORTANT
P-42865
Unplug the connector (Item 1) [Figure 60-120-2] from parts clean. Always use caps and plugs on hoses,
the inching switch. tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888

PEDAL ASSEMBLY (CONT’D) Figure 60-120-7
Figure 60-120-5
1 1
P-42870
1 1 Remove the roll pin (Item 1) and pedal (Item 2) [Figure

P-25637 60-120-7].
Figure 60-120-8
Remove the mounting bolts (Item 1) [Figure 60-120-5].

Remove the pedal assembly.
Disassembly And Assembly 2
Figure 60-120-6
1
1 2
P-42871
Installation: Align the hole (Item 1) in the pedal with the

hole (Item 2) [Figure 60-120-8] in the shaft.
P-42869
Remove the bolt (Item 1) and spring (Item 2) [Figure 60-

120-6].

Figure 60-120-9
P-42875
Remove the shaft and bearing assembly [Figure 60-120-

P-42872 11].
Figure 60-120-12
Loosen the two set screws (Item 1) [Figure 60-120-9] on
the two bearings. 1

Figure 60-120-10
1 2
2
1 P-42876
1
Remove the flanges (Item 1) and bearings (Item 2)
P-42874 [Figure 60-120-12].
Remove the three bolts (Item 1) [Figure 60-120-10] from

both bearing flanges.

Figure 60-120-13
P-42879
Remove the brake valve (Item 1) [Figure 60-120-15].

P-42878
Figure 60-120-16
Remove the three fittings (Item 1) [Figure 60-120-13]

from the brake valve.

Figure 60-120-14
1
2
1
1
P-42880
Remove the retainer pin (Item 1) and washer (Item 2)

2 [Figure 60-120-16].
P-42877
Remove the four bolts (Item 1) spacers (Item 2) [Figure

60-120-14] and nuts from the brake valve.

PEDAL ASSEMBLY (CONT’D)
Figure 60-120-17
P-42881
Remove the pedal (Item 1) [Figure 60-120-17].


INCHING SWITCH Adjustment
Removal And Installation Figure 60-130-3
Figure 60-130-1
3
P-42865
1

50-141-1.)
Remove the tie strap (Item 1) and unplug the switch

connector (Item 2) [Figure 60-130-1] from the harness.
MS-01215
Figure 60-130-2
50-141-1.)
With the brake pedal in the rest position, turn the

adjustment bolt (Item 1) so that it is 0.31 in. (8 mm) away
from the switch body (Item 2) [Figure 60-130-3].
1
Check that the potentiometer rod (Item 3) [Figure 60-
1 130-3] is in contact with the center of the adjusting bolt.
P-27147
When adjustment is complete, tighten the nut (Item 4)

Remove the two mounting bolts and nuts (Item 1) [Figure 60-130-3] without turning the adjusting bolt.
[Figure 60-130-2].
Installation: Be sure the switch is on the front side of the

mounting bracket.
Remove the switch.


SERVICE SOFTWARE Figure 60-140-3
Connecting The Laptop Computer S/N A8HL12999 & BELOW, S/N A8HP12999 & BELOW,
Figure 60-140-1
S/N A8HK11001 & ABOVE 1
P-47340
Figure 60-140-4
P-47349
Figure 60-140-2

S97029
Locate the ACD connector (Item 1) [Figure 60-140-3]

P-97028 and [Figure 60-140-4].
Remove the fuse box cover (Item 1) [Figure 60-140-1]

and [Figure 60-140-2].

SERVICE SOFTWARE (CONT’D) Entering The Service Software
Connecting The Laptop Computer (Cont’d) Figure 60-140-7
Figure 60-140-5
2
1
P-45352
P-47342
Click the VersaHANDLER icon (Item 1) [Figure 60-140-
7] to enter the program.
Plug the connector (Item 1) from the laptop computer into
the nine pin connector (Item 2) [Figure 60-140-5]. Figure 60-140-8

Figure 60-140-6
P-45350
P-47344
The option screen will appear when entering the
VersaHANDLER service analyzer [Figure 60-140-8].
Open the laptop and begin [Figure 60-140-6]. The com port can be changed, if com port 1 is already
being used.

SERVICE SOFTWARE (CONT’D) Monitor Screen
Entering The Service Software (Cont’d) Figure 60-140-11
Figure 60-140-9
1
P-45348
P-45348
Select the Monitor icon (Item 1) [Figure 60-140-11].
This is the Main Screen of the VersaHANDLER analyzer Figure 60-140-12

program [Figure 60-140-9].

Figure 60-140-10
P-45329
P-45349 The Monitor screen displays the engine RPM, travel

control position, battery voltage, propel curve, sensor
voltage, brake release switch, inch/brake pedal, creep
The options icon will take you to the options screen potentiometer (is so equipped), transmission mode, drive
[Figure 60-140-10]. The com port can be changed, if switch and creep switch [Figure 60-140-12].
com port 1 is already being used.
If one of the icons does not change when the function is
operated, the circuit is not operating properly or the
susmic controller has a malfunction.

SERVICE SOFTWARE (CONT’D) Figure 60-140-15
Monitor Screen (Cont’d)
Figure 60-140-13
1
P-45332
1 The Work Switch is turned on, the icon (Item 1) will turn
P-45330 on and the Transmission mode will change to work (Item
2) [Figure 60-140-15].
The Inch/Brake pedal graph (Item 1) [Figure 60-140-13] Figure 60-140-16

should move as the pedal is pressed down.

Figure 60-140-14
1
P-45333
P-45331 With the Creep Switch turned on, the icon (Item 1)
[Figure 60-140-16] will turn on. The creep potentiometer
icon will change as the creep adjustment is turned.
The travel control position lever (Item 1) [Figure 60-140-
14] should move as the lever in the VersaHANDLER is
moved.

Warnings Screen
Figure 60-140-17
P-45334
The warning screen will show codes and problem with

P-45348 the controller [Figure 60-140-18].
ERROR # DESCRIPTION
Select on the warning icon (Item 1) [Figure 60-140-17].
01 Sensor supply voltage-sensor voltage
out of range

17 Software did not load properly-Restart
program and reload software
18 Inch pedal calibration failed-recalibrate
the inch pedal
19 Inch/brake potentiometer-no pedal setup
done, value too low, value too high
20 Engine speed pickup-engine speed
missed when starting engine
21 Propel current-short cut, open circuit
22 F-N-R switch-short cut between forward
and reverse
23 Engine speed pickup-engine speed inter-
rupted
24 Hydro motor propel current-short cut,
open circuit
25 Creep drive calibration failed-recalibrate
the creep drive potentiometer
26 Creep drive potentiometer-value too low,
value too high
27 Motor speed pickup-motor speed inter-
rupted

Calibrate Inch Pedal
Figure 60-140-19
P-45345
Press the brake pedal down approximately 1/2 the stroke

P-45348 and click on the set max position icon (Item 1) [Figure
60-140-21].
Select the calibrate inch pedal icon (Item 1) [Figure 60- Figure 60-140-22
140-19].

Figure 60-140-20
1 1
P-45351
P-45346 Release the brake pedal and click on the set min position
icon (Item 1) [Figure 60-140-22].
Click on the Start Calibration (Item 1) [Figure 60-140-

20].

SERVICE SOFTWARE (CONT’D) Calibrate Creep Potentiometer
Calibrate Inch Pedal (Cont’d) Figure 60-140-24
Figure 60-140-23
1
1
P-45348
P-45346
Select the calibrate creep icon (Item 1) [Figure 60-140-
24].
Click the exit (Item 1) [Figure 60-140-23] to get out of the
calibrate inch pedal. Figure 60-140-25

1
2
P-45335
Select the creep box (Item 1) and then click the continue
icon (Item 2) [Figure 60-140-25].

Calibrate Creep Potentiometer (Cont’d)
Figure 60-140-26
1
1
P-45337
Turn the creep potentiometer counterclockwise and click

P-45341 on the set min position icon (Item 1) [Figure 60-140-28].
Figure 60-140-29
Click the start calibration icon (Item 1) [Figure 60-140-
26].

Figure 60-140-27
P-45339
1
Click the exit icon (Item 1) [Figure 60-140-29] to leave
P-45338 the creep calibration screen.
Turn the creep knob clockwise and click the set max
position icon (Item 1) [Figure 60-140-27].

Program / Update Susmic Controller
Figure 60-140-30
P-45347
Click the exit icon (Item 1) [Figure 60-140-32] after the

P-45348 controller has been programed.
Select the Program/Update icon (Item 1) [Figure 60-140-

30].

Figure 60-140-31
P-45342
Click the program controller icon (Item 1) [Figure 60-

140-31].


FRAME LEVEL SPEED SWITCH Removal
Description Lower the boom completely and turn off the engine.
Figure 60-150-1 Figure 60-150-2
2
1
1
1
P-61839 S7421
The V723 VersaHANDLER is equipped with a frame level Remove the two bolts (Item 1) and remove the rear cover
speed switch (Item 1) [Figure 60-150-1] located on the (Item 2) [Figure 60-150-2].

right rear side of the boom. This switch reduces the
speed of the frame leveling after the boom is raised over Unplug the harness connector (Item 2) [Figure 60-150-
25 degrees. 1].
Figure 60-150-3
3
2
1
S3669
Unplug the harness connector (Item 1), remove the two

bolts (Item 2) and the switch/bracket assembly (Item 3)
[Figure 60-150-3].

FRAME LEVEL SPEED SWITCH (CONT’D) Figure 60-150-6
Installation
Figure 60-150-4
2 1
P-50966A
3 Start the engine.

S3669
While holding the frame leveling switch (Item 1) [Figure
60-150-6] raise the boom. When the boom reaches 25
Install the switch/bracket assembly (Item 1) using the two degrees the speed of the frame leveling should
bolts (Item 2) [Figure 60-150-4]. decrease.

Plug the connector (Item 3) [Figure 60-150-4] into the Disassembly And Assembly
harness.
Remove the frame level speed switch. (See Removal on
Figure 60-150-5 Page 60-150-1.)
Figure 60-150-7
1
2
1
B-23273
P-61841
Slide the switch/bracket assembly (Item 1) until the
switch roller (Item 2) [Figure 60-150-5] is in the position
shown. Remove the two bolts and nuts (Item 1) and remove the
switch (Item 2) [Figure 60-150-7].
Tighten the bolts (Item 2) [Figure 60-150-4].

ENGINE SERVICE
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1
OIL COOLER / RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-4
ENGINE AND ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1


ENGINE COMPONENTS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-1
Fuel Injection Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-4
Fuel Injectors Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-7
Checking The Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-9
Fuel Lift Pump Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Compression Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-10
Glow Plug Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-11
Glow Plugs Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-12
ENGINE TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1
ENGINE / HYDROSTAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1

FLYWHEEL AND HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-1

Ring Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
Ring Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1

Turbocharger Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-1
Turbocharger Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-2
Turbocharger Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-2
Exhaust Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-4
Fuel Injector Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-4
Rocker Cover Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-5
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-6

Cylinder Head Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-8
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-9
Rocker Shaft Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-12
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-12
Valve Springs Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-13
Valve Depth Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-13
Valve Guides Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-14
Valve Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-15
Valve Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-15
Valves Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-16
Cutting A Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-16
Valve Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-17
Changing Valve Springs (With Cylinder Head Installed) . . . . . . . . . . . . . . . . . . . . .70-110-18
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-19
Timing Case And Drive Assembly Description . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-20
Timing Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-20
Timing Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-20
Crankshaft Pulley Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-20
Front Oil Seal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-20
Timing Case And Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-21
Timing Case And Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-22

Camshaft And Tappets Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-24
Camshaft And Tappets Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-25
Pistons And Connecting Rods Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-26
Pistons And Connecting Rods Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-26
Pistons And Connecting Rods Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-28
Piston Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-28
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-28
Piston Ring Groove Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-29
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-30
Connecting Rod Bushing Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-30
Piston And Connecting Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-30
Piston And Connecting Rod Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-30
Checking Piston Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-32
Crankshaft And Bearings Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-32
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-32
Inspection Of Crankshaft And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-34
Crankshaft And Bearings Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-35
Rear Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-36
Rear Oil Seal Housing Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-36
Rear Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-37
Checking Crankshaft End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-37
Cooling System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-38
Thermostat Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-39
Thermostat Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-40
Lubricating Oil Cooler Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-40
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-40
Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-40
Engine Lubrication System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-41
Oil Filter Adapter Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-42

Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-42
Oil Screen And Pick-up Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-43
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-43
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-44
Oil Pump Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-45
Oil Pressure Relief Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . .70-110-45
Engine Block Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-46
Engine Block Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-46
Piston Cooling Jet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-47
Piston Cooling Jet Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-47
Piston Cooling Jet Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-47
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-47
Cylinder Liner Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-48
Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-49
Cylinder Liner Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-110-50


TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for assistance in location and correcting problems which are most
common. Many of the recommended procedures must be done by authorized Bobcat Service Personnel only.
PROBLEM CAUSE
Slow cranking speed. 1, 2, 3, 4
Engine will not start (cold). 2, 5, 6, 7
Engine will not start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10
Difficult to start. 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 18, 19 20, 21
No power for engine. 9, 11, 15, 16, 17, 18, 19, 21, 22, 25, 26, 27
Engine is mis-firing. 11, 15, 16, 17, 18, 19, 20,21, 22, 23, 24
Too much fuel consumption. 7, 16, 17, 18, 20,21, 22, 28, 29, 30
Black exhaust. 16, 17, 18, 19 20, 22, 25, 27
Blue/white exhaust. 4, 7, 16, 18, 19, 22, 31, 32
Low oil pressure. 4, 31, 32, 33, 34, 35, 37, 38, 39, 48, 51
Engine knocking. 4, 5, 17, 18, 19,20, 23, 34, 35, 36, 37, 38
Engine running rough. 7, 8, 9, 10, 11, 12, 13, 14, 20, 21, 22, 25, 26, 27, 28, 29, 40, 52

Vibration 16, 30, 50, 51, 52
High oil pressure warning. 4, 33, 36
Overheating. 18, 19, 20, 22, 25, 31, 33, 46, 47, 48, 49
Too much crankcase pressure. 25, 35, 36, 42
Poor compression. 17, 18, 22, 23, 30, 32, 34, 35, 36, 44
Start and stop. 9, 11, 13, 15, 17, 22, 23, 30
Excessive oil consumption 4, 22, 32, 36, 40, 41, 42, 43, 44, 45

TROUBLESHOOTING (CONT'D)
Chart (Cont'd)

1. Battery capacity low. 27. Poor boost pressure.
2. Bad electrical connections 28. Fuel leak.
3. Faulty starter motor. 29. Lubrication oil diluted by fuel.
4. Incorrect grade of oil. 30. Sticking valves.
5. Incorrect grade of fuel. 31. Leaking head gasket.
6. Incorrect use of cold starting equipment. 32. Worn valve guides/stems.
7. Faulty cold starting equipment. 33. Faulty thermostat.
8. Insufficient fuel in tank. 34. Incorrect piston height.
9. Faulty stop control. 35. Broken/worn piston rings.
10. Broken fuel injection pump drive. 36. Worn cylinder liners.
11. Air in the fuel system 37. Worn wrist pins.
12. Restricted fuel feed. 38. Excessive camshaft end play.
13. Fuel tank vent blocked. 39. Excessive timing gear backlash.
14. Plugged fuel filters. 40. Oil leaks.

15. Faulty fuel pump. 41. New or rebuilt engine not broken in.
16. Low compression. 42. Plugged breather pipe.
17. Incorrect valve clearance. 43. Glazed cylinder liners.
18. Incorrect valve timing. 44. Worn pistons.
19. Incorrect fuel pump timing. 45. Worn valve stem seals.
20. Faulty injectors. 46. Coolant level low.
21. Faulty fuel injection pump. 47. Faulty water pump.
22. Plugged air filter. 48. Loose or broken blower fan belt.
23. Broken or weak valve springs. 49. Radiator cooling fins plugged.
24. Overheating. 50. Damaged blower fan.
25. Restricted exhaust system. 51. Loose flywheel.
26. Water in fuel. 52. Broken engine mounts.

ENGINE SPEED CONTROL Figure 70-20-3
Figure 70-20-1
P-53128
2

P-25249
70-20-3] from the linkage.
Remove the floor mat and insulation from the cab floor.
Figure 70-20-4

Remove the speed control cable (Item 1) from the pedal
and mounting bracket (Item 2) [Figure 70-20-1].
Remove the battery box cover.
Figure 70-20-2
P-53127
1
Remove the engine speed control cable from the
mounting bracket (Item 2) [Figure 70-20-4].
P-25250 Remove any necessary cable ties, carefully remove the

speed control cable.
Carefully pull the speed control cable (Item 1) [Figure

70-20-2] through the cab and into the battery box.


MUFFLER Figure 70-30-2
Figure 70-30-1
S3529
1
Remove the muffler mounting bolts (Item 1) [Figure 70-

P-53129 30-2].
Remove the muffler.


Remove the exhaust mounting bolts (Item 1) [Figure 70-
30-1].


AIR CLEANER Figure 70-40-2
Housing Removal And Installation
Figure 70-40-1
1 1
P-53132
Remove both mounting bolts (Item 1) [Figure 70-40-2].

P-53131
Remove the air cleaner housing assembly.

Loosen the clamps (Item 1) [Figure 70-40-1] and remove
the hoses from the air cleaner.


OIL COOLER / RADIATOR For V723 Models With S/N A8HL12999 & Below, S/N
Figure 70-50-3
Remove the engine cover. (See Removal And Installation
on Page 50-70-1.)
1
1
10-70-2.)
Remove the fan motor. (See Removal And Installation on

Page 20-140-1.)
Figure 70-50-1
2 S6891
Remove the two nuts (Item 1) [Figure 70-50-3] from the

condenser.

Figure 70-50-4
1
S6859
1
Remove the two lower radiator hoses (Item 1) [Figure

70-50-1].
Remove the lower hydraulic hose (Item 2) [Figure 70-50-

1].
S6860
Figure 70-50-2
Position the condenser (Item 1) [Figure 70-50-4] (as

shown).
S6890
Remove the upper hydraulic hose (Item 1) [Figure 70-

50-2].

OIL COOLER / RADIATOR (CONT’D) Figure 70-50-6
For V723 Models With S/N A8HL13000 & Above, S/N

A8HP13000 & Above:
1
Figure 70-50-5
S36350
Position the condenser (Item 1) [Figure 70-50-6] (as

shown).
S36349

Loosen the nut (Item 2) [Figure 70-50-5].

For All Models:
Figure 70-50-7
S7438

Install a hoist and chain to the oil cooler/radiator [Figure
70-50-7].
Figure 70-50-8
S7437
Lift and remove the oil cooler/radiator assembly [Figure

70-50-9].
P-22025
Remove both oil cooler/radiator mounting bolts (Item 1)

[Figure 70-50-8] from the bottom of the engine pan.

Figure 70-50-10
1
1
S6865
Remove the wear pads (Item 1) [Figure 70-50-12].

S6863
Figure 70-50-13
Remove both rubber mounts (Item 1) [Figure 70-50-10]

by turning counterclockwise.

Figure 70-50-11
1 1
2 1
2 1 S6866
Remove the bolts (Item 1) and remove the upper bracket

1
(Item 2) [Figure 70-50-13].
S6864
Remove the seven bolts (Item 1) and remove the bracket

(Item 2) [Figure 70-50-11].

Figure 70-50-14
2
2
S6869
Remove the plate (Item 1) by removing the four screws

S6867 (Item 2) [Figure 70-50-16].
Separate the oil cooler from the intercooler.

Support the oil cooler/radiator assembly as shown
[Figure 70-50-14].

Figure 70-50-15
2 1 1
1
S6868
Remove the three bracket mounting bolts (Item 1) (both

sides) and remove the condenser mounting bracket (Item
2) and shroud (Item 3) [Figure 70-50-15].


ENGINE AND ENGINE MOUNTS Figure 70-60-2

NOTE: Set the engine/hydrostat assembly on blocks,

to allow access to remove the motor mount
bolts.
Remove the hydrostatic pump. (See Removal And

Remove the flywheel and housing. (See Removal And

Installation on Page 70-100-1.) S6871
If equipped with air conditioning, remove the hoses from

the compressor. (See Removal And Installation on Page Remove the hose (Item 1) [Figure 70-60-2] and
80-110-1.) reposition.

1
S6870 S6872
Remove the hose (Item 1) [Figure 70-60-1] from the Remove the lower radiator hose (Item 1) [Figure 70-60-
thermostat housing. 3] from the water pump.

ENGINE AND ENGINE MOUNTS (CONT’D) Figure 70-60-6
Figure 70-60-4
P-55515
1
Remove the intake tube from the turbo by loosening the
P-53808 clamp (Item 1) [Figure 70-60-6].
Figure 70-60-7
Remove the intake hose (Item 1) [Figure 70-60-4] from
the turbo.

Figure 70-60-5
S6909
1 Loosen the clamp (Item 1) and remove the intake tube

S6916 (Item 2) [Figure 70-60-7].
Loosen the hose clamp (Item 1) [Figure 70-60-5] and

remove the hose from the engine.

Figure 70-60-8
1
1
S6893
Remove the two bolts and nuts (Item 1) [Figure 70-60-

P-53809 10] and remove the two fuse assemblies.
Figure 70-60-11
Remove the three bolts (Item 1) and exhaust tube (Item
2) [Figure 70-60-8].

Figure 70-60-9
1
2
P-53812
Reposition the electrical harness [Figure 70-60-11] (as

P-53810 shown).
Remove the bolt and nut (Item 1) at the rear of the engine
compartment and remove the access panel (Item 2)
[Figure 70-60-9].

Figure 70-60-12
1
1
S6873
Remove both front engine mount bolts (Item 1) [Figure

S6919 70-60-14].
Installation: Tighten the engine mount bolts to 185-200

Install a lifting bracket (Item 1) [Figure 70-60-12] in the ft.-lb. (250-271 N•m) torque.
position shown.

Figure 70-60-15
Figure 70-60-13
S6918
S6917
Lift and remove the engine [Figure 70-60-15].

Install a hoist and chain to the lifting brackets [Figure 70-
60-13] (as shown).

ENGINE COMPONENTS AND TESTING Figure 70-70-2
Fuel Injection Pump Removal
NOTE: Read and fully understand the following

procedure before removing the fuel injection
pump. Failure to remove the pump correctly
will result in incorrect pump timing and the 2
pump will have to be sent to an authorized
Delpi dealer to be retimed. The internal
adjustment for pump timing is tamper proof.
High and low idle adjustments of the fuel
injection pump are factory set and
adjustments cannot be made to the fuel 1
pump.
P-55774
Set the engine to TDC number one cylinder compression
stroke. (See ENGINE TIMING on Page 70-80-1.)
Loosen the lock bolt (Item 1) and move the washer (Item
Figure 70-70-1 2) [Figure 70-70-2] (to the position shown). Retighten
the locking screw to 12 ft.-lb. (17 N•m) torque.
Remove the nut and washer (Item 1) [Figure 70-70-1].

Figure 70-70-3
1
P-55531
NOTE: If the fuel pump nut (Item 1) [Figure 70-70-1] is

loosened before the fuel pump timing is set
and the pump locked, the fuel pump timing P-55529
will be lost and the fuel pump will have to be
sent into the dealer to be reset.
Using a gear puller, remove the fuel pump gear [Figure
Apply pressure counterclockwise by hand to the fuel 70-70-3].
pump gear to remove backlash from the gears.

ENGINE COMPONENTS AND TESTING (CONT'D) Figure 70-70-6
Fuel Injection Pump Removal (Cont'd)
Figure 70-70-4
P-55524
Remove the fuel line (Item 1) [Figure 70-70-6] from the

P-55522 front of the pump.
Figure 70-70-7
Remove the harness (Item 1) [Figure 70-70-4].

NOTE: Mark the connectors for correct installation.
Figure 70-70-5
1
P-55525
Remove the fuel line (Item 1) [Figure 70-70-7] from the

rear of the pump.
P-55523
Remove the connector (Item 1) [Figure 70-70-5] from

the top of the pump.

