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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operator’s Handbook and
WARNING signs (decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct function after
adjustments, repairs or service. Untrained operators and failure to follow
instructions can cause injury or death. W-2003-0903
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is
involved!” Carefully read the message that follows.
CORRECT CORRECT CORRECT
B-10731a B-15590 B-15591

Never service the Bobcat Skid- Use the correct procedure to lift or Cleaning and maintenance are
Steer Loader without instructions. lower operator cab. required daily.
WRONG WRONG WRONG
B-15592 B-15593 B-15599

Have good ventilation when Disconnecting or loosening any Never work on loader with lift
welding or grinding painted hydraulic tubeline, hose, fitting, arms up unless lift arms are held
parts. component or a part failure can by an approved lift arm support
Wear dust mask when grinding cause lift arms to drop. Do not go device. Replace if damaged.
painted parts. Toxic dust and gas under lift arms when raised Never modify equipment or add
can be produced. unless supported by an attachments not approved by
Avoid exhaust fume leaks which approved lift arm support device. Bobcat Company.
can kill without warning. Exhaust Replace it if damaged.
system must be tightly sealed.
WRONG WRONG WRONG
B-15600 B-15601 B-6589

B-16102 B-16102
Stop, cool and clean engine of Keep body, jewelry and clothing Lead-acid batteries produce
flammable materials before away from moving parts, flammable and explosive gases.
checking fluids. electrical contact, hot parts and Keep arcs, sparks, flames and
Never service or adjust loader exhaust. lighted tobacco away from
with the engine running unless Wear eye protection to guard batteries.
instructed to do so in the from battery acid, compressed Batteries contain acid which
manual. springs, fluids under pressure burns eyes or skin on contact.
Avoid contact with leaking and flying debris when engines Wear protective clothing. If acid
hydraulic fluid or diesel fuel are running or tools are used. contacts body, flush well with
under pressure. It can penetrate Use eye protection approved for water. For eye contact flush well
the skin or eyes. type of welding. and get immediate medical
Never fill fuel tank with engine Keep rear door closed except for attention.
running, while smoking or when service. Close and latch door
near open flame. before operating the loader.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/
operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance
Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat
replacement parts. The Service Safety Training Course is available from your Bobcat dealer.
MSW08-0805
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ALPHABETICAL INDEX
AHC SYSTEM....................................................................60-01 HYDROSTATIC MOTOR................................................... 30-01

AIR CLEANER ...................................................................70-01 HYDROSTATIC PUMP...................................................... 30-01
AIR CLEANER SERVICE ..................................................10-01 HYDROSTATIC SYSTEM INFORMATION ....................... 30-01
AIR CONDITIONING SERVICE.........................................80-01
AIR CONDITIONING SYSTEM FLOW ..............................60-01 INSTRUMENT PANEL ...................................................... 50-01
BASIC TROUBLESHOOTING ...........................................80-01 LIFT ARMS ....................................................................... 50-01

BATTERY.......................................................................... 60-01 LIFT ARM BY-PASS CONTROL VALVE ........................... 20-01
BICS™ ...............................................................................10-01 LIFT ARM SUPPORT DEVICE ......................................... 10-01
BICS™ SYSTEM ...............................................................60-01 LIFTING AND BLOCKING THE LOADER ........................ 10-01
BOBCAT CONTROLLER...................................................60-01 LIGHTS ............................................................................. 60-01
BOB-TACH.........................................................................50-01 LOADER SPECIFICATIONS........................................SPEC-01
BRAKE...............................................................................40-01 LUBRICATION THE LOADER ........................................ 10-01
BUCKET POSITION VALVE ..............................................20-01
MAIN RELIEF VALVE........................................................ 20-01
CHAINCASE ......................................................................40-01 MUFFLER ......................................................................... 70-01
CHARGE PRESSURE.......................................................30-01
COMPONENTS .................................................................80-01 OIL COOLER .................................................................... 30-01
COMPRESSOR .................................................................80-01 OPERATOR CAB ................................................... 10-01, 50-01
CONDENSER ....................................................................80-01 OPERATOR SEAT ............................................................ 50-01
CONTROL PANEL.............................................................30-01
CONTROLS .......................................................................20-01 POWER BOB-TACH (OPTION) .............................. 10-01,50-01
CONVERSIONS .......................................................... SPEC-01 PRESSURE RELIEF VALVE............................................. 80-01
COOLING FAN ..................................................................70-01 PRESSURE SWITCH ....................................................... 80-01
COOLING FAN FILTER .....................................................20-01 PWM CONTROL............................................................... 60-01
CYLINDER(S) ....................................................................20-01
RADIATOR ........................................................................ 60-01
DIAGNOSTICS SERVICE CODES....................................60-01 REAR AUXILIARY DIVERTER ......................................... 20-01
DRIVE BELT ......................................................................30-01 REAR DOOR .................................................................... 50-01
DRIVE COMPONENTS .....................................................40-01 REAR GRILL..................................................................... 50-01
RECEIVER/DRIER............................................................ 80-01
ELECTRICAL/HYDRAULIC CONTROL REF.....................60-01 RECONDITIONING THE ENGINE.................................... 70-01
ELECTRICAL SYSTEM INFORMATION ...........................60-01 REGULAR MAINTENANCE.............................................. 80-01
ENGINE AND ENGINE MOUNTS .....................................70-01 REMOTE START .............................................................. 10-01
ENGINE COMPONENTS AND TESTING .........................70-01
ENGINE COOLING SYSTEM............................................10-01 SAFETY ............................................................................ 80-01
ENGINE LUBRICATION SYSTEM ....................................10-01 SEAT BAR......................................................................... 50-01
ENGINE SPEED CONTROL .............................................70-01 SEAT BAR RESTRAINT SYSTEM.................................... 10-01
ENGINE SPECIFICATIONS ........................................ SPEC-01 SEAT BAR SENSOR......................................................... 60-01
EVAPORATOR ..................................................................80-01 SERVICE SCHEDULE ...................................................... 10-01
EVAPORATOR/HEATER UNIT..........................................80-01 STARTER.......................................................................... 60-01
EXPANSION VALVE ..........................................................80-01 STEERING ........................................................................ 30-01
SYSTEM CHARGING AND RECLAMATION.................... 80-01
FLYWHEEL AND HOUSING .............................................70-01 SYSTEM TROUBLEHOOTING CHART ........................... 80-01
FUEL SYSTEM ..................................................................10-01
FUEL TANK .......................................................................50-01 TEMPERATURE/PRESSURE........................................... 80-01
THERMOSTAT .................................................................. 80-01
GENERAL AIR CONDITIONING SERVICE TILT JUNCTION BLOCK................................................... 20-01
GUIDLINES ...................................................................80-01 TIRE MAINTENANCE ....................................................... 10-01
TOWING THE LOADER.................................................... 10-01
HAND-LEVER BOB-TACH ................................................10-01 TORQUE SPECIFICATIONS FOR BOLTS ..................SPEC-01
HEATER COIL. ..................................................................80-01 TRACTION LOCK ............................................................. 60-01
HEATER/AC FAN...............................................................80-01 TRANSPORTING THE LOADER...................................... 10-01
HEATER VALVE ................................................................80-01 TROUBLESHOOTING ...................................................... 70-01
HYDRAULIC CONTROL VALVE .......................................20-01
HYDRAULIC CONNECTION SPEC ............................ SPEC-01
HYDRAULIC/HYDROSTATIC FILTER...............................20-01
HYDRAULIC/HYDROSTATIC FLUID SPEC................ SPEC-01
HYDRAULIC FLUID RESERVOIR.....................................20-01
HYDRAULIC PUMP...........................................................10-01
HYDRAULIC SYSTEM INFORMATION ............................20-01
HYDRAULIC/HYDROSTATIC SYSTEM ............................10-01
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SAFETY &
CONTENTS
MAINTENANCE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .II
HYDRAULIC
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V SYSTEM
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SYSTEM
BOBCAT LOADER INDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . X
SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

SYSTEM
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL

SYSTEM &
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . . 60-01 ANALYSIS
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01
ENGINE
HEATING, VENTILATION, AIR CONDITIONING . . . . . . . . . . . . . 80-01 SERVICE
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
HVAC
SPECIFICATIONS
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FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS 9. The parking brake must
(Including sidescreens) is in function correctly.
good condition and is not
modified.
2. Check that ROPS mounting 10. Enclosure door latches must

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

correctly installed, functional linkages must function
and in good condition. correctly and be in good
condition.
4. The seat bar and pedal 12. Safety treads must be in good
interlocks must be correctly condition.
adjusted, clean and
lubricated.
5. Check lift arm support device; 13. Check for correct function of
replace if damaged. indicator lamps (Optional on
some models).
6. Machine signs must be 14. Check hydraulic fluid level,

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

pedals must return to neutral. hydraulic fluid leaks.
8. Check for correct function of 16. Lubricate the loader.

the work lights.
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17. Check the condition of the 22. Operate the loader and check
battery and cables. all functions.
18. Inspect the air cleaner for 23. Check for any field
damage or leaks. Check the modification not completed.
condition of the element.
19. Check the electrical charging 24. Check for correct function of
system. the Bobcat Interlock Control
System (BICS™) before the
machine is returned to the
customer.
20. Check tracks for wear. Recommend to the owner that all
necessary corrections be made
before the machine is returned to
service.
21. 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.
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SAFETY INSTRUCTIONS The following publications provide information on the
safe use and maintenance of the Bobcat machine and
attachments:
Safety Alert Symbol
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the machine is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the machine or attachment contains operating
information as well as routine maintenance and
service procedures. It is a part of the machine and can
WARNING be stored in a container provided on the machine.
Replacement Operation & Maintenance Manuals can
be ordered from your Bobcat dealer.
Instructions are necessary before operating or
servicing machine. Read and understand the • Machine signs (decals) instruct on the safe operation
Operation & Maintenance Manual, Operator’s and care of your Bobcat machine or attachment. The
Handbook and signs (decals) on machine. Follow signs and their locations are shown in the Operation
warnings and instructions in the manuals when & Maintenance Manual. Replacement signs are
making repairs, adjustments or servicing. Check for available from your Bobcat dealer.
correct function after adjustments, repairs or
service. Untrained operators and failure to follow • An Operator’s Handbook fastened to the operator
instructions can cause injury or death. cab. It’s brief instructions are convenient to the
W-2003-0903 operator. The handbook is available from your dealer
in an English edition or one of many other languages.
See your Bobcat dealer for more information on
translated versions.
WARNING
• The AEM Safety Manual delivered with the machine
Warnings on the machine and in the manuals are for gives general safety information.
your safety. Failure to obey warnings can cause
injury or death. • The Service Manual and Parts Manual are available
W-2044-1285 from your dealer for use by mechanics to do shop-
type service and repair work.
• The Skid-Steer Loader Operator Training Course is

IMPORTANT available through your local dealer or at
www.training.bobcat.com or www.bobcat.com.
This course is intended to provide rules and practices
This notice identifies procedures which must be of correct operation of the Skid-Steer Loader. The
followed to avoid damage to the machine. course is available in English and Spanish versions.
I-2019-0284
• Service Safety Training Courses are available from

your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com. They provide information for
safe and correct service procedures.
• The Skid-Steer Loader Safety Video is available from

your Bobcat dealer or at www.training.bobcat.com
or www.bobcat.com.
SI SSL-0206 SM
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SAFETY INSTRUCTIONS (CONT’D)
The dealer and owner/operator review the recommended

uses of the product when delivered. If the owner/operator
will be using the machine for a different application(s) he
or she must ask the dealer for recommendations on the
new use.
Call Before You Dig

1-888-258-0808
When you call, you will be directed to a location in
your state/city for information about buried lines
(telephone, cable TV, water, sewer, gas, etc.)
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SAFETY INSTRUCTIONS (CONT’D) • Use the procedure in the Operation & Maintenance
Manual for connecting the battery and for jump
Fire Prevention starting.
The machine and attachments have components that are • Use the procedure in the Operation & Maintenance
at high temperature under normal operating conditions. Manual for cleaning the spark arrestor muffler (if
The primary source of high temperatures is the engine equipped).
and exhaust system. The electrical system, if damaged
or incorrectly maintained, can be a source of arcs or Figure 1
sparks.
Flammable debris (leaves, straw, etc.) must be removed

regularly. If flammable debris is allowed to accumulate, it
will increase fire hazard. Clean often to avoid this
accumulation. Flammable debris in the engine
compartment is a potential hazard.
The spark arrestor muffler 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.
• Do not use the machine where exhaust, arcs, sparks

or hot components can contact flammable material,
explosive dust or gases.
• The operator cab, engine compartment, and engine

cooling system must be inspected every day and • Know where fire extinguishers and first aid kits are
cleaned if necessary to prevent fire hazard and located and how to use them. Fire extinguishers are
overheating. available from your Bobcat dealer [Figure 1].
• Check all electrical wiring and connections for

damage. Keep the battery terminals clean and tight.
Repair or replace any damaged part.
• Check fuel and hydraulic tubes, hoses and fittings for

damage and leakage. Never use open flame or bare
skin to check for leaks. Tighten or replace any parts
that show leakage. Always clean fluid spills. Do not
use gasoline or diesel fuel for cleaning parts. Use
commercial nonflammable solvents.
• Do not use ether or starting fluids on any engine

which has glow plugs. These starting aids can cause
explosion and injure you or bystanders.
• Always clean the machine, disconnect the battery,

and disconnect the wiring from the controllers before
welding. Cover rubber hoses, battery and all other
flammable parts. Keep a fire extinguisher near the
machine when welding. Have good ventilation when
grinding or welding painted parts. Wear a dust mask
when grinding painted parts. Toxic dust or gas can be
produced.
• Stop the engine and let it cool before adding fuel. NO

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

requesting service information or when ordering parts.
Early or later models identification made by serial
number) may use different parts, or it may be necessary
to use a different procedure in doing a specific service
operation.
Loader Serial Number
Figure 2
P-10501
The serial number is on the engine block just above the

fuel injection pump [Figure 3].
DELIVERY REPORT
Figure 4
N-20856
The loader serial number plate is located on the inside of

the left upright, above the grill [Figure 2].
Explanation of loader Serial Number:

xxxx xxxxx
Module 2.- Production
Sequence (Series)
Module 1.- Model/Engine

Combination
B-16315
1. The four digit Model/Engine Combination Module

The Delivery Report must be filled out by the dealer and
number identifies the model number and engine
signed by the owner or operator when the Bobcat loader
combination.
is delivered. An explanation of the form must be given to
the owner. Make sure it is filled out completely [Figure
2. The five digit Production Sequence Number
4].
identifies the order which the loader is produced.
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BOBCAT LOADER INDENTIFICATION
FRONT LIGHTS
OPERATOR SEAT
GRAB
With SEAT BELT
HANDLES
SAFETY TREAD
STEERING
LEVERS
TILT CYLINDERS
† BUCKET AUXILIARY HYDRAULIC

QUICK COUPLERS
STEPS
•OPERATOR CAB
(ROPS & FOPS)
SEAT BAR
LIFT ARM
REAR GRILL
LIFT ARM
SUPPORT DEVICE
REAR LIGHTS
LIFT CYLINDER
TAIL LIGHTS
REAR DOOR
TIRES*
* TIRES - Flotation tires (optional) are shown. The Bobcat loader is factory equipped with standard tires.
† BUCKET - Several different buckets and other attachments are available for the Bobcat loader.
• ROPS, FOPS - Roll Over Protective Structure, Falling Object Protective Structure, per SAE J1040 and ISO
3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level I. Level II is available. The
Bobcat loader is base-equipped with a standard operator cab as shown. Extra insulated cab is available as an
option (Reduced noise level).
B-15641
B-15642
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SAFETY & MAINTENANCE SAFETY &
MAINTENANCE
AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1
Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-120-1
SAFETY &
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . 10-10-1 MAINTENANCE
Additional Inspection For Loaders With Advanced Hand Controls (AHC)10-10-2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED
- Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Inspecting The BICS™ Controller (Engine STOPPED - Key ON) . . . . . . 10-10-1
Inspecting The Lift Arm By-Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . . 10-10-1
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . . 10-10-1 DRIVE
SYSTEM
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-2
Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-2
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-130-1

Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-130-1 ELECTRICAL
Replacing OIl and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-2 SYSTEM &
ANALYSIS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Filling the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1
Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-2 ENGINE
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-1 SERVICE
Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . 10-110-3
HAND-LEVER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 SPECIFICATIO
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-3
Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1
Replacing The Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-2
Replacing The Hydraulic/Hydrostatic Filters . . . . . . . . . . . . . . . . . . . . . 10-150-1
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

Disengaging The Lift Arm support Device . . . . . . . . . . . . . . . . . . . . . . . . 10-50-2
Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1
LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-1
LUBRICATING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1
Continued On Next Page
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SAFETY & MAINTENANCE (CONT’D)
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-3
Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-2
Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1
POWER BOB-TACH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1

Inspection and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1
REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-3
Procedure for Loader With Attachments Control Harness . . . . . . . 10-90-2
Procedure for Loader Without, Attachments Control Harness . . . . 10-90-1
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) 10-81-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81-1
Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81-1
Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-81-1
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) . . . . . . . . . . . . . 10-80-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-100-1
TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1

Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Tire Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
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BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Inspecting Deactivation Of The Auxiliary Hydraulics
System (Engine STOPPED - Key ON)
Inspecting The BICS™ Controller (Engine STOPPED -
Key ON) 3. Sit in the operator's seat, lower the Seat Bar, and
press the PRESS TO OPERATE LOADER Button.
Press the auxiliary hydraulics FLOW Button. The
auxiliary FLOW Button light will come ON. Raise the
WARNING Seat Bar. The light should be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING)

AVOID INJURY OR DEATH
The Bobcat Interlock Control System (BICS™) must
4. Sit in the operator's seat, lower the seat bar, engage
deactivate the lift, tilt and traction drive functions. If it
the parking brake pedal and fasten the seat belt.
does not, contact your dealer for service. DO NOT
modify the system.
W-2151-0394
5. Start the engine and operate at low idle. Press the
PRESS TO OPERATE LOADER Button. While
raising the lift arms, raise the Seat Bar fully. The lift
Figure 10-10-1 arms should stop. Repeat using the tilt function.
Inspecting The Traction Lock (Engine RUNNING)
6. Fasten the seat belt, disengage the parking brake

pedal, press the PRESS TO OPERATE LOADER
Button and raise the Seat Bar fully. Move the steering
levers slowly forward and backward. The TRACTION
lock should be engaged. Lower the Seat Bar. Press
the PRESS TO OPERATE LOADER Button.
7. Engage the parking brake pedal and move the

1 2 3 4 steering levers slowly forward and backward. The
TRACTION lock should be engaged.
B-15551G NOTE: * The TRACTION light on the left instrument

panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
1. Sit in the operator's seat. Turn key ON (Standard
Button is pressed and the parking brake is
Panel), press RUN / ENTER Button (Deluxe Panel,
disengaged.
lower the Seat Bar and disengage the parking brake
pedal. Press the PRESS TO OPERATE LOADER
Inspecting The Lift Arm By-Pass Control
Button. Three BICS lights (Items 1, 2, & 3) [Figure 10-
10-1] [PRESS TO OPERATE LOADER, SEAT BAR,
8. Raise the lift arms 6 feet (2 meters) off the ground.
and LIFT & TILT VALVE] on left instrument panel
Stop the engine.
should be ON [Figure 10-10-1].
Turn the lift arm by-pass control knob clockwise 1/4
2. Raise the Seat Bar fully. All four BICS lights (Items 1,
turn. Pull up and hold the lift arm by-pass control
2, 3, & 4) [Figure 10-10-1] [PRESS TO OPERATE
knob until the lift arms slowly lower.
LOADER, SEAT BAR, LIFT & TILT VALVE and
TRACTION*] on left instrument panel should be OFF
[Figure 10-10-1].
NOTE: Record what lights are blinking (if any) and

the number of light flashes. (See
Troubleshooting Guide on Page 60-90-4.).
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BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(CONT’D)
Additional Inspection For Loaders With Advanced

Hand Controls (AHC)
9. Sit in the operator's seat and fasten the Seat Belt.

Lower the Seat Bar, start the engine and press
10. Raise the lift arms about 6 feet (2 meters) off the
ground.
11. Turn key OFF (Standard Panel), press the STOP

Button (Deluxe Panel, and wait for the engine to
come to a complete stop.
12. Turn key ON (Standard Panel), press RUN/ENTER

Button (Deluxe Panel. Press the PRESS TO
OPERATE LOADER Button, move the left hand
control toward the operator. The lift arms should
not lower.
13. Move the right hand control away from the

operator. The bucket (or attachment) should not tilt
forward.
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LIFTING AND BLOCKING THE LOADER Figure 10-20-2
Procedure
WARNING
servicing machine. Read and understand the
Operation & Maintenance Manual, Handbook and
signs (decals) on machine. Follow warnings and
instructions in the manuals when making repairs,
adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained
N-20922
operators and failure to follow instructions can cause
injury or death.
W-2003-0199
Stop the engine. Put the floor jack under the rear of the
loader. Lift the rear of the loader and install jackstands
Figure 10-20-1 [Figure 10-20-2].
Figure 10-20-3
B-7023A
N-20924
Always park the loader on a level surface.
Put the floor jack under the front of the loader. Lift the
front of the loader and install jackstands under the boom
WARNING stops [Figure 10-20-3].
NOTE: Make sure the jackstands do not touch the

Put jackstands under the front axles and rear corners
tires.
of the frame before running the engine for service.
Failure to use jackstands can allow the machine to
fall or move and cause injury or death.
W-2017-0286
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TRANSPORTING THE LOADER Figure 10-30-2
Procedure BOTH SIDES

N-20218
N-20218
WARNING
Adequately designed ramps of sufficient strength are
needed to support the weight of the machine when
loading onto a transport vehicle. Wood ramps can
break and cause personal injury.
W-2058-0494
Figure 10-30-1 N-20217

N-20217 N-20218
1 N-20219
N-20216
Use the following procedure to fasten the Bobcat loader

Be sure the transport vehicle is of adequate size and to the transport vehicle to prevent the loader from moving
capacity. during sudden stops or when going up or down slopes
[Figure 10-30-2]:
A loader with an empty bucket or no attachment must be
loaded backward onto the transport vehicle [Figure 10- • Lower the bucket or attachment to the floor.
30-1].
• Stop the engine.
The rear of the trailer must be blocked or supported (Item
1) [Figure 10-30-1] when loading or unloading the loader • Engage the parking brake.
to prevent the front end of the trailer from raising up.
Some ramps have a wedge shape (Item 1) [Figure 10- • Install chains at the front and rear loader tie down
30-1] to support the trailer. positions (Inset) [Figure 10-30-2].
• Fasten each end of the chain to the transport vehicle.
Cover the exhaust pipe of the loader before transporting.