Fuel Injection Pump Removal (Cont'd)
Figure 70-70-8
1
1
P-55533
Disconnect the return spring (Item 1) [Figure 70-70-10]

P-55526 from the pump linkage.
Figure 70-70-11
Remove the four fuel tubelines (Item 1) [Figure 70-70-8].

IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them. 1
I-2029-0289
Figure 70-70-9
P-55528
Remove the mount bolt (Item 1) [Figure 70-70-11] from

the bracket.
P-55527
Remove the tubeline (Item 1) [Figure 70-70-9] from the

top of the pump.

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injection Pump Installation
Fuel Injection Pump Removal (Cont'd) The engine must be set to TDC number one cylinder,
compression stroke before the pump is fitted. (See
Figure 70-70-12 ENGINE TIMING on Page 70-80-1.)
NOTE: The new fuel pump will be supplied with the

1 pump shaft in the locked position. Do not
1 unlock the shaft of the fuel pump until the fuel
pump gear is fitted.
Install a new O-ring onto the pump flange.
Figure 70-70-13
1
1
1
P-55532
Remove the three mount bolts (Item 1) [Figure 70-70-12]

and remove the pump.

1
P-55532
Install the fuel pump and tighten the three bolts (Item 1)
Figure 70-70-14
P-55528
Install the mount bolt (Item 1) [Figure 70-70-14]. Do not

tighten at this time.

Fuel Injection Pump Installation (Cont'd)
Figure 70-70-15
2
1
2
P-55775
Loosen the locking bolt (Item 1) and move the washer

P-55531 (Item 2) [Figure 70-70-17] to the position shown and
tighten the bolt to 9 ft.-lb. (12 N•m) torque.
Fit the gear (Item 1) onto the tapered shaft. Make sure Retighten the nut (Item 1) [Figure 70-70-16] to 65 ft.-lb.
the fuel pump gear is correctly in mesh with the idler gear (88 N•m) torque.

and install the washer and nut (Item 2) [Figure 70-70-
15]. Do not tighten at this time. Figure 70-70-18
NOTE: The backlash must be removed before the fuel

injection pump is released. Failure to do so
will make the fuel pump timing incorrect.
1
Figure 70-70-16
P-55776
Remove the two timing pins (Item 1) [Figure 70-70-18].
Lightly lubricate each gear with clean engine oil.

P-55530
Install the timing case cover. (See Timing Cover
Apply pressure counterclockwise by hand to the fuel
pump gear to remove the backlash from all the gears. Install the glow plugs. (See Glow Plugs Removal And
Tighten the nut (Item 1) [Figure 70-70-16] to 18 ft.-lb. (24 Installation on Page 70-70-12.)
N•m) torque.
Install the rocker cover. (See Rocker Cover Removal And

Figure 70-70-19
1
1 1
P-55525
Install the tubelines (Item 1) [Figure 70-70-21] to the

P-55528 pump and tighten to 22 ft.-lb. (30 N•m) torque.
Do not overtighten.
Tighten the mount bolt (Item 1) [Figure 70-70-19] to 32
ft.-lb. (44 N•m) torque. Figure 70-70-22

Figure 70-70-20
1
1
P-55524
P-55533
Connect the return spring (Item 1) [Figure 70-70-20] to

the pump linkage.

ENGINE COMPONENTS AND TESTING (CONT'D) Fuel Injectors Removal And Installation
Figure 70-70-23
WARNING
1 death. Fluid leaks under pressure may not be visible.
2 Use a piece of cardboard or wood to find leaks. Do
enters skin or eyes, get immediate medical attention
W-2072-0807
Figure 70-70-25
P-55523
1
Install the two fuel lines (Item 1) [Figure 70-70-22] and
[Figure 70-70-23].

Install the electrical connector (Item 2) [Figure 70-70-
1 2
23].
Figure 70-70-24
1
S6894
Remove the three bolts (Item 1) and remove the fuel

injector cover (Item 2) [Figure 70-70-25].
1
Figure 70-70-26
P-55522
Install the harness (Item 1) [Figure 70-70-24].
Remove air from the system.
S6895
Remove the breather hose (Item 1) [Figure 70-70-26].

ENGINE COMPONENTS AND TESTING (CONT'D)
Fuel Injector Removal And Installation (Cont'd)

IMPORTANT
Figure 70-70-27
Do not bend the high pressure fuel injection tubes
when removing or installing them.
4 I-2029-0289
3 3
Figure 70-70-29
1
1
2 1
1
S6896
Remove the bolt (Item 1) and remove the breather fitting

(Item 2) [Figure 70-70-27].

S6897
Remove the three bolts (Item 3) and remove the fuel filter
Disconnect the injector tubelines (Item 1) [Figure 70-70-
Figure 70-70-28 29] from the injectors.
Installation: Tighten the tubelines to 22 ft.-lb. (30 N•m)

1 torque.
Remove the tubelines.
Figure 70-70-30
1 1
1
P-55777
2
Disconnect the four injector tubelines (Item 1) [Figure

70-70-28] from the injector pump.
Installation: Tighten the tubelines to 20 ft.-lb. (27 N•m) 3

torque.
P-55614
Remove the fuel return hoses (Item 1) and remove the

bolt (Item 2) and clamp (Item 3) [Figure 70-70-30].
Installation: Tighten bolt to 26 ft.-lb. (35 N•m) torque.

Fuel Injectors Removal And Installation (Cont'd)
Figure 70-70-31
P-55616
Installation: Always replace the copper washer (Item 1)

P-55615 [Figure 70-70-33] at the nozzle. If the washer remains in
the cylinder head, it must be removed.
Remove the injector from the cylinder head [Figure 70- Checking The Fuel Lift Pump
70-31].

Figure 70-70-34
Figure 70-70-32
P-55525
P-55617
Remove the fuel lift pipe (Item 1) [Figure 70-70-34] from

Installation: The roll pin must be in the position shown the injector pump, fit a suitable pipe with a pressure test
[Figure 70-70-32]. point and connect a pressure gauge.
Operate the engine at idler for two minutes to allow any

trapped air to be removed.
Standard pressure should be 6 - 10 PSI (0,41 - 0,69 bar).

ENGINE COMPONENTS AND TESTING (CONT'D) Compression Checking
Fuel Lift Pump Removal And Installation The tools listed will be needed to do the following
procedure:
Figure 70-70-35
MEL10630 - Engine Compression Kit
MEL1352 - Compression Adapter
The engine must be at operating temperature.

2
Remove the glow plugs. (See Glow Plugs Removal And
1 Figure 70-70-37
S6898
Remove the two fuel lines (Item 1) and electrical harness

(Item 2) [Figure 70-70-35] from the fuel lift pump/filter

assembly.
1
Figure 70-70-36
P-55631
Install the correct compression adapter (Item 1) [Figure

1 70-70-37] into the cylinder head.
Figure 70-70-38
S6899
Remove the two fuel lines (Item 1) and three bolts (Item
2) [Figure 70-70-36] and remove the fuel lift pump/filter
assembly.
P-55632
Connect the compression gauge to the adapter [Figure

70-70-38].
Make sure the engine speed control is fully backward

(engine idle).
Disconnect the fuel stop solenoid.
Crank the engine with the starter at 200-300 RPM.

ENGINE COMPONENTS AND TESTING (CONT'D) Glow Plug Checking
Compression Checking (Cont’d) Disconnect the glow plug cables and leads.
If the measurement is below the allowable limit, check Figure 70-70-40

the cylinder, piston ring, top clearance, valve and cylinder
head.
Compression Pressure should be 43.5 - 72.5 PSI (2 - 3

bar).
Compression tests should only be used to compare

between the cylinders of an engine. (If one or more
cylinders vary by more than 51 PSI (3,5 bar) then those
cylinders may be faulty.
Figure 70-70-39
P-55629
Use an ohmmeter to check the glow plugs [Figure 70-70-

40].

Figure 70-70-41
P-55633
Push the button on the compression gauge to release

pressure [Figure 70-70-39].
Connect the fuel stop solenoid.
P-55630
Touch one probe to the end of the glow plug and the
other probe to the body of glow plug [Figure 70-70-41].
The reading must be between 1 and 2 ohms [Figure 70-

70-41]. If the resistance is infinite, the coil of the glow
plug is broken.
Repeat the procedure for each glow plug.

Glow Plugs Removal And Installation
Disconnect the negative (-) cable from the battery. 1

2 1
1
Figure 70-70-42
3
1 2
S6900
Remove the nut (Item 1) [Figure 70-70-44] from the top

of each glow plug.
1
S6894 Installation: Tighten to 1.5 ft.-lb. (2 N•m) torque.
Disconnect the engine harness wire (Item 2) [Figure 70-

Remove the three bolts (Item 1) and remove the fuel 70-44] from the glow plug.
injector cover (Item 2) [Figure 70-70-42].
Remove the glow plug connecting strap (Item 3) [Figure
Figure 70-70-43 70-70-44].
Figure 70-70-45
1
S6895 1
S6901
Remove the hose clamp (Item 1), the bolt (Item 2) and
remove the breather (Item 3) [Figure 70-70-43].
Loosen and remove the glow plugs (Item 1) [Figure 70-
70-45].
Installation: Tighten the glow plug to 13 ft.-lb. (15 N•m)

torque.

ENGINE TIMING Figure 70-80-2
Procedure
The tool listed will be needed to do the following

procedure:
MEL-1638 Camshaft Timing Pin 1
MEL-1639 Crankshaft Timing Pin
Remove the rocker cover. (See Rocker Cover Removal

Remove the glow plugs. (See Glow Plugs Removal And

Installation on Page 70-70-12.) P-55601
Remove the timing case cover. (See Timing Cover Carefully rotate the crankshaft in the normal direction of
Removal on Page 70-110-20.) rotation. Align the hole in the crankshaft with the hole in
the cylinder block and timing case and install the
NOTE: The marks on the timing gears are not to be crankshaft timing pin (MEL-1639) (Item 1) [Figure 70-80-
used as timing marks. The marks indicate the 2]. Push the pin fully into the hole.
front of the gear only.
Figure 70-80-3

Figure 70-80-1
1 2
P-55602
P-55600
Insert the camshaft timing pin (MEL-1638) (Item 1)
[Figure 70-80-3] through the hole in the camshaft gear
To set the number one piston to TDC on the correct and into the body of the timing case. With the two pins
stroke, rotate the crankshaft in the normal direction of fitted the engine is set at TDC number one on the
rotation until the intake valve (Item 1) of the number four compression stroke.
cylinder has just opened and the exhaust valve (Item 2) NOTE: The camshaft timing pin is a push fit into the
[Figure 70-80-1] of the same cylinder has not closed timing case. The camshaft gear can rotate a
completely. small amount when the pin is fitted. This
allows the assembly of the gears and removal
of the backlash from the gears, with the timing
pins fitted.
Remove the timing pin from each gear.
Install the timing case cover. (See Timing Cover
Install the glow plugs. (See Glow Plugs Removal And


ENGINE / HYDROSTAT ASSEMBLY Figure 70-90-2
Remove the engine cover. (See Removal And Installation

on Page 50-70-1.)
Remove the air intake cowling. (See Removal And

1
P-44577
Drain the radiator. (See Removal And Installation on
Page 70-50-1.)
Remove the battery. (See Removal And Installation on 90-2].
Page 60-20-1.)
Figure 70-90-3
Remove the muffler. (See Removal And Installation on
Page 70-30-1.)

Remove the drive shaft. (See Removal And Installation
on Page 40-70-1.)
If equipped with air conditioning, remove the refrigerant

from the A/C system. (See Reclamation Procedure on
Page 80-100-1.)
1
Figure 70-90-1
P-44578

90-3].
2
S4592

(Item 2) [Figure 70-90-1] located on the back of the
canopy.
NOTE: Mark all hoses and electrical connectors, for


ENGINE / HYDROSTAT ASSEMBLY (CONT'D) Figure 70-90-6
Figure 70-90-4
2
2
1
P-44932

P-44925 connector (Item 2) [Figure 70-90-6].
Figure 70-90-7

Figure 70-90-5
1
1 P-44933

P-44930 [Figure 70-90-7].

5].

For V723 models with S/N A8HL12999 & Below, S/N

Figure 70-90-8 1
P-53572
Remove the cover (Item 1) [Figure 70-90-10].
Figure 70-90-11
P-53570A

1
Figure 70-90-9
P-53573
1
Temporarily remove the protective covering (Item 1)
[Figure 70-90-11] from the A/C hoses and expansion
valve.
S4599

ENGINE / HYDROSTAT ASSEMBLY (CONT'D) For V723 models with S/N A8HL13000 & Above, S/N
A8HP13000 & Above:
Figure 70-90-14
Figure 70-90-12
P-97028
P-53574

90-12]. Remove the A/C hoses. Remove the dash cover / steering column cover. (See

NOTE: Plug the A/C hoses to prevent contamination.
Figure 70-90-13 Installation on Page 50-151-1.)
Figure 70-90-15
P-53585
S36381
Unplug the connector (Item 1) [Figure 70-90-13] located
under the fuse box.

ENGINE/HYDROSTAT ASSEMBLY (CONT'D) Figure 70-90-18
Figure 70-90-16
1
S36344
Unplug the connectors (Item 1) [Figure 70-90-18]

S36333 located under the fuse box.
Mark and remove both A/C hoses (Item 1) [Figure 70-90-

16].

NOTE: Plug the A/C hoses (Item 1) [Figure 70-90-16] to
prevent contamination.
Remove the heater hose (Item 2) [Figure 70-90-16] NOT

connected to the heater valve (Item 3) [Figure 70-90-17].
Figure 70-90-17
2
3
S36334
Remove the heater hose (Item 1) [Figure 70-90-17].
Remove bolt, nut and clip (Item 2) [Figure 70-90-17].


1
For all models:
Figure 70-90-19
1 1
P-56463

1 the backside of the pump.
P-53575 Figure 70-90-22

19].
Figure 70-90-20
2
1
P-56477
2
Remove the four bolts (Item 1) and remove the hose
(Item 2) [Figure 70-90-22] from the hydrostatic pump.
1
P-53576
Remove the two A/C hoses (Item 1) and harness (Item 2)

WARNING
[Figure 70-90-20] completely from the rear corner of the
cab. Hydraulic fluid escaping under pressure can have
immediately.
W-2145-0290

Figure 70-90-23
P-56468
Loosen the hose clamp (Item 1) [Figure 70-90-25] and

P-56478 remove the hose.
Figure 70-90-26
backside of the pump.

Figure 70-90-24
1
P-56470
Loosen the hose clamp (Item 1) and remove the hose

P-56464 (Item 2) [Figure 70-90-26].
IMPORTANT
IMPORTANT When repairing hydrostatic and hydraulic systems,
When repairing hydrostatic and hydraulic systems, tubelines and ports to keep dirt out. Dirt can quickly
clean the work area before disassembly and keep all damage the system.
parts clean. Always use caps and plugs on hoses, I-2003-0888
damage the system.
I-2003-0888

Figure 70-90-27
1 P-56486

P-58089
Figure 70-90-30

hydrostatic pump.

Figure 70-90-28 1
1
P-56488

the solenoids.
P-56485

Figure 70-90-31
P-56491

P-58092
Figure 70-90-34

tubeline.

Figure 70-90-32
P-56493
1
P-56490
Remove the four bolt flange hose (Item 1) [Figure 70-90-

32] from the front of the pump.

Figure 70-90-35
S6839
1

P-58088 the tow valve.
Figure 70-90-38
the hydraulic reservoir.

Figure 70-90-36
1
P-53603

S6902 70-90-38].
Remove the two heater hoses (Item 1) [Figure 70-90-36]

from the engine.

Figure 70-90-39
P-29534
Remove the heater hoses, fuel lines and speed control

P-53604 cable from the engine compartment and route through
the access hole [Figure 70-90-41].
Remove the engine speed control cable (Item 1) [Figure Figure 70-90-42

Figure 70-90-40
1
1
2
2 1
P-44924
S6903 Remove the three hoses (Item 1) [Figure 70-90-42].
Remove any necessary nylon ties.

Cut the tie strap (Item 1) and remove the two fuel lines
(Item 2) [Figure 70-90-40].

Figure 70-90-43
S7483
Install a chain hoist to lift and secure the engine

S6904 assembly [Figure 70-90-45].
Figure 70-90-46
Remove nut (Item 1) [Figure 70-90-43] from the starter.

Figure 70-90-44
P-53619
P-53624 Remove the engine assembly mounting bolt (Item 1)

[Figure 70-90-46] from the lower front.
Route the ground strap mounting bolt (Item 1) [Figure

70-90-44].

Figure 70-90-47
S6907
Remove the three engine assembly mounting bolts (Item

S6906 1) [Figure 70-90-47], [Figure 70-90-48], and [Figure 70-
90-49].
Figure 70-90-48 Figure 70-90-50

1
S6908 P-53629
Lift the engine assembly up approximately one inch (25

mm) and remove the engine assembly from the machine
[Figure 70-90-50].


FLYWHEEL AND HOUSING Figure 70-100-3

1
NOTE: Set the engine/hydrostat assembly on blocks,
to allow access to remove the motor mount
bolts.
Remove the hydrostatic pump. (See Removal And

Remove the starter. (See Removal And Installation on

Page 60-40-1.) P-53796
Figure 70-100-1
Remove both rear engine mounting bolts (Item 1)
[Figure 70-100-2] and [Figure 70-100-3].
Installation: Tighten engine mounting bolts to 185 - 200

ft.-lb. (250 - 271 N•m) torque.

Figure 70-100-4
P-53793
Install lifting brackets and hoist on the housing to lift and

support [Figure 70-100-1].
Figure 70-100-2
P-53797
Lifting from the housing assembly, raise the engine

slightly and place support blocks under the oil pan
1 [Figure 70-100-4].
Lower the engine assembly on the support blocks.
P-53794

FLYWHEEL AND HOUSING (CONT'D) Figure 70-100-7
Figure 70-100-5 1
1
1
P-53800
Remove the six coupler mounting bolts (Item 1) [Figure

P-53798 70-100-7]. Remove the coupler.
Installation: Tighten the bolts to 40 - 45 ft.-lb. (54 -

Loosen and remove the ten flywheel housing mount bolts 61 N•m) torque.
(Item 1) [Figure 70-100-5].

Figure 70-100-8
Installation: Tighten to 40 - 45 ft.-lb. (54 - 61 N•m)
torque.
Figure 70-100-6
P-53801
Remove two of the flywheel mount bolts and install two

P-53799 guide studs (Item 1) [Figure 70-100-8] in the flywheel to
prevent the fly wheel from falling.
Remove the flywheel housing from the engine [Figure

70-100-6].

FLYWHEEL AND HOUSING (CONT'D) Figure 70-100-11
Figure 70-100-9
B-05559
2 Install a dial indicator to check the flywheel run out

P-53803 [Figure 70-100-11].
Flywheel run out must be less than 0.012 in. (0,30 mm).
Install a chain hoist (Item 1) [Figure 70-100-9].
Figure 70-100-12

Remove the remainder of the bolts (Item 2) [Figure 70-
100-9]. Remove the flywheel by sliding outward over the
guide studs.
8” (203 mm)
Installation: Tighten the flywheel bolts to 85 ft.-lb. (115
N•m) torque.
Figure 70-100-10
3 3
2 2
1
B-05560
2 Check the alignment of the flywheel face [Figure 70-100-

2 12].
The misalignment must not be more than 0.001 in. (0,03

mm) total indicator reading for every 1.0 in. (25 mm) of
P-53804 the flywheel radius from the crankshaft axis to the dial
gauge plunger.
If removing the backing plate (Item 1) is required, loosen Example: The misalignment must not be greater than
and remove the eight mounting bolts (Item 2 and 3) 0.008 in. (0,203 mm) at 8 in. (203 mm) from the
[Figure 70-100-10]. centerline of the crankshaft towards the outside of the
flywheel.
Installation: Tighten the bolts (Item 2) to 46 ft.-lb. (63
N•m) and the bolts (Item 3) to 55 ft.-lb. (75 N•m) torque. During this check keep the crankshaft pressed toward
the front so crankshaft end play will not affect the
Check the flywheel and ring gear for wear or damage. reading.
Replace as needed.

FLYWHEEL AND HOUSING (CONT'D) Ring Gear Installation
Ring Gear Removal The ring gear is a heat expansion fit on the flywheel.
Before the ring gear is removed note the position of the Do not heat the ring gear to a temperature greater than
chamfer on the teeth. 480°F (250°C) make sure the ring gear chamfer is in the
correct position.
Heat the ring gear enough to expand it and hit it with a
hammer evenly to remove it.
Be careful not to damage the flywheel during this

operation.

RECONDITIONING THE ENGINE
Turbocharger Troubleshooting
The chart below is given to assist in the correct diagnosis of turbocharger faults.
If the inside of the intake manifold is wet, check that there is not a fuel leak from the starting aid.
PROBLEM CAUSE
Not enough power 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Black Smoke 1, 4, 5, 6, 7, 8, 9, 10, 11, 18, 20, 21, 22, 25, 26, 27, 28
Blue Smoke 1, 2, 4, 6, 8, 9, 17, 19, 20, 21, 22, 30, 31, 32
High Lubricating Oil Consumption 2, 8, 15, 17, 19, 20, 28, 29, 31, 32
Two Much Lubricating Oil At Turbine End 2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32
Two Much Lubricating Oil At Compressor End 1, 2, 4, 5, 6, 8, 19, 20, 21, 28, 31, 32
Not Enough Lubrication 8, 12, 14, 15, 16, 23, 24, 29, 32, 33, 34, 35
Lubricating Oil In The Exhaust Manifold 2, 7, 17, 18, 19, 20, 22, 28, 31, 32
Inside The Induction Manifold Wet 1, 2, 3, 4, 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32, 36, 37
Damaged Compressor Impeller 3, 4, 6, 8, 12, 15, 16, 20, 21, 23, 24, 29, 32, 33, 35, 36
Damaged Turbine Rotor 7, 8, 12, 13, 14, 15, 16, 18, 20, 22, 23, 24, 25, 27, 29, 29, 32, 33, 34,
35
Rotating Assembly Does Not Turn Freely 3, 6, 7, 8, 12, 13, 14, 15, 16, 18, 20, 21, 22, 23, 24, 29, 32, 33, 34, 35

Worn Bearings, Bearing Bores, Journals 6, 7, 8, 12, 13, 14, 15, 16, 23, 24, 29, 33, 34, 35
Noise From Turbocharger 1, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 20, 21, 22, 23,
24, 29, 32, 33, 34, 35
Sludge or Carbon Deposit In Bearing Housing 2, 11, 13, 14, 15, 17, 18, 24, 29, 33, 34, 35

1. Air filter element dirty. 17. Restricted lubricating oil drain pipe.
2. Restricted crankcase breather. 18. Turbine housing damage or restricted.
3. Air filter element missing, leaking or not sealing 19. Leakage from turbocharger seals.
correctly. Loose connection to turbocharger.
4. Internal distortion or restriction in pipe from air filter to 20. Worn turbocharger bearings.
turbocharger.
5. Damaged/restricted crossover pipe, turbocharger to 21. Excessive dirt in turbocharger housing.
induction manifold.
6. Restriction between air filter and turbocharger. 22. Excessive carbon behind turbine rotor.
7. Restriction in exhaust system. 23. Engine speed raised too rapidly at initial start.
8. Turbocharger loose or clamps/setscrews loose. 24. Insufficient engine idle period.
9. Induction manifold cracked or loose, flanges distorted. 25. Faulty fuel injection pump.
10. Exhaust manifold cracked or loose. 26. Worn or damaged fuel injectors.
11. Restricted exhaust system. 27. Valves burned.
12. Delay of lubricating oil to turbocharger at engine start. 28. Worn piston rings. flanges distorted.
13. Insufficient lubrication. 29. Lubricating oil leakage from supply pipe.
14. Dirty lubricating oil. 30. Excessive starting fluid (on initial engine start).
15. Incorrect lubricating oil. 31. Excessive engine idle period.
16. Restricted lubricating oil supply pipe. 32. Restriction in turbocharger bearing housing.
33. Restriction in lubricating oil filter.
34. Engine stopped too soon from high load.
35. Insufficient lubricating oil.
36. Fuel leakage from fuelled starting aid.
37. Crack in back plate of compressor.