Air entering the exhaust pipe can turn the turbocharger
and cause damage due to lack of lubrication.
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TOWING THE LOADER Figure 10-40-2
Procedure 1
To prevent damage to the loaders hydrostatic system the

loader must be towed only a short distance at a slow
speed. (Example: Moving the loader onto a transport
vehicle.)
The towing chain (or cable) must be rated 1 and 1/2 times
the weight of the loader. (See Loader Dimensions on
Page SPEC-10-1.)
Lift and block the rear of the loader. (See LIFTING AND
BLOCKING THE LOADER on Page 10-20-1.)
N-19659
Remove the rear wheels. (See TIRE MAINTENANCE on
Page 10-160-1.)
NOTE: The steering panel assembly (Item 1) [Figure
Remove the hydrostatic motor access cover (both sides). 10-40-2] has been removed in [Figure 10-40-3]
(See Cover Removal And Installation on Page 30-40-15.) to show the brake block more clearly. The
panel does not need to be removed for this
Figure 10-40-1 procedure.
2 3
P-10540 P-10536
Remove the plugs (Item 1) [Figure 10-40-1] from the

motor (both sides).
Remove the shuttle valve (Item 2) [Figure 10-40-1] using

a small screwdriver (both sides).
NOTE: The plug (Item 3) [Figure 10-40-1] and relief

valve may need to be removed so that the
shuttle spool can be removed from the
housing bore.
Install and tighten the plugs (Item 1) [Figure 10-40-1].
Install the rear wheels. Lower the loader to the ground.
Raise the operator cab. (See Raising The Operator Cab

on Page 10-70-1.)
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TOWING THE LOADER (CONT’D)
Procedure (Cont’d)
Figure 10-40-3
N-21837
Disengage the parking brake solenoid valve by pushing

IN on the red Traction Lock By-Pass Knob (Item 1)
[Figure 10-40-3] and turning it 1/4 TURN
counterclockwise. The knob will come out to release the
solenoid valve.
Connect a Port-a-Power to the coupler (Item 2) [Figure

10-40-3] at the brake/two speed block.
Operate the Port-a-Power to approximately 350 PSI

(24134 kPa) to release the parking brake.
Lower the operator cab.
Remove the blocks from front wheels.
Move the loader to the desired location.
Park the loader on level ground and block the rear wheels
to prevent the loader from rolling.
NOTE: Before using the loader again, disconnect the

Port-a-Power, push in and turn the red
Traction Lock By-Pass Knob (Item 1) [Figure
10-40-3] 1/4 turn clockwise to engage the
brake solenoid valve. Install the shuttle valve
(Item 2) [Figure 10-40-1] and plugs (Item 1)
[Figure 10-40-1] into the hydrostatic motors.
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LIFT ARM SUPPORT DEVICE support device (Item 2) [Figure 1] with your hand and
remove the retaining pin.
Figure 10-50-2
WARNING
Never work on a machine with the lift arms up unless
the lift arms are secured by an approved lift arm 1
support device. Failure to use an approved lift arm
support device can allow the lift arms or attachment
to fall and cause injury or death.
W-2059-0598
WARNING
N-20264
Service lift arm support device if damaged or if parts
are missing. Using a damaged lift arm support or
with missing parts can cause lift arms to drop
causing injury or death. Lower the lift arm support device on top of the lift
W-2271-1197 cylinder. Hook the free end of the spring (Item 1) [Figure
10-50-2] to the lift arm support device so there will be no
interference with the support device engagement.
Engaging The Lift Arm Support Device
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Press the PRESS TO OPERATE LOADER button.
Figure 10-50-3
Figure 1
2
1
N-20922
N-20286
Raise the lift arms, until the lift arm support device drops
1 onto the lift cylinder rod [Figure 10-50-3].
N-20263 Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move pedals or the hand controls
Install jackstands under the rear of the loader frame until both pedals lock.
(Inset) [Figure 1].
Disconnect the spring from the lift arm support device Install pin (Item 1) [Figure 10-50-3] into the rear of the lift
retaining pin (Item 1) [Figure 1]. Support the lift arm arm support device below the cylinder rod.
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LIFT ARM SUPPORT DEVICE (CONT’D) Figure 10-50-5
Disengaging The Lift Arm support Device
Remove the pin from the lift arm support device.

2
Figure 10-50-4
1
1
P-10201 N-20263
Raise the support device into storage position and insert

pin (Item 1) [Figure 10-50-5] through lift arm support
device (Item 2) [Figure 10-50-5] and bracket. Connect
N-20287 spring to pin (Inset) [Figure 10-50-5].
Remove jackstands.
Connect the spring (Item 1) [Figure 10-50-4] from the lift
arm support device to the bracket below the lift arms.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Press the PRESS TO OPERATE LOADER button.
Raise the lift arms a small amount and the spring will lift
the support device off the lift cylinder rod. Lower the lift
arms. Stop the engine.
Raise the seat bar and move pedals (or hand controls)
until both pedals lock.
Disconnect the spring from the bracket.
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HAND-LEVER BOB-TACH The spring loaded wedge (Item 1) [Figure 1] must
contact the lower edge of the hole in the attachment (Item
Inspection And Maintenance 1) [Figure 10-60-2] and [Figure 10-60-3].
Figure 10-60-3
WARNING BOB-TACH
WEDGE
Bob-Tach wedges must extend through the holes in
attachment. Levers must be fully down and locked.
Failure to secure wedges can allow attachment to
come off and cause injury or death.
W-2102-0588
Figure 1 WEDGE MUST

CONTACT LOWER EDGE
OF HOLE IN THE
ATTACHMENT
B-15177
1
N-17048 If the wedge does not contact the lower edge of the hole
[Figure 10-60-2] and [Figure 10-60-3], the attachment
will be loose and can come off the Bob-Tach.
Figure 10-60-4
N-17050
Move the Bob-Tach levers to engage the wedges [Figure

1]. The levers and wedges must move freely.
The wedges must extend through the holes in the

attachment mounting frame (Item 1) [Figure 1].
Figure 10-60-2
TS-1062
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-60-4]. Replace any parts that are
damaged, bent, or missing. Keep all fasteners tight.
Look for cracked welds. Contact your Bobcat dealer for

repair or replacement parts.
1
Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-100-1 and See LUBRICATING THE BOBCAT
N-17046 LOADER on Page 10-170-1).
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POWER BOB-TACH (OPTION) Figure 10-61-3
Inspection and Maintenance
Figure 10-61-1
FRONT ACCESSORY PANEL
Wedge Must Contact

Lower Edge Of Hole
In The Attachment N-17046
If the wedge does not contact the lower edge of the hole
B-15554 [Figure 10-61-3], the attachment will be loose and can
come off the Bob-Tach.
Push and hold the BOB-TACH "WEDGES UP" switch Figure 10-61-4
[Figure 10-61-1] until wedges are fully raised. Push and
hold the BOB-TACH "WEDGES DOWN" switch [Figure
10-61-1] until the wedges are fully down. The wedges
must move freely.
Figure 10-61-2
1
N-17048
TS-1062
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage [Figure 10-61-4]. Replace any parts including
N-17050 decals and lever that are damaged, bent, or missing.
Keep all fasteners tight. Inspect the hoses, tubelines and
fittings for leaks.
The wedges must extend through the holes in the
attachment mounting frame (Item 1) [Figure 10-61-2] Look for cracked welds. Contact your Bobcat dealer for
and must contact the lower edge of the hole in the repair or replacement parts.
attachment [Figure 10-61-2] and (Item 1) [Figure 10-
61-3]. Lubricate the wedges. (See SERVICE SCHEDULE on
Page 10-100-1 and See LUBRICATING THE BOBCAT
LOADER on Page 10-170-1).
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OPERATOR CAB Figure 10-70-1
Description
The Bobcat loader has an operator cab (ROPS and

FOPS) as standard equipment to protect the operator
from rollover and falling objects. Check with your dealer if
the operator cab has been damaged. The seat belt must
be worn for 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, Level l. Level ll
is available.
Level l - Protection from falling bricks, small concrete N-20922

blocks and hand tools encountered in operations such as
highway maintenance, landscaping, and other
construction site services. Install jackstands under the rear of the loader frame
[Figure 10-70-1].
Level ll - Protection from falling trees, rocks; for machines
involved in site clearing, overhead demolition or forestry. Figure 10-70-2
Raising The Operator Cab
WARNING
Never modify operator cab by welding, grinding,
drilling holes or adding attachments unless
instructed to do so by Bobcat. Changes to the cab
can cause loss of operator protection from rollover
and falling objects, and result in injury or death.
W-2069-1299
N-20289 N-20290
Always stop the engine before raising or lowering the
cab.
Remove the nuts and plates [Figure 10-70-2] (both
Stop the loader on a level surface. Lower the lift arms. If sides) at the front corners of the cab.
the lift arms must be up while raising the operator cab,
install the lift arm support device. (See Engaging The Lift
Arm Support Device on Page 10-50-1.)
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OPERATOR CAB (CONT'D) Figure 10-70-4
Raising The Operator Cab (Cont’d)
Figure 10-70-3
N-20120 N-20292
Pull down on the bottom of the operator cab until it stops

N-20291 at the latching mechanism [Figure 10-70-4].
Release the latching mechanism [Figure 10-70-4] and

Lift on the grab handle and bottom of the operator cab pull the cab all the way down.
slowly until the cab is all the way up and the latching
mechanism engages [Figure 10-70-3]. Figure 10-70-5
Advanced Hand Control Only
N-20289 N-20290
Install the plates and nuts [Figure 10-70-5] (both sides).
Tighten the nuts to 40-50 ft.-lbs. (54-68 Nm) torque.
Lowering The Operator Cab
Always stop the engine before raising or lowering the

cab.
NOTE: Make sure the seat bar is fully raised or

lowered when lowering the cab.
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OPERATOR CAB (CONT’D) Figure 10-70-8
Emergency Exit
The front opening on the operator cab and rear window

provide exits.
REAR WINDOW (If Equipped)
Figure 10-70-6
N-20171
FRONT DOOR (If Equipped)
NOTE: When an Operator Cab Enclosure Kit is

installed, the window of the front door can be
used as an emergency exit. [Figure 10-70-8]
N-19386 Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [Figure 10-70-8].
Pull on the tag on the top of the rear window to remove Figure 10-70-9
the rubber cord [Figure 10-70-6].
Figure 10-70-7
N-20170
N-20296 Push the window out with your foot [Figure 10-70-9] at
any corner of the window.
Push the rear window out of the rear of the operator cab. Exit through the front door.
Exit through the rear of the operator cab [Figure 10-70-

7].
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SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) Maintaining The Seat Bar
Description (See SERVICE SCHEDULE on Page 10-100-1.) and on

the loader for correct service interval.
The seat bar restraint system has a pivoting seat bar with
arm rests and hydraulic valve spool interlocks for the lift Figure 10-80-1
and tilt functions.
The operator controls the use of the seat bar. The seat
bar in the down position helps to keep the operator in the
seat.
The spool interlocks require the operator to lower the

seat in order to operate the foot pedal controls (If
equipped).
1
When the seat bar is down, the PRESS TO OPERATE
LOADER Button is activated and the engine is running,
the lift, tilt, and traction drive functions can be operated.
When the seat bar is up, the lift and tilt control pedals are
locked when returned to the NEUTRAL position.
N-19225
Inspecting The Seat Bar
Use compressed air to clean any debris or dirt from the
pivot points (Item 1) [Figure 10-80-1]. Do not lubricate.
WARNING Inspect all mounting hardware. The correct bolt torque is

26 ft.-lbs. (35 Nm).
AVOID INJURY OR DEATH If the seat bar system and hydraulic valve spool
The seat bar system must lock the lift and tilt control interlocks do not function correctly check all electrical
pedals in neutral when the sear bar is up. Service the wiring and connections. Replace parts that are worn or
system if pedals do not lock correctly. damaged. Use only genuine Bobcat replacement parts.
W-2105-1285
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down. Start
the engine. Press the PRESS TO OPERATE LOADER
Button. Operate each foot pedal to check that both the lift
and tilt functions operate correctly. Raise the lift arms
until the attachment is about 2 feet (600 mm) off the
ground.
Raise the seat bar. Try to move each foot pedal. Pedals
must be firmly locked in the NEUTRAL position. There
must be no motion of the lift arms or tilt (attachment)
when the controls are moved.
Pull the seat bar down, press the PRESS TO OPERATE

LOADER Button, lower the lift arms. Operate the lift
control. While the lift arms are going up, raise the seat
bar. The lift arms must stop.
Lower the seat bar, press the PRESS TO OPERATE

LOADER Button, lower the lift arms and put the
attachment flat on the ground. Stop the engine. Raise the
seat bar and operate the foot pedals to be sure that the
pedals are firmly locked in the NEUTRAL position.
Unfasten the seat belt.
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SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND Maintaining The Seat Bar
CONTROLS)
Description
Figure 10-81-1 WARNING

The seat bar system must deactivate the lift and tilt
control functions when the seat bar is up. Service the
system if hand controls do not deactivate.
W-2355-0799
(See SERVICE SCHEDULE on Page 10-100-1.) and on

the loader for correct service interval.
Use compressed air to clean any debris or dirt from the

1 pivot parts (Item 1) [Figure 10-81-1]. Do not lubricate.
Inspect all mounting hardware. The correct bolt torque is
26 ft.-lbs. (35 Nm).
N-18417 If the seat bar system does not function correctly, replace
parts that are worn or damaged. Use only genuine
Bobcat replacement parts.
The seat bar restraint system [Figure 10-81-1] has a
pivoting seat bar with arm rests.
The operator controls the use of the seat bar. The seat
bar in the down position helps to keep the operator in the
seat.
When the seat bar is down, engine running and the

PRESS TO OPERATE LOADER Button is pressed, the
lift, tilt and traction drive functions can be operated.
When the seat bar is up, the lift, tilt and traction drive
functions are deactivated.
Inspecting The Seat Bar
Sit in the seat. Turn the key ON (Standard Panel), press

RUN/ENTER Button (Deluxe Panel), lower the seat bar
and press the PRESS TO OPERATE LOADER Button.
Move each hand control back and forth. You should hear
the zip-zip sound of the lift and tilt actuators moving the
control valve spools (under the seat).
Raise the seat bar fully. Move each hand control back
and forth. There must be no zip-zip sound of the lift or tilt
actuators. If either actuator makes a sound while the seat
bar is raised, contact your dealer for service.
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REMOTE START
Procedure for Loader Without, Attachments Control

Harness
WARNING
The tool listed will be need to do the following procedure: AVOID INJURY OR DEATH
With the 7-pin connector plugged into the loader and
MEL1563: Remote Start Tool Kit Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
Figure 10-90-1 inside the cab. Placing the key switch of the remote
start tool in the run position disconnects the
operator panel key switch from the start circuit. If the
service technician will be working the engine area it
is important to remove the operator panel keys.
1 W-2357-0899
Figure 10-90-2
P13841
1 2
3
The remote start (Item 1) [Figure 10-90-1] is required
when the operator cab is in the raised position for service
and the service technician needs to turn the key switch
on or start the engine. Example: adjusting the steering
linkage. N-19983 N-19984
Lift and block the loader. (See LIFTING AND BLOCKING

THE LOADER on Page 10-20-1.) Remove the cap (Item 1) [Figure 10-90-2] from the
loader harness (Item 2) [Figure 10-90-2].
Raise the lift arms (if required by the procedure) and
install an approved lift arm support device. (See When the remote start procedure is completed, replace
Engaging The Lift Arm Support Device on Page 10-50-1.) the loader connector cap (Item 3) [Figure 10-90-2].
Raise the operator cab (if required by the procedure).

(See Raising The Operator Cab on Page 10-70-1.)
Open the rear door of the loader.
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REMOTE START (CONT’D) Procedure for Loader With Attachments Control
Harness
Procedure for Loader Without, Attachments Control
Harness (Cont’d) The tool listed will be need to do the following procedure:
Figure 10-90-3 MEL1563: Remote Start Tool Kit
Figure 10-90-4
1
2
1
N-21854 N-19985
P13841
Connect the remote start tool to the engine harness
connector (Item 1) [Figure 10-90-3].
The remote start (Item 1) [Figure 10-90-4] is required
The connector (Item 2) [Figure 10-90-3] from the remote when the operator cab is in the raised position for service
start harness is not used in the remote start procedure and the service technician needs to turn the key switch
and should remain capped. on or start the engine. Example: adjusting the steering
linkage.
NOTE: The key switch on the right-hand side
operator panel must be in the off position or Lift and block the loader. (See LIFTING AND BLOCKING
the Remote Start Kit will not operate. THE LOADER on Page 10-20-1.)
Raise the lift arms (if required by the procedure) and

install an approved lift arm support device. (See
Engaging The Lift Arm Support Device on Page 10-50-1.)
Raise the operator cab (See Raising The Operator Cab

on Page 10-70-1.)
Open the rear door of the loader.
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REMOTE START (CONT’D) Procedure
Procedure for Loader With Attachments Control Figure 10-90-7