RECONDITIONING THE ENGINE (CONT'D) Turbocharger Removal And Installation
Turbocharger Description Figure 70-110-2
WARNING
Turbochargers, operate at high speed and high 1
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196
2
Figure 70-110-1
P-55619
Remove the two bolts (Item 1) and remove the exhaust

elbow (Item 2) [Figure 70-110-2].
Figure 70-110-3

1
P-55618
The turbocharger (Item 1) [Figure 70-110-1] is placed

between the exhaust and intake manifolds. It is driven by
hot exhaust gases and supplies air at more than 1
atmospheric pressure to the intake. It is lubricated by oil
from the main gallery.
P-55515
The oil flows from the filter adapter through the bearing
housing and returns to the engine block.
Loosen the intake tube clamp (Item 1) [Figure 70-110-3].
The turbocharger should only be serviced by an
authorized dealer or repair shop.

RECONDITIONING THE ENGINE (CONT'D) Figure 70-110-6
Turbocharger Removal And Installation (Cont'd)
Figure 70-110-4
2
1
P-55621
Remove the oil return line (Item 1) [Figure 70-110-6].

S6909
Figure 70-110-7
Loosen the clamp (Item 1) and remove the intake tube

(Item 2) [Figure 70-110-4].

Figure 70-110-5
1 1
1 P-55624
Remove the four nuts (Item 1) [Figure 70-110-7] for the

turbocharger to exhaust manifold flange.
P-55623
Installation: Apply anti-seize compound to the mounting
studs. Tighten the nuts to 33 ft.-lb. (44 N•m) torque.
Disconnect the oil supply tubeline (Item 1) [Figure 70-
110-5]. Remove the turbocharger and gasket from the exhaust
manifold.
Installation: Fill the bearing housing with clean oil
through the oil supply port. Tighten banjo fitting to 16 ft.- The turbocharger must only be serviced by an authorized
lb. (22 N•m) torque. repair shop.
Before starting the engine, disconnect the electrical stop

control. Crank the engine until oil pressure is obtained.
Stop cranking and reconnect the stop control.

RECONDITIONING THE ENGINE (CONT'D) Fuel Injector Cover Removal And Installation
Exhaust Manifold Removal And Installation Figure 70-110-10
Remove the turbocharger. (See Turbocharger Removal

And Installation on Page 70-110-2.) 1
Figure 70-110-8
1
1 1
1
S6894
Remove the three bolts (Item 1) [Figure 70-110-10] and

remove the cover.
P-55625
Installation: Tighten the bolts to 7 ft.-lb. (9 N•m) torque.

Remove the eight mount bolts (Item 1) [Figure 70-110-
8].
Remove the exhaust manifold and gasket.
Figure 70-110-9
5 2 8
1
4 3 7
6
P-55625
Installation: Tighten the bolts in the sequence shown


Rocker Cover Removal And Installation
Remove the fuel injector cover. (See Fuel Injector Cover

Figure 70-110-11 1
S6895
Remove the breather hose (Item 1) [Figure 70-110-13].

1
Figure 70-110-14
P-55515

Loosen the intake tube clamp (Item 1) [Figure 70-110-
11].
Figure 70-110-12
1
2
2
1
S6896
Remove the bolt (Item 1) and remove the breather fitting

(Item 2) [Figure 70-110-14].
S6909
Loosen the clamp (Item 1) and remove the intake tube

(Item 2) [Figure 70-110-12].

RECONDITIONING THE ENGINE (CONT'D) Cylinder Head Removal
Rocker Cover Removal And Installation (Cont'd) Remove the turbo charger. (See Turbocharger Removal
Figure 70-110-15
Remove the exhaust manifold. (See Exhaust Manifold
1 1
Remove the alternator. (See Removal And Installation on
Page 60-30-1.)
Remove the fuel lift pump. (See Fuel Lift Pump Removal
Remove the fuel injectors. (See Fuel Injectors Removal

1
1 Remove the glow plugs. (See Glow Plugs Removal And

1 Installation on Page 70-70-12.)
P-55519
Figure 70-110-17
Remove the ten mount bolts (Item 1) [Figure 70-110-15].

Figure 70-110-16
1 10 3 5
8
P-55681
7
6 4 9 2 Unplug the engine cooling temperature sensor (Item 1)
P-55519 [Figure 70-110-17].
NOTE: Mark wires for correct installation.

Installation: Tighten the bolts in the sequence shown

Cylinder Head Removal (Cont'd)

2
Figure 70-110-18 1
1
P-55684
1
Remove the two bolts (Item 1) and remove the coolant
P-55682 bypass tube (Item 2) [Figure 70-110-20].
Remove the rocker cover. (See Rocker Cover Removal

Unplug the intake manifold pressure sensor (Item 1) And Installation on Page 70-110-5.)
[Figure 70-110-18].

Remove the rocker shaft assembly. (See Rocker Shaft
Reposition the harness. Disassembly And Assembly on Page 70-110-12.)
Figure 70-110-19 Figure 70-110-21
P-55683 P-8718A
Remove the tubeline (Item 1) [Figure 70-110-19]. Remove the push rods [Figure 70-110-21].

RECONDITIONING THE ENGINE (CONT'D) Cylinder Head Inspection
Cylinder Head Removal (Cont'd) Figure 70-110-23
Figure 70-110-22
1 1 1 1 1 3
8
9 5 1 4
2
3
10 7
6 2 3
B-5564
B-23183
Put a straight edge on the cylinder head as shown in
[Figure 70-110-23].
Release the cylinder head bolts evenly and gradually in
the sequence shown [Figure 70-110-22]. Using a feeler gauge between the straight edge and

head, check for warping.
Check the head bolts for distortion and damage. Replace
as needed. Maximum allowed (Item 1) is 0.0012 in. (0,03 mm), (Item
2) is 0.0019 in. (0,05 mm) and (Item 3) [Figure 70-110-
Lift off the cylinder head and clean the bottom face. 23] is 0.0019 in. (0,05 mm).
The head may be machined removing only a minimum

amount. Head thickness must not be less than 4.614 in.
(117,20 mm).
Completely clean the rest of the head.
Check for cracks or other damage.

Cylinder Head Installation

3
2 6 10 7
Make sure the mating surfaces of the head and block are
clean.
Clean the engine block bolt bores with the correct size
tap to ensure correct torque for the cylinder head bolts.
Clean any debris out of the cylinder bores.
Figure 70-110-24 1
5 9 8 4
B-23183
2
1
Tighten the head bolts to 37 ft.-lb. (50 N•m) in the
FRONT TOP
sequence shown [Figure 70-110-25].
Tighten the head bolts to 74 ft.-lb. (100 N•m) in the

sequence shown [Figure 70-110-25].

Figure 70-110-26
B-5562
1
NOTE: The locating pins (Item 1) are pressed in the
engine block so the head gasket (Item 2)
[Figure 70-110-24] can be positioned
correctly.
The head gasket is installed with no sealer.
Place the head gasket in position with the Front Top (Item
2) [Figure 70-110-24] marks in the correct position.
P-8839
Lower the cylinder head in position.
Additional tightening of the head bolts requires the use of

a torque angle gauge (Item 1) [Figure 70-110-26].
Tighten the short bolts to 225° and long bolts to 270° in
the same sequence as shown in [Figure 70-110-25].

Cylinder Head Installation (Cont'd)
Figure 70-110-27 2
225° 270°
2
P-55684
Install the coolant bypass pipe (Item 1) and two screws

B-5563A (Item 2) [Figure 70-110-29].
Tighten the screws to 16 ft.-lb. (22 N•m) torque.

If no angle gauge is available make a suitable mark on
the head bolt corner. Make another mark on the cylinder Figure 70-110-30

head the correct number of flats away [Figure 70-110-
27]. Turn the head bolt until the lines match.
Figure 70-110-28
1
P-55683
Install the tubeline (Item 1) [Figure 70-110-30].

P-8718A
Install the push rods [Figure 70-110-28].
Make sure the push rods seat in the tappet sockets.
Install the rocker shaft assembly. (See Rocker Shaft

Disassembly And Assembly on Page 70-110-12.)


Cylinder Head Installation (Cont'd)
Figure 70-110-31
P-55681
1
Connect the engine cooling temperature sensor (Item 1)

P-55682 [Figure 70-110-32].
Install the glow plugs. (See Glow Plugs Removal And

Connect the intake manifold pressure sensor (Item 1) Installation on Page 70-70-12.)
[Figure 70-110-31].

Install the fuel injectors. (See Fuel Injectors Removal And
Install the fuel lift pump. (See Fuel Lift Pump Removal
Install the alternator. (See Removal And Installation on

Page 60-30-1.)
Install the exhaust manifold. (See Exhaust Manifold

Install the turbo charger. (See Turbocharger Removal


RECONDITIONING THE ENGINE (CONT'D) Valve Removal
Rocker Shaft Disassembly And Assembly NOTE: Mark all components so they can be returned
to the same position.
NOTE: Make an identification mark on each rocker
arm assembly in order to show the location. Figure 70-110-34
Figure 70-110-33
4 5
2 3
3
2 P-8720A
P-8719A
Using a valve spring compressor compress the springs

and remove the retainers (Item 1) [Figure 70-110-34].
Remove the clips (Item 1) [Figure 70-110-33] from both
ends of the shaft. Release the compressor and remove the valve spring
cap (Item 2), spring (Item 3), valve seal/spring seat
Remove the rocker arm (Item 2) and spring (Item 3) washer (Item 4) and valve (Item 5) [Figure 70-110-34].
[Figure 70-110-33].
Clean and inspect all components.
Continue to disassemble the rocker shaft.
Clean and inspect all components for damage and wear.
Check the clearance between the rocker arms and shaft.
Using a press and adapter, remove the old bushing and

press in the new one making sure the oil holes line up.
Shaft O.D. 0.9828 - 0.9837 in.

(24,962 - 24,987 mm)
Rocker Arm Bore Dia. 0.9848 - 09.863 in.
(25,013 - 25,051 mm)
Clearance Between Rocker Arm 0.0010 - 0.0035 in.
and Shaft (0,026 - 0,089 mm)
If the clearance is more than 0.005 in. (0,13 mm) replace

the bushing(s).

RECONDITIONING THE ENGINE (CONT'D) Valve Depth Checking
Valve Springs Checking Figure 70-110-36
Figure 70-110-35
1.3846 in.
(35,17 mm)
N-00533
B-5552
Check the valve depth as shown in [Figure 70-110-36].
Use the following chart [Figure 70-110-35]. The maximum depth is 0.0811 in. (2,06 mm) for both
intake and exhaust valves.

Valve Springs
Compressed Height 1.3846 in. (38,17 mm) If the valve is below the limits, install a new valve and
recheck the valve depth. If it is still below limits a new
Installed Pressure 75 lb. (335 N) valve seat insert must be installed.
When the depth is less than 0.060 - 0.071 in. (1,53 - 1,81
mm) the seat may be ground to lower the valve depth.

RECONDITIONING THE ENGINE (CONT'D) Interference fit of valve guide to cylinder head: 0.0003 -
0.0019 in. (0,007 - 0,047 mm)
Valve Guides Checking
Overall Diameter (Item 3) [Figure 70-110-37]
Figure 70-110-37
Intake and Exhaust 2.018 - 2.027 in.
1 (51,00 - 51,50 mm)
Protrusion from bottom recess for valve spring;

(Item 4) [Figure 70-110-37] 0.486 - 0.498 in.
3 (12,35 - 12,65 mm)
To check the valve guides for wear using a valve.
2 Set up dial indicator gauge (Item 1) [Figure 70-110-37]

as shown.
B-5551
Lift the valve (Item 2) 0.60 in. (15,0 mm) and move the
valve in and away from the gauge (Item 1) [Figure 70-
Figure 70-110-38 110-37]. Record this reading.
If the clearance exceeds 0.005 in. (0,13 mm) for intake or

0.006 in. (0,15 mm) for exhaust (Item 3) [Figure 70-110-
38] the valve guide needs to be replaced.
1 3
B-5566A
The valve guides can be checked for wear with either of

the operations listed in [Figure 70-110-37] or [Figure 70-
110-38].
Use the following chart to check valve guides.
Inside Diameter
(Item 1) [Figure 70-110-37] 0.3543 - 0.3552 in.
(9,00 - 9,022 mm)
Outside Diameter (Item 2) [Figure 70-110-37]

Intake and Exhaust 0.5131 - 0.5137 in.
(13,034 - 13,047 mm)

RECONDITIONING THE ENGINE (CONT'D) Valve Guide Installation
Valve Guide Removal Figure 70-110-40
Clean the guide bore in the head.
Figure 70-110-39

B-5548
Clean the guide bore in the head.
Lubricate the outer surface of the new guide (Item 1)

B-5549 [Figure 70-110-40] with the engine oil.
Put the guide in position on the valve guide removal/

Install a valve guide removal/installation tool (Item 1) on installation tool (Item 2) [Figure 70-110-40].
the valve guide (Item 2) [Figure 70-110-39].
Pull the guide into the cylinder head.
Pull the guide (Item 2) [Figure 70-110-39] out of the
cylinder head. When correctly positioned the top of the guide should
extend 0.486 - 0.498 in. (12,35 - 12,65 mm) above the
valve spring seat [Figure 70-110-37].

RECONDITIONING THE ENGINE (CONT'D) Cutting A Valve Seat
Valves Checking Before any work is done the valve guides must meet
specifications or have been replaced.
NOTE: If the valves do not meet specifications they
need to be replaced. They cannot be ground. Install the pilot in the valve guide.
Figure 70-110-41 Select the correct size cutter.
Valve Seat Angle Inlet/Exhaust 45°/30°
Figure 70-110-42
4
1
B-5567

Use the following chart [Figure 70-110-41] to check the
valve dimensions.
N-00532
Ref. Valve Specifications

1. Intake 5.0724 - 5.0901 in. Carefully turn the cutter in a clockwise direction using
(128,838 - 129,288 mm) even downward pressure. Keep the valve seat as narrow
Exhaust 5.0466 - 5.0643 in. as possible [Figure 70-110-42].
(128,184 - 128,634 mm)
Remove any cutting debris.
2. Intake 0.3525 - 0.3533 in.
(8,953 - 8,975 mm)
Install the valve and lightly tap.
Exhaust 0.3519 - 0.3528 in.
(8,938 - 8,960 mm)
Check the valve depth to make sure that it is within limits.
3. Intake 1.8220 - 1.8319 in. (See Valve Guides Checking on Page 70-110-14.)
(46,28 - 46,53 mm)
Exhaust 1.634 - 1.644 in. NOTE: If the valve seat is worn or damaged, a new
(41,51 - 41,75 mm) valve seat insert can be installed.
4. Intake 0.0630 - 0.0728 in.
(Production) (1,60 - 1,85 mm)
Intake 0.0823 in. (2,09 mm)
(Service Max.)
Exhaust 0.0610 - 0.0713 in.
(Production) (1,55 - 1,81 mm)
Exhaust 0.0811 in. (2,06 mm)
(Service Max.)
Intake/Exhaust 45°/30°
Valve Face Angle

RECONDITIONING THE ENGINE (CONT'D)
Valve Seat Assembly
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-0907
Figure 70-110-43
4 5

1
2 3
P-8720A
Lubricate the valve stems (Item 1) [Figure 70-110-43]

with clean engine oil and install them in the respective
guides.
Install new valve seals/spring seat washer (Item 2)

[Figure 70-110-43].
Install the spring (Item 3) [Figure 70-110-43] on the

washer (make sure the larger diameter is against the
cylinder head).
Place the valve cap (Item 4) [Figure 70-110-43] on the

spring.
Using a valve spring compressor compress the springs

and install the retainers (Item 5) [Figure 70-110-43].

Changing Valve Springs (With Cylinder Head

Installed)
Remove the rocker cover.
Figure 70-110-44
N-00531
Install the valve spring compressor and adapter [Figure

70-110-45].
Compress the valve springs squarely and remove the

B-5565 retainers.

NOTE: Do not rotate the crankshaft while the valve
Rotate the crankshaft clockwise until the intake valve has springs are removed.
opened and the exhaust valve has not fully closed. In this
position the piston (Item 1) [Figure 70-110-44] will be at Release the compressor and remove the valve spring(s).
approximately T.D.C.
Place the new valve springs in position.
Remove the rocker shaft assembly.
Compress the valve springs and install the retainers.

Valve Clearance Adjustment
Adjust the valve clearance as follows:
Figure 70-110-46
1 2 3 4 5 6 7 8
2 1
B-5569
Figure 70-110-48
3 Cylinder
B-5568 No. 1 2 3 4
Valve No. 1 2 3 4 5 6 7 8
Valve

Loosen the lock nut (Item 1) [Figure 70-110-46].
1=Intake I E I E I E I E
E=Exhaust
Turn the adjustment screw (Item 2) [Figure 70-110-46]
until the correct clearance is obtained.
Use the following sequence to set the valves [Figure 70-
NOTE: The clearance is measured between the 110-47] and [Figure 70-110-48].
rocker arm and valve stem tip (Item 3) [Figure
70-110-46]. a. With the rocker arm rocking (valves 7 and 8) on No.
4 cylinder set clearance at No. 1 cylinder (valves 1
Adjust the valve clearance as follows: and 2).
b. With the rocker arm rocking (valves 3 and 4) on No.
0.008 in. (0,20 mm) Intake 2 cylinder set clearance at No. 3 cylinder (valves 5
0.018 in. (0,45 mm) Exhaust and 6).
c. With the rocker arm rocking (valves 1 and 2) on No.
and 8).
d. With the rocker arm rocking (valves 5 and 6) on No.
and 4).

RECONDITIONING THE ENGINE (CONT'D) Crankshaft Pulley Removal And Installation
Timing Case And Drive Assembly Description Figure 70-110-50
The timing case is made of aluminum and the cover is

made of tin and in most applications, the timing gears are
made of steel. The drive from the crankshaft passes to
the idler gear, to the camshaft gear, to the gear on the 1
fuel injection pump and to the water pump.
The camshaft and fuel injection pump run at half the

speed of the crankshaft. 1
Timing Cover Removal 2
Remove the water pump. (See Water Pump Removal on

Page 70-110-40.)
S6912
Figure 70-110-49
Remove the three bolts (Item 1) and thrust block (Item 2)
[Figure 70-110-50].
Installation: Tighten the bolts to 85 ft.-lb. (115 N•m)

torque.

1
2
1 Remove the pulley.
Front Oil Seal Removal And Installation

1 Remove the crankshaft pulley. (See Crankshaft Pulley
1 Removal And Installation on Page 70-110-20.)
Remove the oil seal using a seal removal tool.

1
S6911
Do not damage the edge of the seal housing.
Remove the timing cover bolts (Item 1) and remove the Figure 70-110-51
timing cover (Item 2) [Figure 70-110-49].
Timing Cover Installation
Clean the gasket mating surfaces.
Place the gasket and timing cover on the engine.
Remove the timing pins if fitted.
Hold the timing cover in position and install two bolts that
are on opposite sides of the cover. Do not tighten the
bolts.
1
Install the water pump. (See Water Pump Installation on P-55686
Page 70-110-40.)
Install the oil seal (Item 1) [Figure 70-110-51] into the
Do not tighten bolts at this time. housing using the special tool.
Tighten the cover bolts and water pump bolts to 16 ft.-lb. Install crankshaft pulley. (See Crankshaft Pulley Removal
(22 N•m) torque. And Installation on Page 70-110-20.)

Timing Case And Gear Removal
Remove the timing cover. (See Timing Cover Removal 1

on Page 70-110-20.)
Remove the crankshaft pulley. (See Crankshaft Pulley

Remove the fuel injection pump. (See Fuel Injection

Pump Removal on Page 70-70-1.)
Figure 70-110-52
P-55689
1
Remove the idler gear (Item 1) [Figure 70-110-54] by
moving the gear assembly forward and lifted over the
front oil seal housing.
NOTE: Do not turn the crankshaft with the idler gear

2
removed.

Figure 70-110-55
1
P-55684
2 1
Remove the two bolts (Item 1) and remove the coolant
bypass tube (Item 2) [Figure 70-110-52].
Figure 70-110-53
3 1
P-55690
Remove the bolt (Item 1) and washer (Item 2) [Figure

70-110-55].
2
1
P-55688
Remove the three bolts (Item 1) and plate (Item 2) from

the idler gear (Item 3) [Figure 70-110-53].

RECONDITIONING THE ENGINE (CONT'D) Timing Case And Gear Installation
Timing Case And Gear Removal (Cont'd) Clean the mating surfaces, if the oil pan was not removed
trim the oil gasket flush with the block.
Figure 70-110-56
Figure 70-110-58
1
1 2
2
2
2
2
P-55691
2 P-55692
Remove the camshaft gear (Item 1) [Figure 70-110-56].

Fit the timing case (Item 1) onto the cylinder block and

NOTE: Use care not to lose the key from the key way. hand tighten the bolts (Item 2) [Figure 70-110-58].
Figure 70-110-57 After the cover is correctly aligned, tighten the mount
bolts (Item 2) [Figure 70-110-58] to 16 ft.-lb. (22 N•m)
torque.
1
1
Figure 70-110-59
1
1
1
2
2
2 P-55692
Remove all the timing case mount bolts (Item 1) and the
four bolts (Item 2) [Figure 70-110-57] from the front of
P-55691
the oil pan.
Remove the timing case from the engine. Install the camshaft gear (Item 1) onto the shaft using
alignment pin (Item 2) [Figure 70-110-59] for correct
alignment.

Timing Case And Gear Installation (Cont'd)
Figure 70-110-60
2
1 P-55688
Install the plate (Item 1) and three bolts (Item 2) [Figure

P-55690 70-110-62].
Tighten the bolts to 33 ft.- lb. (44 N•m) torque.

Install the washer (Item 1) and bolt (Item 2) [Figure 70-
110-60] and tighten to 70 ft.-lb. (95 N•m) torque. Figure 70-110-63

Figure 70-110-61
1
2
2
P-55684
P-55689
Install the coolant bypass tube (Item 1) using the two
bolts (Item 2) [Figure 70-110-63].
Install the idler gear (Item 1) make sure the hole (Item 2)
[Figure 70-110-61] is towards the cylinder head. Install the fuel injection pump. (See Fuel Injection Pump
Install the crankshaft pulley. (See Crankshaft Pulley

Install the timing cover.(See Timing Cover Installation on

Page 70-110-20.)

Camshaft And Tappets Removal
Remove the timing case cover. (See Timing Cover

Removal on Page 70-110-20.)
1
Remove the timing case. (See Timing Case And Gear

Removal on Page 70-110-21.)
Remove the rocker cover, rocker assembly and push

rods. (See Rocker Cover Removal And Installation on
Page 70-110-5.) P-8741
Remove the fuel pump and gasket.

Remove the camshaft thrust washer (Item 1) [Figure 70-
Figure 70-110-64 110-65].
Figure 70-110-66

1
P-8740
P-8742
Turn the engine over and remove the oil pan mounting
bolts [Figure 70-110-64].
Carefully remove the camshaft (Item 1) [Figure 70-110-
Remove the oil pan and gasket. 66].
Installation: Tighten the oil pan mounting bolts to 16 ft.-

lb. (22 N•m) torque.

RECONDITIONING THE ENGINE (CONT'D) Camshaft And Tappets Installation
Camshaft And Tappets Removal (Cont’d) Clean and inspect the camshaft and tappets for
excessive wear and damage.
Figure 70-110-67
Inspect the camshaft bushing for excessive wear and
damage.
NOTE: Only the front camshaft journal bore has a

bushing.
1 Clearance between the camshaft journals, the bushing

1 and camshaft bore is 0.0025 - 0.0055 in. (0,06 - 0,14
mm).
Make sure all components are clean and lubricated with

clean engine oil.
Figure 70-110-68
P-8743
Remove the tappets (Item 1) [Figure 70-110-67] from the

block.

1
1
P-08743
Install the tappets (Item 1) [Figure 70-110-68].
Figure 70-110-69
P-8742
Carefully install the camshaft (Item 1) [Figure 70-110-

69].

RECONDITIONING THE ENGINE (CONT'D) Pistons And Connecting Rods Description
Camshaft And Tappets Installation (Cont’d) The pistons have a Quadram combustion chamber. They
have two compression rings and one oil control ring. The
Figure 70-110-70 top ring groove has a hard metal insert to reduce wear.
Full floating piston pins are used and are retained by
snap rings.
Controlled expansion pistons have a steel insert ring in

the piston skirt. The connecting rods are molybdenum
1 steel. The connecting rods on the turbocharged engines
2 have wedge shaped small ends. The location of the
bearing caps to the connecting rods is made by
serrations and the cap is retained by two bolts.
The pistons used in the 1000 series engines have two

compression rings and one oil control ring. All the rings
are above the piston pin. Each of the three piston rings
have different design features. Always use the engine
P-8741 identification number to order new parts.
Pistons And Connecting Rods Removal

Install the camshaft thrust washer (Item 1). Make sure
that the dowel pin (Item 2) [Figure 70-110-70] lines up Figure 70-110-71

with the hole in the thrust washer.
Install the timing case. (See Timing Case And Gear

Check camshaft end play. The end play for a new engine
is 0.004 - 0.022 in. (0,10 - 0,55 mm), service limits 0.023
in. (0,60 mm).
Install the timing gears. (See Timing Case And Gear

Install the injection pump. (See Fuel Injection Pump 1

P-08744
Install the push rods and rocker assembly. (See Rocker
Shaft Disassembly And Assembly on Page 70-110-12.)
Remove the cylinder head. (See Cylinder Head Removal
Install the timing cover. (See Timing Cover Installation on on Page 70-110-6.)
Page 70-110-20.)
Remove all the carbon from the top of the cylinder liners.
Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-110-42.) Remove the oil pan.(See Oil Pan Removal And
Remove the oil pick up screen and tube (Item 1) [Figure

70-110-71].

Pistons And Connecting Rods Removal (Cont’d)
Figure 70-110-72
1 1
1 1 1 1
1
1
P-08746
Inspect the crankshaft journals (Item 1) [Figure 70-110-

P-08743 74] for wear or damage.
NOTE: Keep all parts together so they can be

Mark and remove the connecting rod caps (Item 1) replaced in their original position.
[Figure 70-110-72].

NOTE: Before installing the pistons check cylinder
NOTE: Do not allow the connecting rods to hit the bore for wear or damage. (See Cylinder Liner
cooling jets. Inspection on Page 70-110-48.)
Figure 70-110-73
P-08745
Turn the connecting rods 90° to prevent contact with the

piston cooling jets (Item 1) [Figure 70-110-73]. Push the
piston and rod assemblies out the top of the cylinder.

RECONDITIONING THE ENGINE (CONT'D) Piston Ring End Gap
Pistons And Connecting Rods Disassembly Figure 70-110-77
Figure 70-110-75
1 1
4
4
B-05571
B-05570
Place the piston rings in the upper part of the cylinder to
check the end gap [Figure 70-110-77].
Mark the piston to indicate the cylinder number (Item 1)
[Figure 70-110-75] as shown on the connecting rod. Top Ring End Gap 0.0118 - 0.0117 in.

(0,30 - 0,45 mm)
Figure 70-110-76
Second Ring End Gap 0.0256 - 0.0335 in.
(0,65 - 0,85 mm)
1 Third Ring End Gap 0.0118 - 0.0216 in.
4 (0,30 - 0,55 mm)
Piston Ring Installation
Figure 70-110-78
P-13999
Remove the piston rings (Item 1) [Figure 70-110-76] with

a ring expander.
Remove the snap rings (Item 2) [Figure 70-110-76]

which retain the piston pin.
B-05572
Push the piston pin (Item 3) [Figure 70-110-76] out by
hand. If the pin doesn't push out easily, heat the piston to
100°-120° F (40°-50° C) for easier removal. Install the spring of the oil control ring in the bottom
groove with the latch pin inside both ends of the spring
Remove the connecting rod (Item 4) [Figure 70-110-76]. [Figure 70-110-78].

RECONDITIONING THE ENGINE (CONT'D) Piston Ring Groove Clearance
Piston Ring Installation (Cont'd) Figure 70-110-80
Use a ring expander to install the piston rings.
Install the oil spring on the bottom groove of the piston

with the latch pin inside both ends of the spring.
Figure 70-110-79
2
B-05576
With the piston rings installed, check the groove

1 clearance [Figure 70-110-80].
Top Ring Wedge

B-05575
Second Ring 0.0026 - 0.0043 in.
Side Clearance (0,065 - 0,110 mm)
Install the oil control ring over the spring (Item 1) [Figure Third Ring Side Clearance 0.0011 - 0.0027 in.
70-110-79]. (0,03 - 0,07 mm)
Make sure the ring gap is 180° from the latch pin.
Install the cast iron ring with the tapered face (Item 2)
[Figure 70-110-79] in the second groove with the word
TOP or symbol facing the top of the piston.
New second rings have a green identification mark,

which must be on the left of the ring gap after the ring is
installed and the piston is upright.
The second ring has an external step at the bottom of the

tapered face.
Place the chromium ring (Item 3) [Figure 70-110-79] with

the symbol or word TOP up when installed on the piston.
The top ring (Item 3) [Figure 70-110-79] has an internal

step.
New top rings have a red or blue identification mark,

which must be on the left of the ring gap after the ring is
installed and the piston is uptight.
Make sure the ring gaps are 120° apart.

RECONDITIONING THE ENGINE (CONT'D) Piston And Connecting Rod Assembly
Connecting Rod Inspection Figure 70-110-82
Figure 70-110-81
5” 5”
(127 mm) (127 mm)
0.010” 0.010” 2
(± 0.25 mm) (± 0.25 mm)
P-13999
B-05577
Install the connecting rod (Item 1), piston pin (Item 2) and
two snap rings (Item 3) [Figure 70-110-82] in the piston.
Checking the connecting rod for distortion [Figure 70-
110-81]. Piston And Connecting Rod Installation

NOTE: The large and small end bores must be square Apply a light coat of oil to the piston and piston rings.
and parallel within the limits of ± 0.010 in. (0,25
mm). NOTE: Make sure the piston ring end gaps are 120°
apart.
Measure this 5.0 in. (127 mm) on each side of the
connecting rod axis on a test fixture. Figure 70-110-83
With the piston pin bushing installed the limit is reduced

to ± 0.0025 in. (0,06 mm).
Check the pin bushing for wear or damage. Replace as

needed.
Connecting Rod Bushing Replacement
Press out the old bushing. Clean the bore and remove
any burrs.
Press in the new bushing making sure the oil feed holes
line up.
B-05578
Ream the bushing to get the proper clearance of 0.0009 -
0.0017 in. (0,023 - 0,044 mm) between the small end
bushing and piston pin. Install the ring compressor over the piston rings [Figure
70-110-83].
Carefully place the connecting rod in the cylinder and

using a hammer handle, push the piston in the bore.

Piston And Connecting Rod Installation (Cont'd)
Figure 70-110-84 1
FRONT B-05580
Install the upper and lower bearing shells in position

B-05579 making sure the locating tang (Item 1) [Figure 70-110-
86] is in the correct position.
When the piston has cleared the cooling jet, rotate the NOTE: New connecting rod nuts must be installed
piston assembly so that the arrow or FRONT mark is each time the rod caps are removed.

toward the front of the engine [Figure 70-110-84].
Figure 70-110-87
Figure 70-110-85
1 1
1
1
1 1
P-08743
P-08745
Install the caps (Item 1) [Figure 70-110-87] and nuts.

Clean the bearing surfaces and crank pin. Lubricate the Gradually tighten the nuts to 13 ft.-lb. (18 N•m) torque.
crank pin (Item 1) [Figure 70-110-85] with clean engine Tighten to a final torque of 52 ft.-lb. (70 N•m). The
oil. fasteners must be tightened a further 120°.
Rotate the crankshaft. The crankshaft must rotate

smoothly.

RECONDITIONING THE ENGINE (CONT'D) Crankshaft And Bearings Description
Piston And Connecting Rod Installation (Cont'd) The crankshaft is a chrome-moly forging which has five
main journals. End play is controlled by two half thrust
Figure 70-110-88 washers on both sides of the center main bearing.
The main bearings have steel backs with a aluminium/ tin

bearing material. The main bearing caps are made of
cast iron.
The front and rear oil seals are viton lip seals with a dust
lip to the outside of the main lip.
Crankshaft And Bearings Removal
Figure 70-110-89
1
1
P-08744
Install the oil pick up tube and screen (Item 1) [Figure

70-110-88].

Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-110-42.)
Checking Piston Height
Rotate the crankshaft until the piston is approximately at

P-08748
top dead center (T.D.C.).
Using a dial indication gauge, pre-load the plunger on the Remove the water pump. (See Water Pump Removal on
top surface of the block and zero the gauge. Page 70-110-40.)
Carefully move the dial gauge so that the plunger is on Remove timing case cover. (See Timing Cover Removal
top of the piston above the axis of the piston pin. on Page 70-110-20.)
Rotate the crankshaft to bring the piston to it's highest Remove the fuel injection pump. (See Fuel Injection
point. Record this gauge reading. Pump Removal on Page 70-70-1.)
When installed, the top surface of the piston is slightly Remove the timing gears and timing case. (See Timing
above the surface of the cylinder block. Case And Gear Removal on Page 70-110-21.)
The height above the surface of the block should be Remove the flywheel. (See Removal And Installation on
0.008 to 0.014 in. (0,21 to 0,35 mm). Page 70-100-1.)
Install the cylinder head. (See Cylinder Head Installation Remove the pistons and connecting rods, keeping them
on Page 70-110-9.) in order. (See Pistons And Connecting Rods Removal on
Page 70-110-26.)
Remove the rear oil seal housing (Item 1) [Figure 70-

110-89].

Crankshaft And Bearings Removal (Cont’d)
Figure 70-110-90
1 1
1 1 1 1
1
P-08750
Remove the main bearing caps (Item 1) [Figure 70-110-

P-08749 92].
Figure 70-110-93
Remove the two bolts (Item 1) [Figure 70-110-90]
retaining the bridge piece.

Remove the bridge piece.
Figure 70-110-91
1 1 1 1 1
P-08753
Remove the thrust washers from the sides of the center

main bearing bore [Figure 70-110-93].
P-08746
Mark the main bearing caps (Item 1) [Figure 70-110-91]

for correct installation.
Remove the main bearing cap bolts.

RECONDITIONING THE ENGINE (CONT'D) Inspection Of Crankshaft And Bearings
Crankshaft And Bearings Removal (Cont'd) Figure 70-110-96
Figure 70-110-94
A-02763
P-08751
Check the crankshaft for wear [Figure 70-110-96]. The
maximum wear and out of round of the crank journals is
Remove the crankshaft [Figure 70-110-94]. 0.0016 in. (0,04 mm).

Figure 70-110-95 The main journals and the crank pins of standard size
can be machined 0.010 in. (0,25 mm) 0.020 in. (0,50
mm) or 0.030 in. (0,75 mm).
NOTE: (See ENGINE SPECIFICATIONS on Page

SPEC-20-1.) for more crankshaft
specifications.
Check the oil clearance of the bearings.
All Main Bearings 0.0022 - 0.0046 in.

(0,057 - 0,117 mm)
Thrust Washer Thickness

P-08752
Standard 0.089 - 0.091 in.
(2,26 - 2,31 mm)
Oversize 0.096 - 0.098 in.
Remove the crankshaft bearings from the engine block (2,45 - 2,50 mm)
[Figure 70-110-95].
Keep the bearings with their respective caps for

installation.

Crankshaft And Bearings Installation
Figure 70-110-97
P-08753
Clean and install the upper and lower thrust bearings on

P-08754 each side of the center main bearing [Figure 70-110-99].
Clean the main caps and install the bearings.

Clean the main bearing bores and install the upper
bearing shells in position. Lubricate the bearings with Lubricate the bearings with clean engine oil.

clean engine oil [Figure 70-110-97].
Install the main cap bolts and torque in steps working
NOTE: Only the upper half of the bearings has oil from the center outward.
lubrication holes and must be installed in the
cylinder block. Step 1 65 ft.-lb. (88 N•m)
Figure 70-110-98 Step 2 125 ft.-lb. (170 N•m)

Step 3 180 ft.-lb. (245 N•m)
Clean the bridge piece and apply a bead of Loctite®

#518 in the corners and around the thread holes on the
block.
P-08751
Make sure the main journals are clean and install the
crankshaft in the block [Figure 70-110-98].
Make sure the locating pins for the main caps are in
position.

RECONDITIONING THE ENGINE (CONT'D) Rear Oil Seal Removal
Crankshaft And Bearings Installation (Cont'd) Remove the bolts that retain the seal housing. Remove
the housing.
Figure 70-110-100
Inspect the seal for wear or damage. Replace even if
there is only a small nick or scratch.
Inspect the crankshaft flange for damage.
Clean the block, seal housing, and crankshaft.
Rear Oil Seal Housing Positioning
The tool listed will be needed to do the following

procedure;
MEL1532 - Rear Crankshaft Seal Installation Tool
P-08755 Figure 70-110-102
Install the bridge piece, and using a straight edge, align

the bridge with the cylinder block [Figure 70-110-100].

Tighten the bridge retaining bolts to 12 ft.-lb. (16 N•m)
torque.
Figure 70-110-101
1
2
B-05581
The seal can be installed from flush with the housing face
2 (Item 1) to 0.27 in. (6,86 mm) (Item 2) [Figure 70-110-
102] back from the housing face. Install seal so that the
seal lip does not line up with any worn areas on the
crankshaft.
P-08756
Inject Loctite® #518 into the groove (Item 1) at each end

of the bridge piece. Continue to inject sealant until it
leaves the lower groove (Item 2) [Figure 70-110-101] at
the front and rear of the piece.

RECONDITIONING THE ENGINE (CONT'D) Carefully push the seal and housing (Item 3) [Figure 70-
110-104] over the tool and crankshaft and into position
Rear Oil Seal Housing Positioning (Cont’d) on the dowels. Remove the tool.
Figure 70-110-103 Figure 70-110-105
N-00550 P-08748
Install the seal in the seal housing using the seal Tighten the bolts (Item 1) [Figure 70-110-105] to 16 ft.-lb.
installation tool. Seat the seal to the correct depth (22 N•m) torque.

[Figure 70-110-103].
Checking Crankshaft End Play
Rear Oil Seal Installation
The axial movement of the crankshaft is controlled by two
Install the new seal in the housing. half thrust washers placed on both sides of the center
main bearing.
Figure 70-110-104
Figure 70-110-106
3
B-05581
P-08840
Make sure the dowels (Item 1) [Figure 70-110-104] are

in the block correctly. Install a dial indicator on the end of the crankshaft
[Figure 70-110-106].
Install the new gasket (Item 2) on the housing (Item 3)
[Figure 70-110-104]. Pry the crankshaft to the rear of the cylinder block and
set the dial indicator to zero.
Install the seal replacer tool (PD145-3) (Item 4) [Figure
70-110-104] on the crankshaft.
Lubricate the seal, tool, and crankshaft with clean engine

oil.

RECONDITIONING THE ENGINE (CONT'D) Cooling System Description
Checking Crankshaft End Play (Cont'd) Figure 70-110-109
Figure 70-110-107
1
S6913
P-08841
Coolant from the radiator passes through the centrifugal
water pump (Item 1) [Figure 70-110-109], to assist the
Remove the pry bar and record the dial indicator reading flow of the coolant through the system.
[Figure 70-110-107].

The water pump is gear driven from the gear off the fuel
The end play specification is 0.002 - 0.015 in. (0,05 - 0,38 injection pump.
mm) maximum.
From the water pump, the coolant passes through a
If end play is excessive there is over size thrust washers passage in the timing case.
available to reduce movement.
The coolant passes through a passage in the left side of
Figure 70-110-108 the cylinder block to the rear of the cylinder block.
Figure 70-110-110
B-05583
S6914
The end play can also be checked using a feeler gauge
[Figure 70-110-108].
The oil cooler (Item 1) [Figure 70-110-110] is installed on
Pry the crankshaft to the rear of the cylinder block and the left side of the engine. Coolant from the bypass
measure the distance between the thrust washer and connection at the rear of the coolant pump passes
crankshaft. through a pipe to the oil cooler.

RECONDITIONING THE ENGINE (CONT'D) Thermostat Removal and Installation
Cooling System Description (Cont'd) Drain the engine coolant until it is below the thermostat
level.
Figure 70-110-111
Figure 70-110-112
1 1
P-55778
P-55778
The coolant then passes around the cylinders and in the

cylinder head. The coolant leaves the cylinder head at Remove the bolts (Item 1) [Figure 70-110-112] and

the front and passes into the thermostat housing (Item 1) thermostat housing.
[Figure 70-110-111].
Installation: Make sure all gasket surfaces are clean.
If the thermostat is closed, the coolant goes directly Replace the gasket before installing the thermostat
through a bypass to the inlet side of the water pump. If housing.
the thermostat is open, the thermostat closes the bypass
and the coolant passes to the radiator. Figure 70-110-113
P-55780
Remove the housing and thermostat [Figure 70-110-

113].

RECONDITIONING THE ENGINE (CONT'D) Water Pump Removal
Thermostat Testing Remove the coolant from the cooling system.
Hang the thermostats in a suitable container filled with Figure 70-110-115

coolant.
1
Heat the coolant gradually. Use a thermometer to check
the temperature when it starts to open and when it's fully
open.
1
If the thermostats do not operate correctly they must be 1
replaced.
NOTE: Identify thermostat temperature by the

stamping on the bypass valve.
1
Lubricating Oil Cooler Removal And Installation
Figure 70-110-114 S6913
1 1
from the water pump.

Remove the water pump.
2 Water Pump Installation
Clean the gasket surfaces and replace the gasket.
Install the water pump in the timing cover. The pump is a

tighten fit in the cover and is pulled into position by
tightening the bolts evenly.
1 1
P-55782
Install the water pump bolts (Item 1) [Figure 70-110-115]
and tighten to 16 ft.-lb. (22 N•m) torque.
Remove the eight mounting bolts (Item 1) and remove
the cooler (Item 2) [Figure 70-110-114].
Installation: Check oil level using the dipstick add oil as

needed.

Engine Lubrication System Description
Figure 70-110-116
1 3
S6915
The engine oil passes from the filter (Item 1) [Figure 70-
P-08834 110-118] to the cylinder block.
The oil passes to the main bearings of the crankshaft and

Pressure lubrication is supplied by a rotor type pump through passages in the crankshaft to the big end
(Item 1) [Figure 70-110-116] which is driven through an bearings. The pistons and the cylinder bores are

idler gear from the crankshaft gear. lubricated by splash and oil mist.
Engine oil from the oil pan sump passes through a Engine oil passes from the main bearings through
strainer (Item 2) [Figure 70-110-116] and pipe to the passages in the cylinder block to the journals of the
suction side of the pump. camshaft. Engine oil passes from the center journal of
the camshaft through a passage in the cylinder block and
The engine oil passes from the outlet side of the pump cylinder head to a restriction in the pedestal of the rocker
through a pipe to a relief valve (Item 3) [Figure 70-110- shaft, at a reduced pressure, to feed the rocker bushing.
116], which is installed in the bottom left side of the The oil passes through a passage in the rocker shaft to
cylinder block. The relief valves opens if the oil pressure the bearings of the rocker levers. The valve stems, valve
is too high; this allows some of the engine oil to return to springs and the tappets are lubricated by splash and oil
the sump. mist.
Figure 70-110-117 The hub of the idler gear is lubricated by oil from the
cylinder block and the timing gears are splash lubricated.
1 The turbocharger is lubricated by oil after the filter. Oil is

supplied from a connection on the right side of the
cylinder block through an external pipe to the
turbocharger. The oil passes through the turbocharger
and returns through a pipe to the oil pan sump.
S6449
From the relief valve, engine oil passes to a plate type oil
cooler (Item 1) [Figure 70-110-117].

RECONDITIONING THE ENGINE (CONT'D) Oil Pan Removal And Installation
Engine Lubrication System Description (Cont'd) Figure 70-110-121
Figure 70-110-119
P-08740
P-08745
Remove the oil pan retaining bolts [Figure 70-110-121].
Turbocharged engines have piston cooling jets (Item 1) Remove the pan and gasket.
[Figure 70-110-119]. These jets are connected to the oil

pressure rail and spray lubricating oil inside the pistons to Clean the pan in solvent and dry with compressed air.
keep them cool.
Clean the block surface.
Oil Filter Adapter Removal And Installation
Installation: Place a new gasket on the oil pan. Place
Figure 70-110-120 two bolts on each side to position the oil pan correctly.
Install the remaining bolts. Tighten the bolts to 16 ft.-lb.
(22 N•m) torque [Figure 70-110-121].
2
1
1
S6915
Remove the oil filter.
Remove the four bolts (Item 1) and the filter adapter

(Item 2) [Figure 70-110-120].
Clean the filter adapter and the block mounting surfaces.
Using a new gasket, install the adapter (Item 2) [Figure

70-110-120] on the block.
Install the oil filter.

RECONDITIONING THE ENGINE (CONT'D) Remove the oil pan. (See Oil Pan Removal And
Oil Screen And Pick-up Tube
Figure 70-110-123
Figure 70-110-122
1
2
4
1
3
P-08834 P-08744
Remove the bolt (Item 1) that holds the bracket (Item 2) Remove the oil pressure relief valve (Item 1) [Figure 70-
[Figure 70-110-122] to the main bearing cap. 110-123].

Remove the bolts (Item 3) [Figure 70-110-122] from the Remove the oil screen and pick-up tube.
pick-up tube flange.
The oil pump is installed on the number 1 main bearing
Remove the pick-up tube (Item 4) [Figure 70-110-122] cap.
and gasket.
NOTE: The pump can be removed with the main
bearing cap if a spanner wrench is available
Wash the assembly in solvent and dry with compressed
that will allow the torque to be applied directly
air.
to the main cap bolts.
Check the tube and strainer for cracks or other damage. If there is no spanner wrench, the front timing case cover
Replace as necessary. must be removed. (See Timing Cover Removal on Page
70-110-20.)
Loosely assemble the bracket (Item 2) [Figure 70-110-
122] with the pick-up tube to the main bearing cap. Figure 70-110-124
Install the pick up tube gasket and mounting bolts (Item

3) [Figure 70-110-122].
Tighten the mounting bolts to 16 ft.-lb. (22 N•m) torque.
Tighten the bolt (Item 1) [Figure 70-110-122] for the pick-

up tube bracket.
Tighten the bolt to 16 ft.-lb. (22 N•m) torque. 2
Oil Pump Removal

1
NOTE: The oil pump has a channel in the body of the
pump. Oil from the front main bearing passes P-08835
down the channel of the pump to an oil hole in
the idler shaft for lubrication of the idler shaft
bushing. Remove the snap ring (Item 1), idler gear (Item 2)
[Figure 70-110-124], and washer.
Remove the bolts and oil pump.

Oil Pump Installation
Figure 70-110-125
B-05588
1
Check that there is a minimum of 0.003 in. (0,076 mm)
P-08835 backlash between the idler gear and oil pump gear
[Figure 70-110-126].
Fill the pump with engine oil. End play for the idler gear should be 0.0019/0.0108 in.
(0,050/0,275 mm).