Harness (Cont’d)
Figure 10-90-5
2
1
N-20080
N-19987 Connect the remote start tool (Item 1) [Figure 10-90-7]

to the loader harness connector (Item 2) [Figure 10-90-
6].
Figure 10-90-6
The connector (Item 2) [Figure 10-90-7] on the remote
start harness is not used in the remote start procedure
and should remain capped.
1 NOTE: The key switch on the right-hand side

operator panel must be in the off position or
the Remote Start Kit will not operate.
WARNING
N-20079
With the 7-pin connector plugged into the loader and
Remote Start Key Switch in the OFF position, the
loader can still be started from the operator panel
Disconnect the attachment control harness (Item 1) inside the cab. Placing the key switch of the remote
[Figure 10-90-5] & [Figure 10-90-6] from the loader start tool in the run position disconnects the
harness (Item 2) [Figure 10-90-6]. operator panel key switch from the start circuit. If the
service technician will be working the engine area it
is important to remove the operator panel keys.
W-2357-0899
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REMOTE START (CONT’D) Figure 10-90-9
Figure 10-90-8
2
3 1
N-19541
The traction lock switch (Item 1) [Figure 10-90-9] is used

P13842 to turn traction lock on or off. Push the switch to the
override position. The switch will illuminate to indicate
traction lock OVERRIDE, in this position the wheels are
The remote start tool (Item 1) [Figure 10-90-8] has three able to turn.
rocker switches.
The maximum flow/variable flow switch (Item 2) [Figure
10-90-9] is used to activate the auxiliary hydraulics.
Pressing the switch once will activate variable flow.
Pressing the switch again will activate maximum flow.
The switch will illuminate to indicate which flow rate is
active. Pressing the switch a third time will turn the flow
OFF. The switch is used when checking pressures and
flow rate.
The auxiliary pressure release (Item 3) [Figure 10-90-9]

is used to release hydraulic pressure to the front and/or
rear auxiliary couplers. To release pressure; push and
hold the switch for three seconds.
NOTE: With the engine running; pushing and holding

the pressure release switch this will cause the
engine to stop in three seconds. To relieve the
pressure; continue to press the switch after
the engine has stopped.
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SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read
and understand the Operation & Maintenance Manual, Handbook and signs
(decals) on machine. Follow warnings and instructions in the manuals
WARNING when making repairs, adjustments or servicing. Check for correct function
after adjustments, repairs or service. Untrained operators and failure to
follow instructions can cause injury or death.
W-2003-0199
SERVICE SCHEDULE HOURS

■ ■
■ ■
ITEM SERVICE REQUIRED 8-10 50 100 250 500 1000
Engine Oil Check the oil level and add oil as needed. Do not overfill.
Engine Air Filter and Air System Check display panel for lighted Icon and/or SERVICE CODE. Service only when
required. Check for leaks and damaged components.
Engine Cooling System and Air Clean debris from oil cooler, radiator & grill. Check coolant level in recovery tank
Conditioning Condenser when engine is cold. Add 53% propylene glycol premixed with 47% water as
needed.
Tires Check for damaged tires and correct air pressure. Inflate to MAXIMUM pressure
shown on tire sidewall.
Seat Belt, Seat Bar and control Check the condition of seat belt. Check the seat bar and control interlocks. Clean
interlocks dirt and debris from moving parts.
Safety Signs and Safety Tread Check for damaged signs (decals) and safety treads. Replace any signs ar
safety treads that are damaged or worn.
Indicators & Lights (Opt.) Check for correct operation of all indicators & lights.
Operator Cab Check the fastening bolts, washers & nuts. Check the condition of cab.
Cab Air Filters (Heat & A/C) Check the filters every day for dirt & debris. Clean as needed.
Lift Arms, Cylinders, Bob-Tach Pivot Lubricate with multi-purpose lithium based grease.
Pins and Wedges
Primary Fuel Filter Remove trapped water.
Bobcat Interlock Control System Check that four (4) BICS™ indicator lights and functions are activated. See
(BICS™) details in this Operation & Maintenance Manual.
Hydraulic Fluid, Hoses and Tubelines Check fluid level and add as needed. Check for damage and leaks. Repair or
replace as needed.
Final Drive Transmission Check fluid level. Check for correct operation. Repair or adjust as needed.
(Chaincase)
Hydraulic Controls (Foot or Hand) Check for correct operation. Repair or adjust as needed.
and Steering Levers
Wheel Nuts ❏Check for loose wheel nuts and tighten to 320-350 ft.-lbs. (434-475 Nm)
torque.
Parking Brake Check operation.
Spark Arrestor Muffler Clean the spark chamber.
Battery Check cables, connections and electrolyte level. Add distilled water as needed.
Steering Lever Pivots Grease three fittings.
Engine/Hydrostatic Drive Belt * Check for wear or damage. Adjust or replace as needed.
Alternator and Air Cond. Belt Check belt tension and adjust as needed.
Engine Oil and Filter † Replace oil and filter. Use CD or better grade oil and Bobcat filter.
Fuel Filters Replace the filter elements.
Bobcat Interlock Control System Check lift arm by-pass control.
(BICS™)
Hydraulic Reservoir Breather Cap Replace the reservoir breather cap.
Hydraulic/Hydrostatic Filters • Replace the filter elements.
Cab Air Filters (Heat & A/C) Clean or replace filters as needed.
Hydraulic Reservoir Replace the fluid.
Final Drive Trans. (Chaincase) Replace the fluid.
Machine Name
1 Operation & Maintenance Manual
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Machine Name
2 Operation & Maintenance Manual
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FUEL SYSTEM Figure 10-110-2
Fuel Specifications WRONG

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:
TEMP. F° (C°) NO. 2 NO. 1

+15° (9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (-29°) 0% 100%
B-15651
Contact your fuel supplier for local recommendations.
Filling the Fuel Tank 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! [Figure 10-110-2].
WARNING Install and tighten the fuel fill cap [Figure 10-110-1].
Stop and cool the engine before adding fuel. NO

SMOKING! Failure to obey warnings can cause an
explosion or fire. [Figure 10-110-2]
W-2063-0887
Figure 10-110-1
P16018
Remove the fuel fill cap (Item 1) [Figure 10-110-1].
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FUEL SYSTEM (CONT'D) Support the filter and turn the clamp ring (Items 5 and 6)
to the left [Figure 10-110-3]. Remove the clamp ring.
Fuel Filters
Remove the filter by pulling straight down. Discard the old
filter element(s).
WARNING Remove the sediment bowl from the pre-filter and clean
the bowl.
Always clean up spilled fuel or oil. Keep heat, flames,
Check the two O-Ring seals on the sediment bowl.
sparks or lighted tobacco away from fuel and oil.
Replace if necessary.
Failure to use care around combustibles can cause
explosion or fire which can result in injury or death.
W-2103-1285
Install the sediment bowl on the filter. Hand tighten only.
Clean the filter head and push the filter into the filter
Figure 10-110-3 head.
Hold the filter and install the clamp ring. Turn the clamp
ring to the right to fasten the filter to the filter head.
5 Remove the air from the fuel system. (See Removing Air
From The Fuel System on Page 10-110-3.)
4
N-21893
(See SERVICE SCHEDULE on Page 10-100-1.) for the

service interval to remove the water from the fuel filters
and to replace the fuel filters. (Replace both filters at the
same service interval.)
Open the rear door.
Clean the outside surface of the filter assemblies (Items 1

and 2) [Figure 10-110-3].
Loosen the drain (Items 3 & 4) [Figure 10-110-3] to drain

water from the filters.
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FUEL SYSTEM (CONT'D)
Removing Air From The Fuel System
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
from a physician familiar with this injury.
W-2072-0496
Figure 10-110-4
2
P16020
After replacing the fuel filter elements or when the fuel

tank has run out of fuel, the air must be removed from the
fuel system before starting the engine.
Loosen the vent plug (Item 1) [Figure 10-110-4] on the

filter head.
Squeeze the priming bulb (Item 2) [Figure 10-110-4] until

fuel flows from the vent with no air bubbles.
Tighten the vent plug.
Set the engine speed control to 1/2 speed position. Start