If the number one main cap was removed, reinstall and
tighten to 185 ft.-lb. (250 N•m) torque. Install the oil screen and pick-up tube. (See Page 70-
100-44.)
Install the pump on the main cap and tighten to 16 ft.-lb.
(22 N•m) torque. Install the pressure relief valve.
Check the idler gear and bushing for wear. Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-110-42.)
Lubricate with clean engine oil and install the washer,
idler gear (Item 1) and snap ring (Item 2) [Figure 70-110-
125].
Check the backlash between oil pump and idler gears.
There must be a minimum of 0.003 in. (0,076 mm).

Oil Pump Disassembly And Assembly
Figure 70-110-127
B-05593
Check the rotor end play [Figure 70-110-129].
Rotor end play must be 0.0014 - 0.0035 in. (0,038 - 0,089

B-05591
mm) for the inner rotor.
NOTE: If any part is worn enough to effect Rotor end play must be 0.0010 - 0.0029 in. (0,025 - 0,076
performance replace the complete oil pump. mm) for the outer rotor.

Remove the cover of the oil pump. Install the cover and tighten the bolts to 16 ft.-lb. (22 N•m)
torque.
Remove the outer rotor and thoroughly clean. Check for
cracks or other damage. Oil Pressure Relief Valve Disassembly And Assembly
Install the outer rotor and check the outer rotor to body Figure 70-110-130
clearance [Figure 70-110-127].
Clearance between the outer rotor and body must be

0.0059 - 0.0129 in. (0,152 - 0,330 mm). 2
Figure 70-110-128
5
4
1
3
B-05606
Press the end plate (Item 1) in the valve body (Item 2)

and remove the snap ring (Item 3) [Figure 70-110-130].
Remove the end plate (Item 1), spring (Item 4), and
B-05592 plunger (Item 5) from the body (Item 2) [Figure 70-110-
130].
Check the inner rotor to outer rotor clearance [Figure 70- Clean the parts in solvent and dry with compressed air.
110-128].
Lubricate the bore of the valve body (Item 2), plunger
Clearance between the inner rotor and outer rotor must (Item 5) and the end plate (Item 1) [Figure 70-110-130]
be 0.0015 - 0.005 in. (0,040 - 0,127 mm). with clean engine oil before assembly.

RECONDITIONING THE ENGINE (CONT'D) Engine Block Disassembly And Assembly
Engine Block Description Remove the water pump. (See Water Pump Removal on
Page 70-110-40.)
Figure 70-110-131
Remove the oil cooler. (See Removal And Installation on

Page 70-50-1.)
Remove the oil filter and oil pan. (See Oil Pan Removal
1
Remove the turbocharger.(See Turbocharger Removal
Remove the lift fuel pump. (See Fuel Lift Pump Removal
P-08837
Remove the starter. (See Removal And Installation on
Page 60-40-1.)
The cylinder block is made of cast iron and provides full
length support for the dry liners. Remove the cylinder head. (See Cylinder Head Removal

on Page 70-110-6.)
The liners (Item 1) [Figure 70-110-131] are made of cast
iron. Production liners are a press fit and service liners Remove the timing case and gears. (See Timing Case
are a transion fit. Both types of liners are honed with And Gear Removal on Page 70-110-21.)
silicon carbide tools to a specially controlled finish to
ensure long engine life and low oil consumption. Remove the piston and connecting rod assemblies. (See
Pistons And Connecting Rods Removal on Page 70-110-
Figure 70-110-132 26.)
Remove the camshaft and tappets. (See Camshaft And

Tappets Removal on Page 70-110-24.)
Remove the engine mounting bracket and flywheel. (See

1 Removal And Installation on Page 70-100-1.)
Remove the rear oil seal and the crankshaft. (See Rear
Oil Seal Removal on Page 70-110-36.)
P-08842
A bushing (Item 1) [Figure 70-110-132] is installed in the

cylinder block for the front camshaft journal while the
other camshaft journals run directly in the block.

RECONDITIONING THE ENGINE (CONT'D) Piston Cooling Jet Alignment
Piston Cooling Jet Removal Figure 70-110-135
Figure 70-110-133
1 1
2.2”
(55,25 mm)
0.55”
(14 mm)
N-00535
P-08754
Insert a 0.067 in. (1,70 mm) diameter rod of suitable
length, in the jet.
Remove the piston cooling jet assembly (Item 1) [Figure
70-110-133] from the engine block. The tip of the rod must extend out the top of the cylinder

in an area 2.2 in. (55,25 mm) in height and 0.55 in. (14
Figure 70-110-134 mm) of width to provide proper cooling jet alignment to
cool the pistons [Figure 70-110-135].
Inspection
Clean all passages of coolant and oil.

2
Check the block for cracks or other damage.
NOTE: The top face of the block must not be

machined. This will affect liner flange depth
and piston height above the top face of the
3 cylinder block.
1
Check the camshaft bushing for wear. If the bushing
P-08836 needs to be replaced, press out old one. Press a new
one in, insuring that the oil holes line up.
Inspect the jet tube (Item 1), mount bolt (Item 2) and
alignment pin (Item 3) [Figure 70-110-134] for damage.
Replace as needed.
Piston Cooling Jet Installation
Clean all parts in solvent and dry with compressed air.
Install the cooling jet (Item 1) being sure it is seated

correctly on the dowel (Item 3) [Figure 70-110-134] in
the block.
Install the mounting bolt (Item 2) [Figure 70-110-134]

and tighten to 8 ft.-lb. 9 (N•m) torque.

Cylinder Liner Inspection
Figure 70-110-136
B-04066
Check the cylinder liner bore for out of round or wear

P-08837 beyond service limits [Figure 70-110-137]. The inside
diameter of the service liner should be 4.1338 - 4.1348
in. (105,000 - 105,025 mm).
The condition of a cylinder liner is decided by:
A flex type hone may be used to clean up small scoring

• The amount and location of polished areas. or pitting.
• Wear. Damaged or worn liners must be replaced.
• Damage to the liner wall.
NOTE: It is not necessary to replace the liners if: The

honed finish can be clearly seen. Engine
performance and oil consumption is
acceptable.
Examine the liner surface (Item 1) [Figure 70-110-136]

for cracks, deep scratches and polished areas where the
honed finish is worn away.

RECONDITIONING THE ENGINE (CONT'D)
Cylinder Liner Removal
Figure 70-110-138

6
B-05556
NOTE: Where several liners are to be removed or a

very tight production liner is found, a press
should be used.
When one liner is replaced, a hand tool is available and

the following procedure can be done with the crank shaft
installed.
Rotate the crankshaft (if installed) to provide access to

the liner and protect the crank pin from damage.
Place the tool (Item 1) over the center of the liner (Item
2). Make sure the flat bearing race (Item 3) [Figure 70-
110-138] is against the bottom of the recess.
Install the rod (Item 4) through the handle (Item 5)

[Figure 70-110-138].
Place the adapter (Item 6) [Figure 70-110-138] under the

cylinder liner. Tighten the nut and washer. Turn the
handle and pull out the old liner.

RECONDITIONING THE ENGINE (CONT'D) Place the threaded rod (Item 4) through the handle (Item
5) and liner (Item 1) [Figure 70-110-139].
Cylinder Liner Installation
Adjust the rod until it is below the bottom of the block
surface.
IMPORTANT Install the adapter (Item 6) [Figure 70-110-139] on the

rod. Center the adapter against the bottom of the block.
For the first five hours after the new liners have been Tighten the nut and washer.
installed:
• Do not operate at full load. Turn the handle and press the liner in the bore, stopping
• Do not operate at high speed. when approximately 2 in. (50 mm) remain. Apply Loctite®
• Do not allow engine to idle for extended periods. #603 to the outer surface below the flange and to the
I-2117-1196
flange recess.
Figure 70-110-139 Continue to press the liner into position. Remove the tool.
NOTE: Do Not hit the cylinder liners with a hammer.

4 They will be damaged.
5
Figure 70-110-140
3
1 2

1
2
B-0507
Check liner protrusion with a dial gauge [Figure 70-110-

140].
The liner may have 0.004 in. (0,10 mm) protrusion or

recession from the block face.
6
Allow 15 minutes before measuring the bore. The liner
B-05555
will take six hours to reach full strength.
The inside diameter of the service liner should be 4.1338

Clean the cylinder bore and the outside of the liner.
- 4.1348 in. (105,000 - 105,025 mm).
Lubricate the cylinder bore with engine oil.
New piston rings must be used when the cylinder liners
have been replaced.
Start the liner (Item 1) [Figure 70-110-139] in the bore.
Make sure it is started straight.
The measurement must be from the flange (Item 1) of the
cylinder liner, not the top of the flame ring (Item 2)
With the adapter (Item 2) on the top of the liner, place the
[Figure 70-110-140].
bearing (Item 3) [Figure 70-110-139] in the recess at the
top.

HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1

Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Filter Element Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1
Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-2
BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

Poor A/C Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-2
Checking The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-3

GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Compressor Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Component Replacement And Refrigeration Leaks . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-3
SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-1
Gauge Pressure Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-70-2
TEMPERATURE/PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1

Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
Charging Procedure With A Manifold Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-4
Charging Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-5
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80-110-1
Compressor Clutch Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .80-110-2
CONDENSER (S/N A8HL12999 & BELOW, A8HP12999 & BELOW, A8HK11001 & ABOVE)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1

CONDENSER (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE) . . . . . . . . . . . . . 80-121-1
RECEIVER / DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1

PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

EVAPORATOR / BLOWER UNIT (S/N A8HL12999 & BELOW, A8HP12999 & BELOW,
A8HK11001 & ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1
EVAPORATOR / BLOWER UNIT (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-151-1
EXPANSION VALVE (S/N A8HL12999 & BELOW, A8HP12999 & BELOW, A8HK11001 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-160-1

EXPANSION VALVE (S/N A8HL13000 & ABOVE, A8HP13000 & ABOVE) . . . . . . . . 80-161-1
HEATER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1

Fan Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-2
Core Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-3

AIR CONDITIONING SYSTEM FLOW
Principles
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-2.) 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 80-10-2.).
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver/drier (Item 3) (See Chart on Page 80-10-2.) where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-2.).
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 80-10-2.). As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the blower fan (Item
6) (See Chart on Page 80-10-2.). Since the refrigerant is colder than the air, it absorbs the heat from the air and produces
cooled air, which is pushed into the cab by the blower 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.

AIR CONDITIONING SYSTEM FLOW (CONT'D)
Chart

COMPONENTS Figure 80-20-3
Identification
Figure 80-20-1 1
S6876
1
Receiver/Drier: The receiver/drier (Item 1) [Figure 80-20-

S6874 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 80-20-1] 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 80-20-4
transfer through the condenser and evaporator.
NOTE: The A/C System (compressor) is

recommended to be turned on for at least 5 1
minutes weekly throughout the year to
lubricate the internal components.
Figure 80-20-2
P-27595
1
Pressure Switch: The pressure switch (Item 1) [Figure

80-20-4] is located on the receiver/drier assembly (Item
2) [Figure 80-20-3]. It will disengage the compressor
clutch if the pressure readings are too low or too high,
which indicates loss of refrigerant.
S6875
Condenser: The condenser (Item 1) [Figure 80-20-2] is

the unit that receives the high pressure, high temperature
refrigerant vapor from the compressor and condenses it
into a high temperature liquid.

COMPONENTS (CONT'D) Figure 80-20-7
Identification (Cont'd)

Figure 80-20-5
1
1
S6924
Blower Fan Switch: This is a three position switch (Item

1) [Figure 80-20-7]. When the blower fan switch is in the
OFF position the A/C will not engage.
P-27489

Evaporator Unit: The evaporator unit (Item 1) [Figure 80-
20-5] is located behind the operator seat inside the cab.
The unit delivers the cold air for the A/C into the cab. The
unit also contains the blower fan, evaporator coil and
thermostat which are not serviceable.
Figure 80-20-6
P-27596
Expansion Valve: The expansion valve (Item 1) [Figure

80-20-6] controls the amount of refrigerant entering the
evaporator coil.

COMPONENTS (CONT'D) Figure 80-20-10
Identification (Cont'd)

A8HP13000 & Above:
Figure 80-20-8
2 3 1
P-97010
1. Blower Fan Switch - This is a three position switch

(Item 1) [Figure 80-20-10]. When the blower fan
switch is in the OFF position the A/C will not engage.
S36335 2. Temperature Control - Turn clockwise to increase cab

temperature; counterclockwise to decrease.

Evaporator Unit: The evaporator unit (Item 1) [Figure 80-
3. Air Conditioning Switch (If Equipped) - Press the top
20-8] is located under the dashboard inside the cab. The
of the switch (Item 3) [Figure 80-20-10] to turn the Air
unit delivers the cold air for the A/C into the cab. The unit
Conditioning ON - Press the bottom of the switch to
also contains the blower fan, evaporator coil and
turn the Air Conditioning OFF.
thermostat which are not serviceable.
Figure 80-20-9
S36333
Expansion Valve: The expansion valve (Item 1) [Figure

80-20-9] controls the amount of refrigerant entering the
evaporator coil.


SAFETY Figure 80-30-2
Safety Equipment
In servicing A/C and heater systems you will be exposed

to high pressures, temperatures and several chemical
hazards. Moving belts and pulleys are normal shop
hazards.
Figure 80-30-1
P-22285
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

P-16398 gloves [Figure 80-30-2] to prevent frost bite if you should
get refrigerant on your hands.
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80-30-
1] when you are using R-134a or a leak detector,
adjusting service valves or the manifold gage set
WARNING
connectors. Safety glasses or a transparent face shield
are practical safety items and one or the other is HFC 134A refrigerant can be dangerous if not
absolutely required. 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
WARNING when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
In the event of a leak, wear safety goggles. Escaping even small amounts of 134A in the air.
refrigerant can cause severe injuries to eyes. In Any servicing work that involves release or addition
contact with a flame, R134a refrigerant gives a toxic of 134A to the system must be done by a competent
gas. refrigeration dealer who has the proper equipment,
W-2371-0500 knowledge, and experience to service refrigeration
equipment.
W-2373-0500


REGULAR MAINTENANCE Figure 80-40-3
Filter Element Removal And Installation
Figure 80-40-1
1
2
2
S36339
1
1
Remove the filter (Item 1) and backup screen (Item 2)
S36337 [Figure 80-40-3].
The fresh air filter (Item 1) [Figure 80-40-3] is made of

Remove the four mount bolts (Item 1) from the fresh air open cell foam and should be cleaned with water. A mild
filter cover (Item 2) [Figure 80-40-1] at the front of the detergent can also be used.

cab.
Compressor Drive Belt Inspection
Remove the fresh air filter cover (Item 2) [Figure 80-40-
1]. It is a good rule to regularly inspect (weekly) the
compressor drive belt for tension and wear.
Figure 80-40-2
Remove the drive belt cover.

2
Figure 80-40-4
1 S36338
Remove the two filter mount bolts and nuts (Item 1) from
the filter cover (Item 2) [Figure 80-40-2].
S6874
Check the tension on the compressor belt (Item 1)

[Figure 80-40-4].

REGULAR MAINTENANCE (CONT'D) For V723 Models With S/N A8HL13000 & Above, S/N
A8HL13000 & Above:
Cleaning The Condenser
Figure 80-40-6
2
For V723 With S/N A8HL12999 & Below, S/N
Temporarily remove the air cleaner. (See Filter Element

Removal And Installation on Page 80-40-1.) 1
Figure 80-40-5
S36349
Clean the condenser (Item 1) [Figure 80-40-6] using

water or air pressure.

1 Loosen the nut (Item 2) [Figure 80-40-6] and tilt the
condenser forward.
S6875 Figure 80-40-7
Clean the condenser (Item 1) [Figure 80-40-5] using

water or air pressure. 1
NOTE: Clean between the oil cooler and condenser. 2
S36350
Clean between the oil cooler (Item 1) and the condenser

(Item 2) [Figure 80-40-7].

BASIC TROUBLESHOOTING Figure 80-50-3
Poor A/C Performance
Start the VersaHANDLER, engage the parking brake.

Engage the A/C system with the blower fan on high. Run
the VersaHANDLER at full RPM for approximately 15
minutes, with the cab door closed.
Figure 80-50-1
1
P-27746
Check the temperature at the louvers (Item 1) [Figure

80-50-1] and [Figure 80-50-2] with a thermometer
[Figure 80-50-3].
The louver temperature should be between 36 - 53° F

P-27747 (2,2 - 11,6° C) depending on the amount of humidity in

the air.
Figure 80-50-2 If the louver temperature is too high. (See SYSTEM

S/N A8HL13000 & ABOVE, S/N A8HP13000 & ABOVE TROUBLESHOOTING on Page 80-70-1.)
Check the blower fan for proper operation or noise, and

replace if necessary. (See EVAPORATOR / BLOWER
1 UNIT (S/N A8HL12999 & BELOW, A8HP12999 &
BELOW, A8HK11001 & ABOVE) on Page 80-150-1.) or
(See EVAPORATOR / BLOWER UNIT (S/N A8HL13000
& ABOVE, A8HP13000 & ABOVE) on Page 80-151-1.)
Check the belt tension on the A/C compressor. (See

Compressor Drive Belt Inspection on Page 80-40-1.)
Check the A/C condenser for dirt or mud, and clean if

necessary. (See Cleaning The Condenser on Page 80-
S36340 40-2.)
Inspect the sight glass located on the receiver/drier for air

bubbles. (See REGULAR MAINTENANCE on Page 80-
40-1.)

BASIC TROUBLESHOOTING (CONT'D)
Compressor Drive Belt Inspection
Inspect the compressor drive belt for wear regularly. (See

SERVICE SCHEDULE on Page 10-50-1.)
Remove the belt cover.
Figure 80-50-4

S6874
Check the tension on the compressor belt (Item 1)

[Figure 80-50-4].

BASIC TROUBLESHOOTING (CONT'D) Figure 80-50-7
Checking The Electrical System S/N A8HL13000 & ABOVE, S/N A8HP13000 & ABOVE
Figure 80-50-5
S36336
1
Turn the blower fan switch (Item 1) [Figure 80-50-6] and
S6874 [Figure 80-50-7] to the first on position. The compressor
clutch should make a click sound, which indicates the
clutch is engaging.
Check to see if the compressor clutch (Item 1) [Figure
80-50-5] is engaging. Turn the blower fan switch (Item 1) [Figure 80-50-6] to

the first on position, the compressor clutch should make
Turn the ignition key switch to the RUN position without a click sound, which indicates the clutch is engaging.
starting the machine.
Figure 80-50-8
Figure 80-50-6
1 1
P-52598
S6924
If the compressor clutch does not engage, check the fuse

(Item 1) [Figure 80-50-8]. Replace the fuse if needed.

Checking The Electrical System (Cont'd)
Figure 80-50-9
1
1
P-27738
With a multimeter, check the voltage to the compressor

P-52593 clutch at the main harness (Item 1) [Figure 80-50-11].
If there is no power at the clutch, check the wiring

Unplug the connector (Item 1) [Figure 80-50-9] from the harness for broken wires.
compressor.

If there is no power at the clutch, reconnect the wiring
Figure 80-50-10 harness to the compressor clutch.
Figure 80-50-12
P-52597
S6876
With a multimeter check the resistance to the
compressor clutch connector (Item 1) [Figure 80-50-10].
Disconnect the machine harness (Item 1) [Figure 80-50-
If there is no resistance value replace the compressor 12] from the pressure switch.
clutch. (See COMPRESSOR on Page 80-110-1.)

Checking The Electrical System (Cont'd) S/N A8HL12999 & BELOW, S/N A8HP12999 & BELOW,
Figure 80-50-13
1 1
P-27597
Figure 80-50-16
S6877 S/N A8HL13000 & ABOVE, S/N A8HP13000 & ABOVE
With the key switch to the run position (engine off) and
the blower fan switch on the first position. Use a

multimeter to check the main harness (Item 1) [Figure
80-50-13] for voltage.
There should be 12 volts. If there is no voltage, check the

harness for broken wires.
1
Figure 80-50-14
S36344
Disconnect the thermostat wiring connector (Item 1)

[Figure 80-50-15] and [Figure 80-50-16] from the main
harness.
1
S6878
If there is voltage at the harness, check the resistance at

the pressure switch (Item 1) [Figure 80-50-14].
If there is no resistance value, check for a low refrigerant

level. (See SYSTEM CHARGING AND RECLAMATION
on Page 80-100-1.)
If good resistance value is observed, the pressure switch

is good.
Reconnect the main harness to the pressure switch.

Figure 80-50-17
P-27743
If there is voltage at the wiring harness, check the

P-27742 thermostat wire (green) for resistance. The resistance
value should be 10 ohms at 68° F (20° C) [Figure 80-50-
18].
Check the main harness (Item 1) [Figure 80-50-17] for
voltage. The voltage should be 12 volts. If there is no If there is no resistance, replace the entire blower fan

voltage, check the harness for broken wires. unit.


1
Figure 80-50-19
P-27745
1

voltage. The voltage should be 12 volts if there is no
voltage check the harness for broken wires.
S4598

Figure 80-50-20
P-27744
Disconnect the main wire harness connectors (Item 1)

[Figure 80-50-20] from the switch.
NOTE: Mark the wires for correct assembly.


1
A8HP13000 & Above:
Figure 80-50-22
1 S36342

voltage. The voltage should be 12 volts if there is no
voltage check the harness for broken wires.
1
For all models:
2
Figure 80-50-25
S36336
H C

Remove the four screws (Item 1) [Figure 80-50-22].
Remove the panel (Item 2) [Figure 80-50-22].
M B
Figure 80-50-23
1
L
N-22288
If there is voltage at the main harness check the blower

fan switch [Figure 80-50-25] for resistance.
With the switch in the OFF position, there should be zero

resistance between all terminals.
With the switch in the 1 position, there should be

resistance between C terminal and the B terminal. And
S36341
also between the C terminal and the L terminal frame
[Figure 80-50-25].
Disconnect the main wire harness connector (Item 1)
[Figure 80-50-23] from the switch. With the switch in the 2 position, there should be
also between the C terminal and the M terminal frame
[Figure 80-50-25].
With the switch in the 3 position, there should be

also between the C terminal and the H terminal frame
[Figure 80-50-25].
If any of the above resistance tests fail, replace the

blower fan switch.

GENERAL AIR CONDITIONING SERVICE Compressor Oil Check
GUIDELINES
The compressor oil should be checked as follows when
Compressor Oil oil is being added to an in service machine.
Figure 80-60-1 There is a close affinity between oil and refrigerant.

During normal operation, part of the oil circulates with the
refrigerant in the system. therefore, when checking the
amount of oil in the system or replacing any system
component, the compressor must be run-in advance to
insure return of oil to the compressor.
If the amount of refrigerant in the system has decreased,

charge the system. (See SYSTEM CHARGING AND
RECLAMATION on Page 80-100-1.)
Open the cab door and windows.

1
Run the blower fan at maximum speed.
P-27538 Run the compressor for at least 20 minutes at 800-1200

RPM.
The compressor (Item 1) [Figure 80-60-1] is factory filled
Remove the compressor from the machine. (See
with 150-170 cc's of PAG oil (Poly Alkelene Glycol).

Unlike engine oil, it is not necessary to frequently check
or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases:
1. When the evaporator, condenser or receiver-drier is

replaced.
2. When refrigerant has leaked from the system.
3. When refrigerant is suddenly released from the

cooling cycle.
4. When any related problems occur in the cooling cycle.
When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce (30 cc) of PAG
oil should be added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG oil should be used. Never mix R-12

and R-134a Oils.

GENERAL AIR CONDITIONING SERVICE Figure 80-60-4
GUIDELINES (CONT'D)
Compressor Oil Check (Cont'd)
Figure 80-60-2
1
P-27542
NOTE: After draining the oil through the drain hole

and the connectors, extract the remaining oil
P-27539 through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-60-
4] several times by hand.
Figure 80-60-3

Measure the drained oil in a measuring cylinder.
Check the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
Figure 80-60-5
1
2
1
P-27545
Remove the oil drain plug (Item 1) [Figure 80-60-2] and

drain the oil through the connectors and the oil drain hole
(Item 2) [Figure 80-60-3].
Installation: Tighten the oil drain plug to 9.4-10.8 ft.-lb.

(13-15 N•m) torque.
P-27543
Add new compressor oil through the suction side

Installation: Add 150-170 cc's of PAG oil.
NOTE: The suction port on the compressor is marked

with an S and is the large port on the
compressor.

GENERAL AIR CONDITIONING SERVICE
GUIDELINES (CONT'D)
Component Replacement And Refrigeration Leaks
Figure 80-60-6
S6876
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 80-60-6] must be changed.
Never leave hose fittings, compressor fittings or

components uncapped while working on the A/C system.


SYSTEM TROUBLESHOOTING
Chart
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
connection. connector.
3. Fan motor malfunction. Check the lead wires from the motor with a circuit tester. Replace Evaporator/Blower
Unit.
4. 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 Check evaporator for plugging. Remove obstruction and
obstruction clean evaporator fins with
air or water.
2. Defective thermo. Check thermostat using a circuit tester. Replace Evaporator/Blower
switch (frozen unit.

evaporator).
Insufficient cooling although air flow and compressor operation are normal

1. System low on The high side pressure will be low and bubbles may be present Repair any leaks and
refrigerant. in sight glass on receive drier. recharge 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 at0 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 Clutch slips. Replace or clean the
surface. clutch surface.
6. Open coil. Clutch does not engage and there is not reading when a circuit Replace clutch.
tester is connected between the coil and terminals.
7. Broken wiring or poor Clutch will not engage. Inspect the ground and connections. Repair.
ground.
8. Wiring harness Test the conductance of the pressure switch, thermostat, Check operation.
components. Relay, etc.

SYSTEM TROUBLESHOOTING (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86° - 96° F (30° -
38° 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 then the low side pressure

Low pressure side Too The low pressure side pressure normally becomes too
high. high when the high pressure side pressure is too high. As
this is explained below, the following inspection is only
used when the low pressure side is too high.
1. Expansion valve opens Frost is present on the suction hose. Replace expansion valve
too far.
2.Defective compressor The high and low pressure side gauge pressures Replace compressor.
equalize when the magnetic clutch is disengaged.
Low pressure side Too
low.
1. Low refrigerant charge The high side pressure will be low and bubbles may be Repair any leaks and recharge

present in sight glass on receiver drier. the refrigerant to the correct
level.
2. Clogged or closed ex- The expansion valve's inlet side is frosted. Moisture or Clean or replace the expansion
pansion valve. other Contaminants can be the cause. Valve.
3. Restriction between Frost on the line between drier and expansion valve. A Flush system or replace hose.
drier and expansion Negative low pressure reading may be shown.
valve.
4. Thermostat malfunc- The evaporator is frozen. Replace Evaporator/Blower unit.
tion.
High pressure side Too
high.
1. Poor condenser per- Dirty or clogged condenser fins. Condenser fans not Clean fins, and/or repair the fan.
formance. Operating.
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.
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 will Evacuate and flush system
condenser or high pres- be low. replacing defective parts.
sure line.

SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting (Cont’d)

High pressure side Too
low.
1. Low refrigerant charge The high side pressure will be low and bubbles may be Repair any leaks and recharge
present in sight glass on receiver drier. the refrigerant to the correct
level.
System pressures Equal
1. Clutch not operating See magnetic clutch related topics above.
2.Compressor not pump- Equal high and low pressures. Replace compressor.
ing.


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° F to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40° F to the ambient temperature to get
the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient temperature.
Example: Ambient Temperature=90° F

90° F
+40° F
130° F condenser temperature=200 psig
Conditions and pressures will vary from system to system.


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:


SYSTEM CHARGING AND RECLAMATION NOTE: This test is run with the engine OFF, and the
A/C switch in the OFF position.
Reclamation Procedure
Figure 80-100-3
Figure 80-100-1
N-23024
P-52599
NOTE: Before reclaiming a refrigeration system, it is

Open the engine cover. recommended to identify the type of
Remove the access cover mounting bolt (Item 1). refrigerant that is in the A/C system and if it is

Remove the access cover (Item 2) [Figure 80-100-1]. pure enough to use. The tool MEL1592,
Refrigerant Identifier (Item 1) [Figure 80-100-3]
Figure 80-100-2 will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
1 further contamination to other A/C systems
that are reclaimed and charged from your
MEL 1581 Recovery/Recycling/Recharging
Machine.
2 Remove the protective cap and connect the refrigerant

identifier to the low pressure hose (Item 1) [Figure 80-
100-2].
Connect the refrigerant identifier to its power source.

P-27478
Locate the low pressure port (Item 1) and high pressure

port (Item 2) [Figure 80-100-2] on the back side of the
compressor.
WARNING
In the event of a leak, wear safety goggles. Escaping
refrigerant can cause severe injuries to eyes. In
contact with a flame, R134a refrigerant gives a toxic
gas.
W-2371-0500

SYSTEM CHARGING AND RECLAMATION (CONT'D) Figure 80-100-5
Reclamation Procedure (Cont'd)
Figure 80-100-4
N-22291
Use an approved recovery/charging unit [Figure 80-100-

S6879 5] to evacuate the system.
Connect the reclaimer to the A/C charge ports.

Follow the steps displayed on the refrigerant identifier
screen [Figure 80-100-4].

Allow two minutes for the refrigerant identifier to display
the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
Disconnect the refrigerant identifier from the A/C.
If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safety disposed of.
If R134a is found, evacuate the system.
WARNING
HFC 134A refrigerant can be dangerous if not
properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot
substances.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air.
Any servicing work that involves release or addition
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment,
knowledge, and experience to service refrigeration
equipment.
W-2373-0500

Reclamation Procedure (Cont'd)
Figure 80-100-6
2
N-22381
NOTE: The reclaimer unit, has a complete step by

P-25225 step set of instructions [Figure 80-100-8] to
follow for reclamation and recharging of the
A/C system. a trained technician should
Connect the Red hose (Item 1) [Figure 80-100-6] to the follow these instructions as they may very
high pressure port and open the valve. slightly depending on the model and brand of

reclaimer used.
Connect the Blue hose (Item 2) [Figure 80-100-6] to the
low pressure port and open the valve.
Figure 80-100-7
N-22292
Turn the reclaimer unit [Figure 80-100-7] to the ON

position and follow the on screen instructions.

Charging Procedure With A Manifold Gauge Set
Open the hood.
WARNING
2
contact with a flame, R134a refrigerant gives a toxic 1
gas.
W-2371-0500
S6880
Figure 80-100-9
Connect the Red hose (Item 1) [Figure 80-100-10] to the
high pressure port and open the valve.
Connect the Blue hose (Item 2) [Figure 80-100-10] to the

low pressure port and open the valve.
1

1 Figure 80-100-11
P-52622 1
Check to see that the hand valves (Item 1) [Figure 80-

100-9] 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 Procedure on Page 80-100-1.) S6882
Connect the gauges to the A/C charge ports.

Connect the Yellow hose (Item 1) [Figure 80-100-11] to
the vacuum pump.

SYSTEM CHARGING AND RECLAMATION (CONT'D) Determine the problem with the A/C system and repair it.
Charging Procedure With A Manifold Gauge Set Figure 80-100-14

(Cont’d)
Figure 80-100-12
1 1
P-27485
P-52626 A thermistor vacuum gauge (Item 1) [Figure 80-100-14]

can be used to determine the critical vacuum level during
evacuation. It is a solid state instrument that constantly
Start the vacuum pump and open ISO-valve (Item 1) monitors and visually indicates the vacuum level.

[Figure 80-100-12] on the vacuum pump.
The thermistor vacuum gauge is used with the vacuum
Run the vacuum pump for at least 5-10 minutes to insure pump [Figure 80-100-14].
that a vacuum has been pulled on the system.
Start the vacuum pump and open ISO-valve on the
Close the ISO-valve (Item 1) [Figure 80-100-12] (which vacuum pump.
isolates the vacuum pump from the A/C system) and turn
OFF the vacuum pump. Be sure that both hand valves, and both charge port
valves are open.
Charging Procedure
Run the vacuum pump for at least 45 minutes to insure
Figure 80-100-13 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

1
remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
Remove the vacuum pump and thermistor vacuum

gauge.
S6880
Note vacuum pressure indicated on the low pressure

(Blue) gauge (Item 1) [Figure 80-100-13]. Let stand for
5-10 minutes and recheck the pressure for changes.
If the pressure drops, this may be an indication of a leak

in the A/C system.

Charging Procedure (Cont’d)
Figure 80-100-15
S6924
1
2
Figure 80-100-18
S6883
Place a refrigerant container with R134a (Item 1) on a

charging scale (Item 2) [Figure 80-100-15] and zero out

the scale.
1
Connect the yellow hose (Item 3) [Figure 80-100-15]
from the manifold gauge set to the valve on the
refrigerant tank.
Figure 80-100-16
2 S36336
Turn the A/C fan switch (Item 1) [Figure 80-100-17] and

[Figure 80-100-18] to HIGH position.
Start the machine, and run at medium speed.
1 Watch the scale and run system until the predetermined

amount of refrigerant is added to the A/C system.
The A/C system holds 1.76 lb. (0,800 Kg) of refrigerant.

S6884
Turn off the valve on the refrigerant container, and hand
valves on the manifold gauge set.
Open the valve on the refrigerant container (Item 1) and
open the low pressure hand valve (Blue) (Item 2) [Figure Turn off the engine and remove the A/C charging
80-100-16] on the manifold gauge set. Allow the vacuum equipment from the machine.
to pull in the refrigerant until the pressure stabilizes.
Install access cover.

COMPRESSOR

WARNING
Evacuate the A/C system. (See Reclamation Procedure
on Page 80-100-1.) In the event of a leak, wear safety goggles. Escaping
Remove the alternator. (See Removal And Installation on contact with a flame, R134a refrigerant gives a toxic
Page 60-30-1.) gas.
W-2371-0500
Remove the compressor belt.
Figure 80-110-3
Figure 80-110-1
1
1

P-52609
S6885
Remove the compressor hoses (Item 1) [Figure 80-110-

Remove the two tensioner pulley mount belts (Item 1)
3].
[Figure 80-110-1]. Remove the pulley assembly.
Figure 80-110-2 Installation: Tighten the hoses to 22 ft.-lb. (29,8 N•m)

torque.
Cap and plug the hoses and fittings with the proper A/C
caps and plugs.
1
Figure 80-110-4
P-52608 1
Unplug the connector (Item 1) [Figure 80-110-2] from the

compressor.
Mark the compressor hoses for correct installation. S6886
Remove the mount bolts (Item 1) [Figure 80-110-4].
Remove the compressor.

COMPRESSOR (CONT'D) Figure 80-110-7
Compressor Clutch Disassembly And Assembly

1
Figure 80-110-5
1.25” 1.25”
1.25”
P-27524
1
The armature plate puller (Item 1) [Figure 80-110-7] can
P-27519 be constructed by drilling three 0.315 in. (8 mm) holes in
a flat circular plate, located 1.25 in. (31,75 mm) apart.
Remove the center armature nut (Item 1) [Figure 80- Figure 80-110-8
110-5].

Assembly: Tighten the armature nut to 8 ft.-lb. (12 N•m).
Figure 80-110-6
1
P-27522
Attach the armature puller plate (Item 1) to the armature

plate using the three bolts (Item 2) [Figure 80-110-8].
P-27520
To remove the armature plate (Item 1) [Figure 80-110-6]

from the clutch face you must make an armature plate
puller.

COMPRESSOR (CONT'D) 0.0197 in. (0.5 mm)
Figure 80-110-11
(Cont'd)
Figure 80-110-9
1
P-27525
Remove the snap ring (Item 1) [Figure 80-110-11] from

P-27521 the pulley assembly.
Figure 80-110-12
Attach a slide hammer puller to the armature puller tool

[Figure 80-110-9].
Figure 80-110-10
2 1
P-27526
Remove the pulley from the compressor [Figure 80-110-

P-27523 12].
Remove the armature plate (Item 1) [Figure 80-110-10]

from the compressor clutch.
Remove the shims (Item 2) [Figure 80-110-10] from the

armature shaft or armature plate.
Assembly: Insure that the clutch has the correct

clearance by adding the shims (Item 2) [Figure 80-110-
10].
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)


(Cont'd)
Figure 80-110-13
1
P-27529
Remove the harness retainer screw assembly (Item 1)

[Figure 80-110-15].
P-27527
Figure 80-110-16
The pulley assembly and bearing [Figure 80-110-13]

must be replaced as a complete unit.
Figure 80-110-14
1
2 1
P-27530
Remove the snap ring (Item 1) [Figure 80-110-16] from

the coil.
P-27528
Remove the lock (Item 1) and connector (Item 2) [Figure

80-110-14] from the compressor harness.


(Cont'd)
Figure 80-110-17
P-27527
The compressor [Figure 80-110-18] must be replaced as

a complete unit.
P-27531
Remove the coil from the compressor [Figure 80-110-

17].


CONDENSER (S/N A8HL12999 & BELOW, A8HP12999 Figure 80-120-2
& BELOW, A8HK11001 & ABOVE)
Remove the refrigerant from the A/C system. (See

Reclamation Procedure on Page 80-100-1.)
WARNING
gas. S6888
W-2371-0500
Remove the A/C hose (Item 1) [Figure 80-120-2] from

Figure 80-120-1 the condenser.
Figure 80-120-3

1
1
S6887
S6889
condenser.
Remove the two nuts (Item 1) [Figure 80-120-3] from
NOTE: Install caps and plugs on all fittings. each side of the condenser.
Tilt the condenser forward and remove.


CONDENSER (S/N A8HL13000 & ABOVE, A8HP13000 Figure 80-121-2
& ABOVE)

Reclamation Procedure on Page 80-100-1.) 2
WARNING 1
gas. S36353
W-2371-0500
Remove two nuts (Item 1) from the condenser mount

Figure 80-121-1 (Item 2) [Figure 80-121-2].
NOTE: One nut is hidden on [Figure 80-121-2].

3
Figure 80-121-3

1
1
2
S36351
Remove the tie straps (Item 1) [Figure 80-121-1] from

the condenser.
S36352

condenser. Remove the nut (Item 1) [Figure 80-121-3] from the
condenser.
Remove the A/C hose (Item 3) [Figure 80-121-1] from
the condenser. Tilt the condenser forward and remove.
NOTE: Install caps and plugs on all fittings.


RECEIVER / DRIER Figure 80-130-2
Removal And Installation 1 1

Remove the air cleaner. (See AIR CLEANER on Page

70-40-1.)
2
WARNING P-52616

refrigerant can cause severe injuries to eyes. In Remove the two hoses (Item 1) [Figure 80-130-2] from
contact with a flame, R134a refrigerant gives a toxic the Receiver/Drier.
gas.
W-2371-0500
Figure 80-130-1 NOTE: Install caps and plugs on all fittings.

Loosen the bolt (Item 2) [Figure 80-130-2] on the
mounting bracket.
S6876

the pressure switch.


PRESSURE SWITCH Figure 80-140-2

Reclamation Procedure on Page 80-100-1.) 1
WARNING
P-52616
gas.
W-2371-0500
Remove the pressure switch (Item 1) [Figure 80-140-2]
from the Receiver/Drier assembly.
Figure 80-140-1

2
S6876
Unplug the connector (Item 1) from the pressure switch

(Item 2) [Figure 80-140-1].


EVAPORATOR / BLOWER UNIT (S/N A8HL12999 & Figure 80-150-3
BELOW, A8HP12999 & BELOW, A8HK11001 &
ABOVE)

1
WARNING
P-25243
gas.
W-2371-0500 Temporarily remove the covering (Item 1) [Figure 80-
150-3] from the A/C hoses and expansion valve.
Figure 80-150-1
Figure 80-150-4
1
2

1
P-25221
P-25244

Figure 80-150-2 150-4]. Remove both A/C hoses.
NOTE: Plug the A/C hoses to avoid contamination.
P-25242
Remove the rear panel (Item 1) [Figure 80-150-2].

BELOW, A8HP12999 & BELOW, A8HK11001 &
ABOVE) (CONT'D)
Figure 80-150-5
P-27599
Remove the front mounting bolt (Item 1) [Figure 80-150-

1 7].
P-27597 Lay the evaporator/blower unit on the seat.
Figure 80-150-8
Unplug the thermostat wiring connector (Item 1) [Figure

80-150-5].
Figure 80-150-6
2
1 1
P-27600
Remove the drain hose (Item 1) [Figure 80-150-8].

P-27598
Remove the evaporator/blower unit from the machine.
Remove the three mount bolts (Item 1) and ground wire
(Item 2) [Figure 80-150-6] from the back of the
evaporator unit.

ABOVE, A8HP13000 & ABOVE)

WARNING 1

gas. S36343
W-2371-0500
Remove the two screws (Item 1) [Figure 80-151-2].

Removal And Installation on Page 50-141-1.) Remove the vent (Item 2) [Figure 80-151-2].
Figure 80-151-1 Figure 80-151-3

2
S36333 S36344
Mark and remove both A/C hoses (Item 1) [Figure 80- Unplug the connectors (Item 1) [Figure 80-151-3]
151-1]. located under the dashboard.
NOTE: Plug the A/C hoses (Item 1) [Figure 80-151-1]

to avoid contamination.
Remove the two heater hoses (Item 2) [Figure 80-151-

1].

ABOVE, A8HP13000 & ABOVE) (CONT’D)

1
Figure 80-151-4
1
S36347
Remove the evaporator / blower unit (Item 1) [Figure 80-

151-6].
S36345
Remove the two bolts (Item 1) [Figure 80-151-4] on the

right side of the evaporator / blower unit.

Figure 80-151-5
S36346
Remove the two bolts (Item 1) [Figure 80-151-5] on the

left side of the evaporator / blower unit outside the cab.

EXPANSION VALVE (S/N A8HL12999 & BELOW, Figure 80-160-3
Remove the refrigerant from the A/C system. (See 1

WARNING
P-25243
gas.
W-2371-0500
Temporarily remove the covering (Item 1) [Figure 80-
Figure 80-160-1 160-3] from the A/C hoses and expansion valve.
Figure 80-160-4
1

2
P-25221
P-25244
Figure 80-160-2 160-4]. Remove both A/C hoses.
NOTE: Plug the A/C hoses to avoid contamination.
P-25242
Remove the rear panel (Item 1) [Figure 80-160-2].

EXPANSION VALVE (S/N A8HL12999 & BELOW, Figure 80-160-6
(CONT'D)
Removal And Installation (Cont'd) 1
Figure 80-160-5
1
P-27666
The expansion valve (Item 1) [Figure 80-160-6] is

replaced as a complete unit.
P-27667
Remove the two mount bolts (Item 1) [Figure 80-160-5].

Remove the expansion valve.

EXPANSION VALVE (S/N A8HL13000 & ABOVE, Figure 80-161-2
A8HP13000 & ABOVE)

WARNING 1

gas. S36363
W-2371-0500
Remove the two evaporator fittings (Item 1) [Figure 80-

Remove the dash cover / steering column cover. (See 161-2] from the expansion valve.
Installation: Tighten the two evaporator fittings to 22 ft.-
Figure 80-161-1 lb. (29,8 N•m) torque.

NOTE: Plug the evaporator tubelines to prevent
contamination.
Figure 80-161-3
1
S36333
1
Mark and remove both A/C hoses (Item 1) [Figure 80-
161-1].
S36348
NOTE: Plug the A/C hoses (Item 1) [Figure 80-161-1] to
prevent contamination.
Remove the two mount bolts (Item 1) [Figure 80-161-3].
Remove the expansion valve (Item 2) [Figure 80-161-3].
NOTE: The expansion valve (Item 2) [Figure 80-161-3]

is replaced as a complete unit.


HEATER ASSEMBLY Figure 80-170-2

A8HP13000 & Above: (See Removal And Installation on
Page 80-151-1.)

Remove the travel / signal levers. (See Removal And

1

P-25590
on Page 60-90-1.)
Remove the vent hoses (Item 1) [Figure 80-170-2] from
Remove the dash cover / steering column cover. (See the top of the assembly.
Figure 80-170-3
Figure 80-170-1

1
P-25591
P-25589
Clamp the heater hoses [Figure 80-170-3].
Unplug the connector (Item 1) [Figure 80-170-1].

HEATER ASSEMBLY (CONT'D) Fan Removal And Installation
Removal And Installation (Cont'd) Figure 80-170-6
Figure 80-170-4
P-25594
P-25592
Carefully remove the clip (Item 1) and cable (Item 2)
[Figure 80-170-6].
Remove the heater hoses (Item 1) [Figure 80-170-4]
from the heater assembly. Figure 80-170-7

Figure 80-170-5
1
1
P-25595
1 Remove the fan mounting bolts (Item 1) [Figure 80-170-

7] and remove the fan.
P-25593

and remove the heater assembly.

HEATER ASSEMBLY (CONT'D) Figure 80-170-10
Core Removal And Installation
Figure 80-170-8 1
1 P-25604
Remove the two bolts (Item 1) [Figure 80-170-10] and

save for later use.
P-25602
Figure 80-170-11
Remove the two flange mounting nuts (Item 1) [Figure
80-170-8]. 1

Figure 80-170-9
1 1
P-25601
Remove the four screws (Item 1) [Figure 80-170-11]

from the vent bracket.
P-25603
Remove the flange/linkage assembly (Item 1) [Figure

80-170-9] from assembly.

HEATER ASSEMBLY (CONT'D) Figure 80-170-14
Core Removal And Installation (Cont'd)
Figure 80-170-12
P-25607
1 Slide the core from the housing [Figure 80-170-14].

P-25605
Remove the end bracket (Item 1) and spacer (Item 2)

[Figure 80-170-12] from the assembly.

Figure 80-170-13
2 1
P-25606
Be sure to separate the bracket (Item 1) and tab (Item 2)

[Figure 80-170-13].

SPECIFICATIONS
VERSAHANDLER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1

Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-1
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Fan Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-10-4
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-1
Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Intake Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2

Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-2
Rocker Shaft, Rockers And Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-3
Pistons And Piston Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-3
Connecting Rods And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-4
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-4
Crankshaft Re-Grind Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-5
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-6
Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-6
Camshaft And Thrust Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-6
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-6
Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-7
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-7
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-7
Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-7
Timing Case And Timing Gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-8
Oil Pump, Gear And Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-9
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-9
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-9
Water Pump And Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-20-10
Engine Torque Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-11
876 of 913 SPEC-01 V723 Service Manual

MACHINE TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Drive Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-1
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-30-2
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1

Torque for General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-2
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1

O-ring Face Seal Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Tubelines And Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-1
Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-2
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-3
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-50-5
HYDRAULIC / HYDROSTATIC FLUID SPECIFICATIONS . . . . . . . . . . . . . . . . . . . .SPEC-60-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-60-1
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
Decimal And Millimeter Equivalent Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
U.S. To Metric Conversion Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-70-1
877 of 913 SPEC-02 V723 Service Manual

VERSAHANDLER SPECIFICATIONS
Each attachment and each VersaHANDLER TTC have different Load

Capacity Charts. For example: An 84 inch bucket used on a V518 will have
WARNING its own chart; that same 84 inch bucket when used on a V723 will have a
different chart. Be sure you use the correct chart for your attachment and
VersaHANDLER TTC combination. W-2493-0204
Dimensions are given for machine equipped with

standard tires and may vary with other tire types.
• All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
• Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.
Machine Dimensions

V723 V723 WITH FRAME LEVELING
A 93.4 in. (2372 mm) 93.4 in. (2372 mm)
B 70.8 in. (1798 mm) 70.8 in. (1798 mm)
C 87.2 in. (2215 mm) 87.2 in. (2215 mm)
D 122 in. (2850 mm) 122 in. (2850 mm)
E 163 in. (4143 mm) 163 in. (4143 mm)
F 195.6 in. (4969 mm) 195.6 in. (4969 mm)
G 20.2 in. (513 mm) 20.2 in. (513 mm)
H 199.4 in. (5066 mm) 199.4in. (5066 mm)
J 55.1 in. (1400 mm) 55.1 in. (1400 mm)
K 152.9 in. (3885 mm) 152.9 in. (3885 mm)
L 283.6 in. (7205 mm) 283.6 in. (7205 mm)
M 54.9 in. (1395 mm) 54.9 in. (1395 mm)
878 of 913 SPEC-10-1 V723 Service Manual

VERSAHANDLER SPECIFICATIONS (CONT’D)
Performance
Operating Weight V723 V723 w/Frame Level

15,805 lb. (7169 kg) 15,827 lb. (7179 kg)
Maximum Rated Capacity *7000 lb. (3175 kg) *7000 lb. (3175 kg)
*Rated Load Capacity can change depending on which approved attachment is used
• Where applicable, specifications conform to SAE, ASME or ISO standards and are subject to change without notice.
Engine
Make/Model PERKINS 1104D-44TA (Turbo-charged)

Fuel/Cooling Diesel/Liquid
Horsepower (SAE Net) 100 HP (74,5 kW)
Number of Cylinders Four
Lubrication Pressure System W/Filter

Air Cleaner Dry replaceable cartridge w/safety element
Max Torque (ISO 14396) 410 N•m @ 1400 rpm
Fan Pump
Cylinder capacity 16 cm³

Max work pressure 175 bar
ventilator speed: normal/ 3200 rpm
reducted (motor 2400 rpm)
ventilator speed: normal/ 1100 rpm
reducted (motor 810 rpm)

Controls
Steering Steering Wheel w/3 Mode Selections (Front-Wheel, All-Wheel, Crab)

Hydraulics Joystick w/switches
Auxiliary Hydraulics Electric Switches on Joystick
Parking Brake Hand Operated Lever
Drive System
Main Drive Hydrostatic 4 wheel drive

Transmission Infinitely variable hydrostatic piston pump, driving 1 fully reversing hydrostatic motor
Final Drive Front Differential with reduction gear box, Rear Differential, Planetary Axles with Oil
Lubrication.
Travel Speed V723 V723 w/Frame Level

Low Range 0-4.4 mph (7.1 km/hr.) 0-4.4 mph (7.1 km/hr.)