the engine.
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AIR CLEANER SERVICE Outer Filter
Replacing Filter Element Figure 10-120-3
Figure 10-120-1
1 1
N-20220
B-15552
B-15553
Remove the wing nut and remove the dust cover (Item 1)
[Figure 10-120-3].
It is important to change the air filter element only when
the Air Cleaner Icon in the right panel is ON (Item 1) Figure 10-120-4
[Figure 10-120-1] and you hear three beeps from the
alarm.
Replace the inner filter every third time the outer filter is
replaced or as indicated on (See Replacing Filter
Element (Cont’d) on Page 10-120-2.)
Figure 10-120-2
1
2
N-20221
1
Remove the wing nut and remove the outer filter element
(Item 1) [Figure 10-120-4].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
B-15551
Install a new outer element and the wing nut.
Press and hold the LIGHT Button (Item 1) [Figure 10- Install the dust cover and the wing nut [Figure 10-120-3].
120-2] for two seconds.
Check the air intake hose and the air cleaner housing for
If the filter element needs replacement, the CODE [01- damage. Make sure all connections are tight.
17] (Air Filter Plugged) will show in the HOURMETER /
CODE DISPLAY (item 2) [Figure 10-120-2].
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AIR CLEANER SERVICE (CONT’D) Figure 10-120-6
Replacing Filter Element (Cont’d)
Figure 10-120-5
1 N-20220
Install the dust cover and the wing nut (Item 1) [Figure
N-20222 10-120-6].
Inner Filter
Only replace the inner filter element under the following

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

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

engine and run at full RPM. If the HOURMETER /
CODE DISPLAY shows [01-17] (Air Filter Plugged),
replace the inner filter element.
Remove the wing nut and remove the inner filter element
(Item 1) [Figure 10-120-5]
Note: Make sure all sealing surfaces are free of dirt

and debris.
Install the new inner element and wing nut.
Install the outer element and wing nut.
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ENGINE LUBRICATION SYSTEM Figure 10-130-2
Checking Engine Oil
Figure 10-130-1
2
1
Keep Oil
Level Between
These Marks
P-10302
Keep the oil level between the marks on the dipstick

[Figure 10-130-2].
Remove the fill cap (Item 2) [Figure 10-130-1] and add

P-16022 oil as necessary.
Use a good quality motor oil that meets API Service

Check the engine oil level every day before starting the Classification of CD or better. (See OIl Chart below.)
engine for the work shift.
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
Open the rear door and remove the dipstick (Item 1) C°
[Figure 10-130-1].
F°
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CD, CF4, CG4)
*Can be used ONLY when available with appropriate diesel rating.
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ENGINE LUBRICATION SYSTEM (CONT’D) Figure 10-130-4
Replacing OIl and Filter

2
WARNING
W-2103-1285 1
Figure 10-130-3 P-16022
Remove the oil filter (Item 1) [Figure 10-130-4].
Clean the filter housing surface.
Put clean oil on the new filter gasket. Install the filter and
hand tighten.
Connect the drain hose (Item 1) [Figure 10-130-3].
Remove the filter cap (Item 2) [Figure 10-130-4].

1
Put oil in the engine. (See Capacities on Page SPEC-10-
P-16021 4.)
Start the engine and let it run for several minutes.

service interval for replacing the engine oil and filter. Stop the engine.
Run the engine until it is at operating temperature. Stop Check for leaks at the oil filter and check the oil level.
the engine.
Add oil as needed if it is not at the top mark on the
Open the rear door. dipstick. Do not overfill.
Disconnect the drain hose (Item 1) [Figure 10-130-3]. Install the filler cap and close the rear door before
operating the loader.
Drain the oil into a container and recycle or dispose of the
used oil in an environmentally safe manner.
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ENGINE COOLING SYSTEM Figure 10-140-2
Check the cooling system every day to prevent over-

heating, loss of performance or engine damage.
WARNING
Wear safety glasses to prevent eye injury when any
of the following conditions exist:
• When fluids are under pressure.
• Flying debris or loose material is present.
• Engine is running.
• Tools are being used.
W-2019-1285 N-20235
Cleaning The Cooling System Raise the oil cooler and clean the top of the radiator
[Figure 10-140-2].
Raise the rear grill.
Check cooling system for leaks.
Figure 10-140-1
N-20231
Use air pressure or water pressure to clean the top of the

oil cooler [Figure 10-140-1].
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COOLING SYSTEM (CONT’D) Replacing The Coolant
Checking The Coolant Level
WARNING
IMPORTANT Do not remove radiator cap when the engine is hot.
You can be seriously burned.
AVOID ENGINE DAMAGE W-2070-1285
Always use the correct ratio of water to antifreeze.
Figure 10-140-4
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. 1
Always add a premixed solution. Adding full strength

concentrated coolant can cause serious premature
engine damage.
I-2124-0497
Open the rear door and raise the rear grill.

N-20234
Figure 10-140-3
Open the rear door and raise the rear grill.
Remove the radiator cap (Item 1) [Figure 10-140-4].
N-20233
Check the coolant level in the coolant recovery tank (Item

1) [Figure 10-140-3].
The coolant level must be at the COLD mark on the

coolant recovery tank when the engine is cold.
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COOLING SYSTEM (CONT’D) NOTE: The loader is factory filled with propylene
glycol coolant (purple color). DO NOT mix
Replacing The Coolant (Cont’d) propylene glycol with ethylene glycol.
Add premixed coolant, 47% water and 53% propylene

glycol to the recovery tank if the coolant level is low.
IMPORTANT One gallon and one pint (4,3 L) of propylene glycol mixed
with one gallon (3,8 L) of water is the correct mixture of
AVOID ENGINE DAMAGE coolant to provide a -34°F (-37°C) freeze protection. Use
Always use the correct ratio of water to antifreeze. a refractometer to check the condition of propylene glycol
in your cooling system.
Too much antifreeze reduces cooling system
efficiency and may cause serious premature engine Install the radiator cap.
damage.
Add coolant to the recovery tank. The coolant level must
Too little antifreeze reduces the additives which be at the COLD mark on the coolant recovery tank.
protect the internal engine components; reduces the
boiling point and freeze protection of the system. Run the engine until it is at operating temperature.
Always add a premixed solution. Adding full strength Stop the engine.
concentrated coolant can cause serious premature
engine damage. Check the coolant level in the recovery tank when cool.
I-2124-0497
Add coolant to the recovery tank as needed.

Figure 10-140-5
Lower the rear grill and close the rear door.
P-16023
Connect a hose to the engine block drain valve (Item 1)

[Figure 10-140-5].
Open the drain valve and drain the coolant into a

container Recycle or dispose of used coolant in an
enviromentally safe manner.
Close the drain valve.
Mix the coolant in a separate container and fill the

radiator. (See Capacities on Page SPEC-10-4.)
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963 Bobcat Loader
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HYDRAULIC/HYDROSTATIC SYSTEM Replacing The Hydraulic/Hydrostatic Filters
Checking And Adding Fluid Figure 10-150-3
Figure 10-150-1
1
1
N-20293
N-20255
correct service interval.
Use only recommended fluid in the hydraulic system.
(See Hydraulic System on Page SPEC-10-3.) The filter is under the operator cab at the left side of the
loader.
Put the Bobcat loader on a level surface. Lower the lift
arms and tilt the Bob-Tach fully back. Raise the operator Cab. (See Raising The Operator Cab
on Page 10-70-1.)
Stop the engine.
Figure 10-150-4
Check the fluid level in the sight gauge (Item 1) [Figure
10-150-1] on the left side of the loader.
The fluid level must be visible in the sight gauge.
Figure 10-150-2
1
P-16031
Remove the filter elements (Item 1) [Figure 10-150-3] &