High Range 0-18.7 mph (30,1 km/hr.) 0-18.7 mph (30,1 km/hr.)
Tires
V723 V723 w/Frame Level

Standard Tires Dunlop T37 400/80 x 24 - 62 PSI (4.25 bar) Dunlop 400/80 x 24 - 62 PSI (4.25 bar)
Optional Tires Titan Lift Rigger II 400/70-20-58 PSI (4 bar) Titan Lift Rigger II 400/70-20-58 PSI (4 bar)
Mitas Traction TR-01 15.5/80-24-73 PSI (5 Mitas Traction TR-01 15.5/80-24-73 PSI (5 bar)
bar)
Dunlop T37 400/70 x 20- 58 PSI (4 bar) Dunlop T37 400/70 x 20-58 PSI (4 bar)

Capacities
*Rated Load Capacity can change depending on which approved attachment is used.
V723 V723 w/Frame Level Type

Fuel Tank 38.3 Gal. (145 L) 38.3 Gal. (145 L) Diesel #2 or #1
Hyd./Hydros. System 33 Gal. (125 L) 33 Gal. (125 L) 6563328
Eng. Cooling System 18 qt. (17 L) 18 qt. (17 L) Antifreeze mixture (Ethylene
Glycol)
Engine Oil Change w/Filter 9 qt. (8,5 L) 9 qt. (8,5 L) See oil chart
Front Axle 11.1 qt. (10,5 L) 11.1 qt. (10,5 L) 100032-06A
Rear Axle 11qt. (10 L) 11 qt. (10 L) 100032-06A
Front Reduction Gearbox 0.85 qt. (0,8 L) 0.85 qt. (0,8 L) 100032-06A
Planetary Carrier 1.3 qt. (1,3 L) 1.3 qt. (1,3 L) 100032-06A
Hydraulic System

V723
Hydraulic Pump Engine driven, 25.6 GPM (96,9 L/min.)
Hydraulic Pressure 3843 PSI (265 bar)
Auxiliary Flow @ High idle 0-21 GPM (0-80 L/min.)
Electrical
Alternator 12-Volts, 85 A, A127i

Battery 12 Volts, 105 Ah, 720 A, 900 CCA @ 0° F (-18° C)
Starter 12 Volts, 3 kW, P95 (min. starting temperature: -10° C)
Instrument Panel
Full compliment of instrumentation for engine, hydraulic and machine functions.

ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by
parentheses.
General
Number Of Cylinders 4
Cylinder Arrangement In-line
Cycle 4 Stroke
Direction Of Rotation Clockwise From The Front
Intake System Turbocharged
Combustion System Direct Injection
Nominal Bore 4.133 (105)
Stroke 5.000 (127)
Compression Ratio 18.2:1
Displacement 269 in³. (4,4 liters)
Firing Order 1-3-4-2
Cylinder Head

Head Thickness 4.643 - 4.647 (117,95 - 118,05)
Head Thickness After Machining (Minimum) 4.614 (117,20)
Valve Seat Angle Inlet/Exhaust 45°/30°
Leak Test Pressure 29 PSI (2 bar)
Valve Guides
Inside Diameter 0.3543 - 0.3552 (9,000 - 9,022)

Outside Diameter 0.5131 - 0.5137 (13,034 - 13,047)
Valve Guide Clearance In The Cylinder Head (Interference) 0.0003 - 0.00019 (0,007 - 0,047)
Overall Length:
Intake 5.0724 - 5.0901 (128,838 - 129,288)
Exhaust 5.0466 - 5.0643 (128,184 - 128,634)
Protrusion From Bottom 0.486 - 0.498 (12,35 - 12,65)

ENGINE SPECIFICATIONS (CONT'D)
parentheses.
Exhaust Valves
Valve Stem Diameter 0.3519 - 0.3 528(8,938 - 8,960)

Valve Guide Clearance 0.0016 - 0.0024 (0,040 - 0,062)
Maximum 0.006 (0,15)
Valve Head Diameter 1.634 - 1.644 (41,51 - 41,75)
Valve Face Angle 30°
Overall Length 5.0466 - 5.0643 (128,184 - 128,634)
Seal Type Stem seal with integral seating washer
Valve Seat Angle 30°
Valve Clearance 0.018 (0,45)
Exhaust Depth (Production) 0.0610 - 0.0713 (1,55 - 1,81)
Exhaust Depth (Service) 0.0811 (2,06)
Intake Valves

Valve Stem Diameter 0.3525 - 0.3535 (8,953 - 8,975)
Valve Guide Clearance 0.0010 - 0.0027 (0,025 - 0,069)
Maximum 0.005 (0,13)
Valve Head Diameter 1.8220 - 1.8319 (46,28 - 46,53)
Valve Face Angle 45°
Overall Length 5.0724 - 5.0901 (128,838 - 129,288)
Seal Type Stem seal with integral seating washer
Valve Seat Angle 45°
Valve Clearance 0.008 (0,20)
Intake Depth (Production) 0.0630 - 0.0728 (1,60 - 1,85)
Intake Depth (Service) 0.0823 (2,09)
Valve Springs
Installed Height 1.4240 (36,17)

Installed Height Pressure 70 lb. (312 N)
Number Of Active Coils 3.8

parentheses.
Rocker Shaft, Rockers And Bushings
Shaft Outside Diameter 0.9828 - 0.9837(24,962 - 24,987)

Clearance Between Rocker Arm Bushing and Shaft 0.0010 - 0.0035 (0,026 - 0,089)
Maximum 0.007 (0,17)
Pistons And Piston Rings
Type Fastram combustion bowl inserted top ring groove,

graphite skirt
Piston Pin Bore Diameter 1.5631 - 1.5633 (39,703 - 39,709)
Piston Projection Above the Block Deck 0.008 - 0.0137 (0,21 - 0,35)
Top Ring Groove Width Tapered
Second Ring Groove Width 0.1008 - 0.1016 (2,56 - 2,58)
Third Ring Groove Width 0.1189 - 0.1197 (3,02 - 3,04)
Top Ring Barrel Face, Molybdenum insert, Keystone

Second Ring Taper Face, Cast Iron, Internal Bottom Step
Oil Control Ring Two Piece Coil Spring Loaded, Chromium Face
Top Ring Width Tapered
Second Ring Width 0.0972 - 0.0982 (2,470 - 2,495)
Third Ring Width 0.1169 - 0.1177 (2,97 - 2,99)
Top Ring Side Clearance Wedge
Second Ring Side Clearance 0.0026 - 0.0043 (0,065 - 0,110)
Third Ring Side Clearance 0.0011 - 0.0027 (0,03 - 0,07)
Top Ring End Gap 0.0118 - 0.0117 (0,30 - 0,45)
Second Ring End Gap 0.0275 - 0.0374 (0,65 - 0,85)
Third Ring End Gap 0.0118 - 0.0216 (0,30 - 0,55)
Piston Pin Type Full Floating
Piston Pin Outside Diameter 1.5628 - 1.5630 (39,694 - 39,700)
Piston Height Above Cylinder Block 0.008 - 0.014 (0,21 - 0,35)
Bushing Type Steel Back, Lead Bronze Tin Bearing Material
Bushing Outside Diameter 1.7190 - 1.7259 (43,66 - 43,84)
Bushing Inside Diameter (Reamed) 1.5638 - 1.5645 (39,723 - 39,738)
Piston Pin Bushing Clearance 0.0009 - 0.0017 (0,023 - 0,044)

parentheses.
Connecting Rods And Bearings
Connecting Rod Type H Section, Wedge Shape Small End

Connecting Rod Cap Location Flat joint face with dowels
Crank Pin End Diameter 2.6460 - 2.6465 (67,21 - 67,22)
Length Between Centers 8.624 - 8.626 (219,05 - 219,10)
Bearing Type Steel Back, Lead Bronze Bearing Material with Lead Finish
Bearing Width 1.245 - 1.255 (31,62 - 31,88)
Bearing Thickness At The Center 0.0723 - 0.0725 (1,835 - 1,842)
Bearing Clearance 0.0013 - 0.0032 (0,034 - 0,081)
Bearing Undersize Available -0.010 (-0,25), -0.020 (-0,50), -0.030 (-0,75)
Crankshaft
Main Journals 2.9984 - 2.9992 (76,159 - 76,180)

Maximum Wear And Out Of Round Of The Journals And 0.0016 (0,04)

Crank Pins
Crank Pin Diameters 2.499 - 2.500 (63,47 - 63,49)
Width Of Crank Pins 1.589 - 1.591 (40,35 - 40,42)
Maximum Crankshaft End Play 0.0201 (0,51)
Thrust Washer Thickness: Std. 0.089 - 0.091 (2,26 - 2,31)
Oversize 0.096 - 0.098 (2,45 - 2,50)
Main Bearing Oil Clearance 0.0022 - 0.0046 (0,057 - 0,117)

parentheses.
Crankshaft (Cont'd)
Undersize Journals And Crank Pins 0.010 (0,25), 0.020 (0,50), 0.030 (0,75)
With the crankshaft on V-blocks check the maximum run-out of the journals. They must not exceed these specifications
below and the difference in run-out between journals must not exceed 0.004 (0,10)
Journal #1 Mounting
Journal #2 0.0031 (0,08)
Journal #3 0.0059 (0,15)
Journal #4 0.0031 (0,08)
Journal #5 Mounting
Crankshaft Re-Grind Data

The finished sizes for crankshaft journals which have been ground undersize are given in the table below:
ITEM 0.010 (0,25) 0.020 (0,51) 0.030 (0,76)

1 2.9884 - 2.9892 2.9784 - 2.96792 2.9684 - 2.9692
(75.905 - 75.926) (75,651 - 75,672) (75,397 - 75,418)
2 2.4888 - 2.4896 2.4788 - 2.4796 2.4688 - 2.4696
(63,216 - 63,236) (62,962 - 62,982) (62,708 - 62,728)
3 1.5539 (39,47) maximum - -
4 1.4740 (37,44) maximum - -
5 1.7591 (44,68) maximum - -
6 1.5965 (40,55) maximum - -
7 Do not machine this diameter - -
8 0.1449 - 0.1559 (3,68 - 3,96) - -
9 0.1717 - 0.1811 (4,36 - 4,60) - -
Crankshaft Heat Treatment: 60 Hour Nitride
NOTE: Crankshafts that have been nitrided for 60 hours can be machined 0.010 (0,25) without the need to harden
again. Check the crankshaft for cracks before and after machining. Demagnetize the crankshaft after it
has been checked for cracks. Remove any sharp corners from the oil holes. Surface finish and fillet radii
must be maintained.

parentheses.
Main Bearings
Type Steel Back, 20% Tin Aluminium

All Others 1.244 - 1.255 (31,62 - 31,88)
Bearing Thickness (center) 0.0820 - 0.0823 (2,083 - 2,089)
Bearing Clearance 0.0022 - 0.0046 (0,057 - 0,117)
Bearing Undersize Available -0.010 (-0,25) -0.020 (-0,50) -0.030 (-0,75)
Thrust Washers
Type Steel back, bearing material

Position Each Side Of Center Main Bearing
Standard 0.089 - 0.091 (2,26 - 2,31)
Oversize 0.096 - 0.098 (2,45 - 2,50)
Camshaft And Thrust Washer

Journal #1 Diameter 1.9965 - 1.9975 (50,711 - 50,737)
Cam Lift (Intake) 0.2768 - 0.2807 (7,031 - 7,131)
Cam Lift (Exhaust) 0.2899 - 0.2938 (7,363 - 7,463)
Maximum Wear And Out Of Round 0.0021 (0,05)
Camshaft End Play (Production) 0.004 - 0.022 (0,10 - 0,55)
Service Limits 0.023 (0,60)
Thrust Washer Type 360°
Thrust Washer Thickness 0.216 - 0.218 (5,49 - 5,54)
Thrust Washer Recess Depth 0.218 - 0.222 (5,54 - 5,64)
Cylinder Block
Cylinder Bore Diameter 4.1338 - 4.1348 (105,000 - 105,025)

Main Bearing Bore Diameter 3.166 - 3.167 (80,416 - 80,442)

parentheses.
Cylinder Liners
Production Dry, Interference Fit, Flanged, With Flame Ring

Service Dry, Interference Fit, Flanged, With Flame Ring
Production Liner Outside Diameter 4.105 - 4.106 (104,25 - 104,28)
Production Liner Clearance 0.001 - 0.003 (0,03 - 0,08)
Production Liner Inside Diameter 3.937 - 3.938 (100,00 - 100,03)
Service Liner Clearance ±0.001 (±0,03)
Inside Diameter Of Service Liner With Flame Ring 3.937 - 3.961 (100,0 - 100,63)
(Installed)
Maximum 0.010 (0,25)
Flange Thickness 0.150 - 0.152 (3,81 - 3,86)
Liner Projection From Deck Surface 0.004 (0,10) Above or 0.004 (0,10) Below
Hose Angle 30/35°
Piston Cooling Jets 7 ft.-lb. (9 N•m)

Fuel Injection Pump
Type DELPHI DP 310 with locking screw

Rotation From Drive End Clockwise
Fuel System Self Vent
Fuel Injectors
Working Pressure 4263 PSI (294 bar)
Fuel Lift Pump
Type Electrically operated

Method of Drive Electric Motor 12V/24V
Standard Pressure 6 - 10 PSI (0,41 - 0,69 bar)
Minimum Pressure (@ idle speed) 3.6 PSI (0,25 bar)

parentheses.
Timing Case And Timing Gears
Camshaft Gear Number Of Teeth 68

Camshaft Gear Bore Diameter 1.375 - 1.376 (34,93 - 34,95)
Camshaft Hub Outside Diameter 1.3741 - 1.3747 (34,90 - 34,92)
Fuel Pump Gear Number Of Teeth (Electronic) 68
Fuel Pump Gear Bore (Electronic) 1.417 - 1.419 (29,99 - 30,02)
Crankshaft Gear Number Of Teeth 34
Crankshaft Gear Bore Diameter 1.875 - 1.8760 (47,625 - 47,650)
Crankshaft Gear Hub Diameter 1.875 - 1.8758 (47,625 - 47,645)
Crankshaft Gear Clearance -0.0008 - +0.0008 (-0,020 - +0,020)
Idler Gear Number Of Teeth 73
Idler Gear Bore Diameter 2.2495 - 2.2512 (57,14 - 57,18)
(With Needle Bearings) 2.8484 - 2.8488 (72,35 - 72,36)
Width Of Idler Gear And Bushing Assembly (Fitted) 1.186 - 1.187 (30,14 - 30,16)

Flanged Bushing Inside Assembly (Fitted) 1.999 - 2.000 (50,78 - 50,80)
Idler Gear Hub Outside Diameter 1.9961 - 1.9976 (50,70 - 50,74)
Idler Gear Hub Bushing Clearance 0.0016 - 0.0039 (0,04 - 0,10)
Gear End Play (Production Limits) 0.004 - 0.008 (0,10 - 0,20)
Service Limit 0.015 (0,38)
Backlash For All Gears 0.003 (0,08) Minimum

parentheses.
Oil Pump, Gear And Relief Valve
Type of Oil Pump Gear Driven, Differential Rotor

Number Of Lobes Inner 5, Outer 6
Clearance Of Outer Rotor To Body 0.0059 - 0.0129 (0,152 - 0,330)
End Play
Inner Rotor 0.0014 - 0.0035 (0,038 - 0,089)
Outer Rotor 0.0010 - 0.0029 (0,025 - 0,076)
Oil Pump Idler Gear Bushing I.D. 0.6303 - 0.6314 (16,012 - 16,038)
Idler Shaft O.D. 0.6285 - 0.5292 (15,966 - 15,984)
Idler Gear Shaft Bushing Clearance 0.0011 - 0.0028 (0,028 - 0,072)
Oil Pump Idler Gear End Play 0.0019 - 0.0108 (0,050 - 0,275)
Relief Valve Plunger Bore Diameter 0.7578 - 0.7598 (19,250 - 19,300)
Relief Valve Plunger Outside Diameter 0.7553 - 0.7563 (19,186 - 19,211)
Clearance 0.0015 - 0.0044 (0,039 - 0,114)

Length Of The Spring (Installed) 3.1866 (80,94)
Load On The Spring (Installed) 3.6 - 5.2 PSI (0,25 - 0,36 bar)
Pressure To Open Pressure Relief Valve 60 - 68 PSI (4,14 - 4,69 bar)
Oil Filter Type Full Flow Screw-on Type Canister
Pressure To Open Bypass Valve In Oil Filter 8 - 12 PSI (0,55 - 0,83 bar)
Turbocharger
Type Garrett GT25
Flywheel
Run-Out Less than 0.012 (0,30)

Misalignment 0.001 (0,03) @ 1.0 (25)

parentheses.
Water Pump And Thermostat
Type Centrifugal, Gear Drive

Shaft Outside Diameter 0.8435 - 0.8440 (21,425 - 21,438)
Drive Gear Bore Diameter 0.8415 - 0.8425 (21,375 - 21,400)
Drive Gear Shaft Clearance 0.0009 - 0.0024 (0,025 - 0,063)
Impeller Bore Diameter 0.4701 - 0.4712 (11,943 - 11,971)
Impeller Shaft Outside Diameter 0.4723 - 0.4727 (11,997 - 12,008)
Impeller Clearance On Shaft 0.0010 - 0.0025 (0,026 - 0,065)
Bearing Bore Diameter 1.5743 - 1.5753 (39,989 - 40,014)
Bearing Diameter 1.5743 - 1.5747 (39,989 - 40,000)
Bearing Clearance In Pump Body +0.0009/-0.0005 (+0,025/-0,011)
Thermostat Type Wax Pellet, Bypass Blanking
NOMINAL TEMPERATURE

STAMPED ON START TO OPEN FULLY OPEN MINIMUM VALVE LIFT,
THERMOSTAT BYPASS TEMPERATURE TEMPERATURE FULLY OPEN
VALVE
180° F (82° C) 170°/185° F (77°/85° C) 198°/208° F (92°/98° C) 0.35 (9,0)

Engine Torque Component
COMPONENT ft.-lb. N•m

Bridge Piece To Block 12 16
Camshaft Gear Bolt 70 95
Connecting Rod Nuts
Step 1 13 18
Final 52 70
Crank Pulley Bolts 85 115
Cylinder Head Bolt
Step One 37 50
Step Two 74 100
Step Three 225°
Step Three - Long Bolts 270°
Engine Mounting Bridge To Frame 200 271
Exhaust Manifold Bolts 33 40
Flywheel Cover To Housing 46 63
Flywheel Housing To Cylinder Block 55 75
Flywheel To Crankshaft Bolts 85 115
Fuel Injector Nut 26 35

Fuel Injection Pump Gear Nut 18 24
Fuel Injection Pump Flange Nuts 18 24
Fuel Lift Pump Bolts 16 22
High Pressure Fuel Lines Fittings 22 30
Idler Gear Hub Bolts 33 44
Main Bearing Bolts
Step 1 65 88
Step 2 125 170
Step 3 185 250
Oil Pan Bolts 8.9 10
Oil Pan Plug 25 34
Oil Pump Cover 16 22
Oil Pump To Front Main Cap 8.4 9,5
Oil Transfer Plate Bolts 32 44
Piston Cooling Jets 7 9
Rear Oil Seal Housing Bolts 16 22
Rocker Cover Nuts (With Shim Washer) 7 9
Rocker Shaft Bracket Nuts 20 27
Timing Case To Block 16 22
Timing Case Cover To Timing Case Bolts 16 22
Turbocharger To Manifold Nuts 33 44
Water Pump To Timing Case Bolts and Nuts 16 22


MACHINE TORQUE SPECIFICATIONS
Axle
ft.-lb. N•m
Axle To Frame Mounting Bolts 275-300 370-410
Brake Housing Hex Bolt 59 80
Brake Housing Spring Bolts 7 10
Brake Housing Stud 88 120
Differential Lock Retainer Bolt 10 13
Fender Mount Bolt 90-100 125-140
Housing Bolt 236 320
Housing Nut 140 190
King Pin Mount Bolts 140 190
Pinion Ring Gear Bolts 10 13
Planetary Cover Bolts 18 25
Planetary Gear Mount Bolts 88 120
Steering Cylinder Bolts 88 120
Tie Rod Jam Nut 185 250
Tie Rod Nut 160 220
Tie Rod Swivel End 300 406

Turn Stop Adjust Jam Nut 110 150
Wheel Nuts 221 300
Boom
ft.-lb. N•m
Extension Cylinder Base End 133 180
Extension Cylinder Rod End 188-210 255-285
Wear Pads Front 43 58
Wear Pads Rear 29 39
Drive Box
ft.-lb. N•m
Cover Bolts 44 60
Inner Housing Bolts 88 120
Mounting Flange Bolts 44 60
Drive Motor
ft.-lb. N•m
End Cap Bolts 85 115
Mounting Bolts 155 210
Mounting Plate Bolts 46 63

MACHINE TORQUE SPECIFICATIONS (CONT’D)
Engine
ft.-lb. N•m
A/C Compressor Mount Bolts 88 120
Alternator Mount Bolts 45 54
Starter Mount Bolts 45 54
Hydraulic Pump
ft.-lb. N•m
Filter Head 90 122
Flange Adapter 90 122
Guide Post Bolts 17 23
Mounting Bolts 78 106
Retaining Plate 10 13
Servo End Cap 10 13
Side Cover Bolts 24 32

TORQUE SPECIFICATIONS FOR BOLTS
Torque for General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Bobcat that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8
in.-lb. 0.250 80 - 90 (9,0 - 10,2) 110 - 120 (12,4 - 13,6)

(N•m) 0.3125 180 - 200 (20,3 - 22,6) 215 - 240 (24,2 - 27,1)
0.375 25 - 28 (34 - 38) 35 - 40 (47 - 54)
0.4375 40 - 45 (54 - 61) 60 - 65 (81 - 88)
0.500 65 - 70 (88 - 95) 90 - 100 (122 - 136)
0.5625 90 - 100 (122 - 136) 125 - 140 (170 - 190)
0.625 125 - 140 (170 - 190) 175 - 190 (240 - 260)
0.750 220 - 245 (300 - 330) 300 - 330 (410 - 450)
0.875 330 - 360 (450 - 490) 475 - 525 (645 - 710)
ft.-lb. 1.000 475 - 525 (645 - 710) 725 - 800 (985 - 1085)
(N•m) 1.125 650 - 720 (880 - 975) 1050 - 1175 (1425 - 1600)
1.250 900 - 1000 (1200 - 1360) 1475 - 1625 (2000 - 2200)

1.375 1200 - 1350 (1630 - 1830) 2000 - 2200 (2720 - 2980)
1.500 1500 - 1650 (2040 - 2240) 2600 - 2850 (3530 - 3870)
1.625 2000 - 2800 (2720 - 2980) 3450 - 3800 (4680 - 5150)
1.750 2500 - 2750 (3390 - 3730) 4300 - 4800 (5830 - 6500)
1.875 3150 - 3500 (4270 - 4750) 5500 - 6100 (5830 - 6500)
2.000 3800 - 4200 (5150 - 5700) 6500 - 7200 (8800 - 9800)

TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
Thread Size (Dia. x Material

Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0.8 3 - 4 ft.-lb.
(4 - 5 N•m)
M 6 x 1.0 6 - 7 ft.-lb. 6 - 9 ft.-lb.
(8 - 9 N•m) (8 - 12 N•m)
M 8 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)
M 10 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)
M 12 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)
M 14 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)

HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting
O-ring Face Seal Connection Figure SPEC-50-2
IMPORTANT Nut Nut
When repairing hydrostatic and hydraulic systems, Washer

clean the work area before disassembly and keep all Washer
O-ring
tubelines and ports to keep dirt out. Dirt can quickly O-ring
damage the system.
I-2003-0888
Figure SPEC-50-1
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-50-
2].

Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
Replace hoses which show signs of wear, damage or

B-07575
weather cracked rubber.
When the fitting is tightened, you can feel when the fitting Always use two wrenches when loosening and tightening
is tight to eliminate leakage caused by under or over hose or tubeline fittings.
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [Figure
SPEC-50-1].

HYDRAULIC CONNECTION SPECIFICATIONS Tighten the nut until it makes contact with the seat. Make
(CONT'D) a mark across the flats of both the male and female parts
of the connection (Item 1) [Figure SPEC-50-3].
Flare Fitting
Use the chart below to find the correct tightness needed
Use the following procedure to tighten the flare fitting: (Item 2) [Figure SPEC-50-3]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
Figure SPEC-50-3 damage.
TS-1619

FLARE FITTING TIGHTENING TORQUE
TUBELINE NEW ROTATE RE-ASSEMBLY

TORQUE
WRENCH SIZE OUTSIDE THREAD SIZE NO. OF HEX ROTATE NO. OF
ft.-lb. (N•m)
DIAMETER FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4

HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the O-ring flare
(CONT'D) fitting.
O-ring Flare Fitting Figure SPEC-50-5
Figure SPEC-50-4 Hex Flat Tightening Method
Primary O-ring Flare

Seal
1
Secondary
TS-1619
Seal
P-13009
Tighten the nut until it contacts with the seat. Make a
mark across the flats of both the male and female parts of
The flare is the primary seal, the O-ring is the secondary the connection (Item 1) [Figure SPEC-50-5].
seal and helps absorb vibration and pressure pulses at

the connection [Figure SPEC-50-4]. Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC-50-5]. If the fitting leaks after
If necessary, the O-ring-flare fitting can be used without tightening, disconnect it and inspect the seat area for
an O-ring. damage.
FLARE FITTING TIGHTENING TORQUE
** ***
TUBELINE *
NEW ROTATE RE-ASSEMBLY
WRENCH SIZE OUTSIDE THREAD SIZE TORQUE
NO. OF HEX ROTATE NO. OF
DIAMETER ft.-lb. (N•m)
FLATS HEX FLATS
5/8" 5/16" 1/2" - 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" - 18 22 (30) 2 1
7/8" 1/2" 3/4" - 16 40 (54) 2 1
1" 5/8" 7/8" - 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16" - 12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" - 12 118 (160) 3/4 3/4
* If a torque wrench is used to tighten a new fitting to a used hose/tubeline.
* If a torque wrench is used to tighten a used fitting to a new hose/tubeline.
* If a torque wrench is used to tighten a new fitting to a new hose/tubeline.
** If using the hex flat tightening method to tighten a new fitting to a new hose/tubeline.
** If using the hex flat tightening method to tighten a new fitting to a used hose/tubeline.
*** If using the hex flat tightening method to tighten a used fitting to a new hose/tubeline.

HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC-50-7
(CONT'D)
O-ring Flare Fitting (Cont'd)

2
NOTE: O-ring flare fittings are not recommended in
all applications. Use the standard flare fittings
in these applications.
Do not use a O-ring flare fitting when a copper bonnet

orifice is used. When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing.
Figure SPEC-50-6
1
P-13573
Copper Bonnet Orifice
Always remove the O-ring (Item 1) [Figure SPEC-50-7]

from the flare face as shown.
An O-ring (Item 2) [Figure SPEC-50-7] is added to the

flat boss of the fitting to seal the connection in this
application.

1
P-13572
Use a standard flare fitting (Item 1) [Figure SPEC-50-6]

as shown.
When a O-ring flare fitting is used as a straight thread

port adapter the O-ring flare face is not used to seal. The
O-ring may come off the fitting and enter the system.

HYDRAULIC CONNECTION SPECIFICATIONS Do not over tighten the port seal fitting.
(CONT'D)
NOTE: If a torque wrench cannot be used, use the
Port Seal Fitting hex flat tightening method as an approximate
guideline.
Figure SPEC-50-8
NOTE: Port seal fittings are not recommended in all
applications. Use O-ring boss fittings in these
applications.
PORT SEAL AND O-RING BOSS TIGHTENING

TORQUE
FITTING NUT TORQUE

THREAD SIZE
WRENCH SIZE ft.-lb. (N•m)
11/16" 9/16" - 18 22 (30)
15/16" 3/4" - 16 40 (54)
1-1/8" 7/8" - 14 60 (81)
Nut Seals 1-1/4" 1-1/16" - 12 84 (114)
to Fitting 1-1/2" 1-5/16" - 12 118 (160)
Figure SPEC-50-9

Nut Seals
to Port
Secondary O-ring Seal
1
P-13008
The nut is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at P-13571
the connection [Figure SPEC-50-8].
Do not use port seal fittings when a thread in orifice (Item
The hex portion of the nut does not contact the surface of 1) [Figure SPEC-50-9] is used in the port. The orifice
the component when the nut is tight. may interfere with the fitting and prevent it from sealing.
Use the following procedure to tighten the port seal Use an O-ring boss fitting (Item 2) [Figure SPEC-50-9]
fitting: as shown.
Port seal and nut, washer and O-ring (O-ring Boss)
fittings use the same tightening torque valve chart.
If a torque wrench cannot be used, use the following

method.
Tighten the nut until it just makes metal to metal contact,

you can feel the resistance.
Tighten the nut with a wrench no more than one hex flat
maximum.


HYDRAULIC / HYDROSTATIC FLUID
SPECIFICATIONS
Specifications
Use Bobcat axle fluid (P/N 100032-06A), for the transfer

case, planetarys and axle housings.
Use Bobcat hydraulic/hydrostatic transmission fluid (P/N

6563328). If this fluid is not available, use 10W-30 or
10W-40 SAE Motor Oil (5W-30 for 0° F [-18° C] and
Below).
DO NOT use automatic transmission fluids in the

machine or permanent damage to the hydraulic/
hydrostatic system will result.
WARNING

death. Fluid leaks under pressure may not be visible.
Use a piece of cardboard or wood to find leaks. Do
enters skin or eyes, get immediate medical attention
W-2072-0807
When temperatures below zero degree F (-18° C) are

common, the machine must be kept in a warm building.
Extra warm-up time must be used each time the machine
is started during cold temperature conditions. Cold fluid
will not flow easily and it makes action on the hydraulic
function slower. Loss of fluid flow to the hydrostatic pump
can cause damage in less than 60 seconds.
WARNING
During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
five minutes at less than half throttle. This warm-up
period is necessary for foot pedal operation and safe
stopping. Do not operate controls during warm-up
period.
When temperatures are below -20°F (-30°C), the

hydrostatic oil must be heated or kept warm. The
hydrostatic system will not get enough oil at low
temperatures. Park the machine in an area where the
temperature will be above 0°F (-18°C) if possible.
W-2027-1285


CONVERSIONS
Decimal And Millimeter Equivalent Chart

U.S. To Metric Conversion Chart


ALPHABETICAL INDEX
ACCUMULATOR . . . . . . . . . . . . . . . . 20-230-1 ENGINE AND ENGINE MOUNTS . . . .70-60-1

AIR CLEANER SERVICE . . . . . . . . . . . 10-60-1 ENGINE COMPONENTS AND TESTING
AIR CLEANER . . . . . . . . . . . . . . . . . . . 70-40-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70-70-1
AIR CONDITIONING SERVICE . . . . . . 80-90-1 ENGINE COOLING SYSTEM . . . . . . .10-70-1
AIR CONDITIONING SYSTEM FLOW . 80-10-1 ENGINE COVER . . . . . . . . . . . . . . . .10-160-1
AIR INTAKE COWLING . . . . . . . . . . . . 50-80-1 ENGINE COVER . . . . . . . . . . . . . . . . .50-70-1
ALTERNATOR . . . . . . . . . . . . . . . . . . . 60-30-1 ENGINE LUBRICATION SYSTEM . . . .10-90-1
APPROVED BOOM STOP . . . . . . . . . 10-150-1 ENGINE SPECIFICATIONS . . . . . .SPEC-20-1
AXLE AND DIFFERENTIAL (FRONT) . 40-20-1 ENGINE SPEED CONTROL . . . . . . . .70-20-1
AXLE AND DIFFERENTIAL (REAR) . . 40-21-1 ENGINE TIMING . . . . . . . . . . . . . . . . .70-80-1
AXLE TOE-IN . . . . . . . . . . . . . . . . . . . . 40-40-1 ENGINE / HYDROSTAT ASSEMBLY . .70-90-1
AXLES (FRONT AND REAR) . . . . . . 10-110-1 EVAPORATOR / BLOWER UNIT (S/N
BASIC TROUBLESHOOTING . . . . . . . 80-50-1 A8HK11001 & ABOVE) . . . . . . . . . . . .80-150-1
BATTERY . . . . . . . . . . . . . . . . . . . . . . . 60-20-1 EVAPORATOR / BLOWER UNIT (S/N
BOBCAT VERSAHANDLER IDENTIFICATION A8HL13000 & ABOVE, A8HP13000 &
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14 ABOVE) . . . . . . . . . . . . . . . . . . . . . . .80-151-1
BOOM ASSEMBLY . . . . . . . . . . . . . . . 50-40-1 EXPANSION VALVE (S/N A8HL12999 &

BRAKE LIGHT SWITCH . . . . . . . . . . 60-100-1 BELOW, A8HP12999 & BELOW, A8HK11001 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . .80-160-1
BRAKE VALVE . . . . . . . . . . . . . . . . . . 20-120-1
EXPANSION VALVE (S/N A8HL13000 &
BUCKET POSITIONING CYLINDER . . 20-30-1 ABOVE, A8HP13000 & ABOVE) . . . .80-161-1
CANOPY . . . . . . . . . . . . . . . . . . . . . . . 50-20-1 EXTENSION CYLINDER . . . . . . . . . . .20-40-1
COMPONENTS . . . . . . . . . . . . . . . . . . 80-20-1 FAN MOTOR . . . . . . . . . . . . . . . . . . .20-140-1
COMPRESSOR . . . . . . . . . . . . . . . . . 80-110-1 FENDER . . . . . . . . . . . . . . . . . . . . . . .50-120-1
CONDENSER (S/N A8HL12999 & BELOW, FIRE PREVENTION . . . . . . . . . . . . . . . . . 1-10
A8HP12999 & BELOW, A8HK11001 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . 80-120-1 FLOW CONTROL VALVE . . . . . . . . . .20-190-1
CONDENSER (S/N A8HL13000 & ABOVE, FLYWHEEL AND HOUSING . . . . . . .70-100-1
A8HP13000 & ABOVE) . . . . . . . . . . . 80-121-1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . 1-7
CONVERSIONS . . . . . . . . . . . . . . . SPEC-70-1 FRAME LEVEL SPEED SWITCH . . .60-150-1
DASH COVER / STEERING COLUMN COVER FRAME LEVELING CYLINDER . . . . .20-100-1
(S/N A8HL12999 & BELOW, A8HP12999 & FRONT AXLE . . . . . . . . . . . . . . . . . . . .40-30-1
BELOW, A8HK11001 & ABOVE) . . . . 50-140-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . .10-80-1
DASH COVER / STEERING COLUMN COVER
(S/N A8HL13000 & ABOVE, A8HP13000 & FUEL TANK . . . . . . . . . . . . . . . . . . . . .50-90-1
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . 50-141-1 GEAR PUMP . . . . . . . . . . . . . . . . . . .20-130-1
DELIVERY REPORT . . . . . . . . . . . . . . . . 1-13 GENERAL AIR CONDITIONING SERVICE
DRIVE BOX . . . . . . . . . . . . . . . . . . . . . 20-70-1 GUIDELINES . . . . . . . . . . . . . . . . . . . .80-60-1
DRIVESHAFT . . . . . . . . . . . . . . . . . . . . 40-70-1 HEATER ASSEMBLY . . . . . . . . . . . . .80-170-1
ELECTRICAL SYSTEM INFORMATION (S/N HYDRAULIC / HYDROSTATIC FLUID
A8HL12999 & BELOW, A8HP12999 & BELOW, SPECIFICATIONS . . . . . . . . . . . . .SPEC-60-1
A8HK11001 & ABOVE) . . . . . . . . . . . . 60-10-1 HYDRAULIC / HYDROSTATIC SYSTEM
ELECTRICAL SYSTEM INFORMATION (S/N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-100-1
A8HL13000 & ABOVE, A8HP13000 & HYDRAULIC CONNECTION
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . . 60-11-1 SPECIFICATIONS . . . . . . . . . . . . .SPEC-50-1
EMERGENCY EXIT . . . . . . . . . . . . . . 10-200-1 HYDRAULIC CONTROL VALVE . . . .20-170-1
908 of 913 INDEX-01 V723 Service Manual

HYDRAULIC RESERVOIR . . . . . . . .20-150-1 QUICK-TACH . . . . . . . . . . . . . . . . . . 50-100-1
HYDRAULIC SYSTEM INFORMATION REAR AXLE . . . . . . . . . . . . . . . . . . . . 40-90-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1 REAR WEIGHTS . . . . . . . . . . . . . . . .50-110-1
HYDROSTATIC DRIVE MOTOR . . . . .30-30-1 RECEIVER / DRIER . . . . . . . . . . . . . 80-130-1
HYDROSTATIC PUMP . . . . . . . . . . . . .30-40-1 RECONDITIONING THE ENGINE . . .70-110-1
HYDROSTATIC SYSTEM INFORMATION REGULAR MAINTENANCE . . . . . . . . 80-40-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1
SAFETY INSTRUCTIONS . . . . . . . . . . . . . 1-9
INCHING SWITCH . . . . . . . . . . . . . . .60-130-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
INNER BOOM . . . . . . . . . . . . . . . . . . .50-50-1
SERIAL NUMBER LOCATION . . . . . . . . . 1-12
INSTRUMENT PANEL . . . . . . . . . . . . .60-80-1
SERVICE BRAKE . . . . . . . . . . . . . . . . 40-80-1
JOYSTICK PANEL (S/N A8HL12999 &
BELOW, S/N A8HP12999 & BELOW, SERVICE MANUAL REVISION . . . . . . SMR-1
A8HK11001 & ABOVE) . . . . . . . . . . .50-150-1 SERVICE SCHEDULE . . . . . . . . . . . . 10-50-1
JOYSTICK PANEL (S/N A8HL13000 & SERVICE SOFTWARE . . . . . . . . . . . 60-140-1
ABOVE, A8HP13000 & ABOVE) . . . .50-151-1 SPARK ARRESTOR MUFFLER . . . . 10-140-1
JOYSTICK . . . . . . . . . . . . . . . . . . . . .20-200-1 STARTER . . . . . . . . . . . . . . . . . . . . . . 60-40-1
LATERAL OPERATOR RESTRAINT SYSTEM STEERING ANGLE ADJUSTMENT . . 40-60-1
(LORS) . . . . . . . . . . . . . . . . . . . . . . . .10-170-1
STEERING CYLINDER (FRONT) . . . 20-60-1
LATERAL OPERATOR RESTRAINT SYSTEM
(LORS) . . . . . . . . . . . . . . . . . . . . . . . . .60-50-1 STEERING CYLINDER (REAR) . . . . . 20-61-1

LIFT CYLINDER . . . . . . . . . . . . . . . . . .20-20-1 STEERING MODE VALVE BLOCK . .20-110-1
LIFTING AND BLOCKING THE STEERING VALVE . . . . . . . . . . . . . . 20-160-1
VERSAHANDLER . . . . . . . . . . . . . . . .10-10-1 STOPPING THE ENGINE AND LEAVING THE
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . .60-60-1 VERSAHANDLER . . . . . . . . . . . . . . 10-190-1
LUBRICATION . . . . . . . . . . . . . . . . . .10-120-1 SWITCH PANEL (S/N A8HL12999 & BELOW,
S/N A8HP12999 & BELOW, S/N A8HK11001 &
MACHINE TORQUE SPECIFICATIONS ABOVE) . . . . . . . . . . . . . . . . . . . . . . . 60-90-1
. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
SWITCH PANEL (S/N A8HL13000 & ABOVE,
MAIN RELIEF VALVE . . . . . . . . . . . . . .20-80-1 A8HP13000 & ABOVE) . . . . . . . . . . . 60-91-1
MAINTENANCE SAFETY . . . . . . . . . . . . . 1-1 SYSTEM CHARGING AND RECLAMATION
MUFFLER . . . . . . . . . . . . . . . . . . . . . .70-30-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
OIL COOLER / RADIATOR . . . . . . . . .70-50-1 SYSTEM TROUBLESHOOTING . . . . 80-70-1
OIL COOLER . . . . . . . . . . . . . . . . . . . .30-20-1 TEMPERATURE/PRESSURE . . . . . . 80-80-1
OPERATOR CAB (S/N A8HL12999 & BELOW, TILT CYLINDER . . . . . . . . . . . . . . . . . 20-50-1
A8HP12999 & BELOW) . . . . . . . . . . . .50-10-1 TIRE MAINTENANCE . . . . . . . . . . . 10-130-1
OPERATOR CAB (S/N A8HL13000 & ABOVE, TORQUE SPECIFICATIONS FOR BOLTS
A8HP13000 & ABOVE) . . . . . . . . . . . . 50-11-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . .SPEC-40-1
OPERATOR CAB / CANOPY . . . . . . . .10-20-1 TOW VALVE . . . . . . . . . . . . . . . . . . . 20-240-1
OPERATOR SEAT . . . . . . . . . . . . . . . .50-30-1 TOWING THE VERSAHANDLER . . . . 10-40-1
PARKING BRAKE . . . . . . . . . . . . . . .20-210-1 TRANSPORTING THE VERSAHANDLER ON
PARKING BRAKE . . . . . . . . . . . . . . . .40-50-1 A TRAILER . . . . . . . . . . . . . . . . . . . . . 10-30-1
PEDAL ASSEMBLY . . . . . . . . . . . . . .60-120-1 TRAVEL / SIGNAL LEVER (S/N A8HL12999 &
PIVOT LINK . . . . . . . . . . . . . . . . . . . .50-130-1 BELOW, A8HP12999 & BELOW, A8HK11001 &
ABOVE) . . . . . . . . . . . . . . . . . . . . . . . 60-70-1
PORT RELIEF VALVES . . . . . . . . . . .20-180-1
TRAVEL / SIGNAL LEVER (S/N A8HL13000 &
PRESSURE REDUCING VALVE . . . .20-220-1 ABOVE, A8HP13000 & ABOVE) . . . . 60-71-1
PRESSURE SWITCH . . . . . . . . . . . .80-140-1 TROUBLESHOOTING . . . . . . . . . . . . 40-10-1
QUICK-TACH CYLINDER . . . . . . . . . .20-90-1 TROUBLESHOOTING . . . . . . . . . . . . 70-10-1

VERSAHANDLER SPECIFICATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
VERSAHANDLER STORAGE AND RETURN
TO SERVICE . . . . . . . . . . . . . . . . . . . 10-180-1
WEAR PADS (FRONT) . . . . . . . . . . . . 50-60-1
WEAR PADS (REAR) . . . . . . . . . . . . . . 50-61-1
WIPER MOTOR (FRONT) . . . . . . . . . 60-110-1
WIPER MOTOR (REAR) . . . . . . . . . . 60-112-1
WIPER MOTOR (TOP) . . . . . . . . . . . 60-111-1


ROUTE TO
ATTENTION
SERVICE MANUAL PARTS MANAGER
SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: V723 - 1

Date: 15 April 2010
Product: Bobcat VersaHANDLER
Model: V723
Manual No: 6986675 (4-10)

V723 Service Manual (P/N 6986675) Dated 3-08 contains updated service information which replaces the previous
V723 Service Manual (P/N 6986675) Dated 4-10.
912 of 913 SMR-1 V723 Service Manual

913 of 913 SMR-2 V723 Service Manual

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What is the purpose of this manual?

What is the purpose of this manual?

What safety precautions are outlined in the manual?

What safety precautions are outlined in the manual?

Service Manual

S/N A8HL11001 & Above (with Cab)

Dealer Copy -- Not for Resale

6986675 (4-10) Printed in U.S.A. © Bobcat Company 2010

Safety Alert Symbol: This symbol with a warning statement,

CORRECT WRONG WRONG

Dealer Copy -- Not for Resale

WRONG WRONG WRONG

B-16081 B-16078 B-6589

3 of 913 1-1 V723 Service Manual

4 of 913 1-2 V723 Service Manual

SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01

ELECTRICAL SYSTEM & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-01

ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01

HEATING, VENTILATION AND AIR CONDITIONING (HVAC) . . . . . . . . . . . . . . . . . . . . . 80-01

ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .INDEX-01

Dealer Copy -- Not for Resale

5 of 913 1-3 V723 Service Manual

6 of 913 1-4 V723 Service Manual

SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

Dealer Copy -- Not for Resale

BOBCAT VERSAHANDLER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

7 of 913 1-5 V723 Service Manual

8 of 913 1-6 V723 Service Manual

2. Check that ROPS mounting 9. Enclosure door latches must

3. The seat belt must be 10. Attachment locking pins must

Dealer Copy -- Not for Resale

5. Machine signs (decals) must 12. Check for correct function of

7. Check for correct function of 14. Inspect for fuel, oil or

9 of 913 1-7 V723 Service Manual

18. Check the electrical charging 22. Check function or condition of

Dealer Copy -- Not for Resale

20. Inspect for loose or broken

10 of 913 1-8 V723 Service Manual

Dealer Copy -- Not for Resale

• The Telescopic Handler Operator Training Course is

DANGER available through your local dealer or at

The dealer and owner / operator review the

11 of 913 1-9 V723 Service Manual

The machine and some attachments have components

Flammable debris (leaves, straw, etc.) must be removed

The operator’s area, engine compartment and engine

Dealer Copy -- Not for Resale

All fuels, most lubricants and some coolants mixtures are

Do not use the machine where exhaust, arcs, sparks or

Check all electrical wiring and connections for damage.

Battery gas can explode and cause serious injury. Use

12 of 913 1-10 V723 Service Manual

Hydraulic System Always clean the machine and attachment, disconnect