[Figure 10-150-4].
N-20232 Clean the surface of the filter housing where the seal
contacts the housing.
Remove the fill cap (Item 1) [[Figure 10-150-2] and add Put clean oil on the seal of the new filter element.
fluid as needed to bring the level to the center of the sight
gauge [Figure 10-150-1]. Do not overfill. Install and hand tighten the new filter elements.
Install the fill cap. Lower the operator cab. (See Lowering The Operator
Cab on Page 10-70-2.)
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HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D) Figure 10-150-6
Replacing The Hydraulic Fluid
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
N-20840
Pull the end of the drain hose through the access hole
WARNING [Figure 10-150-6]. Remove the drain plug and drain the
fluid into a container.
Always clean up spilled fuel or oil. Keep heat, flames, Recycle or dispose of the used fluid in an
sparks or lighted tobacco away from fuel and oil. environmentally safe manner.
explosion or fire which can result in injury or death. Replace the hydraulic/hydrostatic filter element. (10-150-
W-2103-1285 1.))
Figure 10-150-5 Install the plug in the hose and put the hose back into the
access hole. Add fluid as needed to bring the level to the
center of the sight gauge [Figure 10-150-6]. (See
Specifications on Page SPEC-60-1 and See Capacities
on Page SPEC-10-4) DO NOT overfill.
Start the engine and operate the loader hydraulic

controls. Stop the engine and check for leaks.
Check the fluid level in the sight gauge and add as

1 needed. (See Checking And Adding Fluid on Page 10-
150-1.)
Install the access cover and install the tire. Remove the
loader from the jackstands.
N-20232

service interval.
The fluid must be replaced if it becomes contaminated or
after major repairs.
Remove the reservoir fill cap (Item 1) [Figure 10-150-5].
Raise the loader and put four jackstands under the axle
housings of the loader.
Remove the left rear tire. (See TIRE MAINTENANCE on
Page 10-160-1.)
Remove the hydrostatic motor access cover.
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HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)
Breather Cap
Figure 10-150-7
P-16031

correct service interval.
Raise the cab (See Raising The Operator Cab on Page

10-70-1.).
Remove the breather cap (Item 1) [Figure 10-150-7] and

discard. The breather cap is located at the top of the
reservoir on the left side of the loader frame. (The
steering control panel is removed for clarity.)
Install a new breather cap.
Lower the cab (See Lowering The Operator Cab on Page

10-70-2.).
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TIRE MAINTENANCE Recommended tire pressure must be maintained to avoid
excessive tire wear and loss of stability and handling
Wheel Nuts capability. Check for the correct pressure before
operating the loader.
Figure 10-160-1
Tire Mounting
WARNING
Do not inflate tires above specified pressure. Failure
to use correct tire mounting procedure can cause an
explosion which can result in injury or death.
W-2078-1285
N-16244
WARNING
(See SERVICE SCHEDULE on Page 10-100-1.) for the Do not inflate tires above specified pressure. Failure
service interval to check the wheel nuts. The correct to use correct tire mounting procedure can cause an
torque is 320-350 ft.-lbs. (434-475 Nm) torque [Figure explosion which can result in injury or death.
10-160-1]. W-2078-1285
Tire Rotation Tires are to be repaired only by an authorized person

using the correct procedures and type of equipment.
Check the tires regularly for wear, damage and pressure.
(See Tires on Page SPEC-10-4.) for the correct tire Tires and rims must always be checked for correct size
pressure. before mounting. Check rim and tire bead for damage.
The rim flange must be cleaned and free of rust. The tire
Figure 10-160-2 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.
E-1655
Rear tires usually wear faster than front tires. To keep tire
wear even, move the front tires to the rear and rear tires
to the front [Figure 10-160-2].
It is important to keep the same size tires on each side of

the loader. 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.
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LUBRICATING THE BOBCAT LOADER Figure 10-170-3
Procedure
Lubricate the loader as specified (See SERVICE

SCHEDULE on Page 10-100-1.) for the best
performance of the loader.
Record the operating hours each time you lubricate the

Bobcat loader. 3
Always use a good quality lithium based multi-purpose

grease. Apply the lubricant until extra grease shows.
Lubricate the following locations on the loader:

N-20258
Figure 10-170-1
3. Lift Arm Pivot Pin (Both Sides) [Figure 10-170-3].
Figure 10-170-4
N-20256
1. Rod End Lift Cylinder (Both Sides) [Figure 10-170-1].

N-20260
Figure 10-170-2
4. Base End Tilt Cylinder (Both Sides) [Figure 10-170-

4].
N-20257
2. Base End Lift Cylinder (Both Sides) [Figure 10-170-

2].
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LUBRICATING THE BOBCAT LOADER (CONT'D)
Figure 10-170-5
7
N-20261
5. Rod End Tilt Cylinder (Both sides) [Figure 10-170-5].
6. Bob-Tach Wedge (Both Sides) [Figure 10-170-5].
7. Bob-Tach Pivot Pin (Both Sides) [Figure 10-170-5].
Every 250 Hours:
Figure 10-170-6
N-20923
8. Add grease to the fittings [Figure 10-170-6] on the

steering mechanism under the cab.
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HYDRAULIC SYSTEM
BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-2
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-100-1 HYDRAULIC
SYSTEM
CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Control Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Control Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-90-1
Control Pedals Mounting Panel Removal And Installation. . . . . . . . . 20-90-1
COOLING FAN FILTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-71-1
CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-13
Checking The Lift Cylinder(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
Checking The Tilt Cylinder(s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-4
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-11
Lift Cylinder Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-9
Removal And Installation Of Lift Cylinder(s) . . . . . . . . . . . . . . . . . . . 20-20-1
Removal And Installation Of Tilt Cylinder(s) . . . . . . . . . . . . . . . . . . . 20-20-5
Tilt Cylinder Base End Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-7
Tilt Cylinder Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-10
HYDRAULIC CONTROL VALVE (ADVANCE HAND CONTROL) (AHC) 20-41-1
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HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC CONTROL VALVE (FOOT CONTROL) . . . . . . . . . . . . . . . . 20-40-1

Anti-Cavitation Valve, Lift Spool (Linkage End) . . . . . . . . . . . . . . . . . 20-40-15
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool (Bonnet End) . . . . 20-40-15
Auxiliary Plug Removal And Installation . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Auxiliary Electric Solenoid Disassembly . . . . . . . . . . . . . . . . . . . . . . 20-40-30
Auxiliary Spool Removal And Installation (Bonnet End) . . . . . . . . . . 20-40-28
Auxiliary Spool Removal And Installation (Linkage End) . . . . . . . . . . 20-40-29
BICS™ Valve, Check Valve Disassembly And Assembly . . . . . . . . . . 20-40-8
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly . 20-40-7
BICS™ Valve, Lock Valve Disassembly And Assembly. . . . . . . . . . . . 20-40-9
BICS™ Valve, Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . 20-40-6
BICS™ Valve, Solenoid Disassembly And Assembly . . . . . . . . . . . . 20-40-10
BICS™ Valve, Solenoid Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Cleaning And Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-32
Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
Lift And Tilt Lock Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Lift Spool and Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-17
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-13
Port Relief-Auxiliary Section Disassembly . . . . . . . . . . . . . . . . . . . . . 20-40-31
Port Relief Valve, Lift Spool (Bonnet End) . . . . . . . . . . . . . . . . . . . . . 20-40-14
Port Relief Valve, Tilt Spool (Linkage End) . . . . . . . . . . . . . . . . . . . . 20-40-14
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-16
Tilt Spool Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-26
HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1

HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1

Checking the Output of the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-1
Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60-4
HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-1
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-61-4
HYDRAULIC/HYDROSTATIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1

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HYDRAULIC SYSTEM (CONT’D)
HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Glossary of Hydraulic/Hydrostatic Symbols for Loaders . . . . . . . . . . . 20-10-1
Tighten Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-6
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5
LIFT ARM BY-PASS CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-2
MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-6
Checking Main Relief Valve At Control Valve. . . . . . . . . . . . . . . . . . . . 20-30-3
Checking Main Relief Valve At Front Auxiliary Hydraulics . . . . . . . . . . 20-30-1
MAIN RELIEF VALVE (ADVANCED HAND CONTROL) (AHC) . . . . . . . . 20-31-1
REAR AUXILIARY DIVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-5
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-4
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-5
Solenoid Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-120-5
TILT JUNCTION BLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-110-1

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963 Bobcat Loader
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HYDRAULIC/HYDROSTATIC SCHEMATIC
963 (S/N 562215001 and Above)
(S/N 516515001 and Above)
(Printed February 2000)
MC2656LE
LEGEND
1 RESERVOIR: 17 SOLENOID ACTIVATED DIRECTIONAL 31 PILOT ACTIVATED DIRECTIONAL 47 DISPLACEMENT CONTROL SPOOL:

C apacity 30 Q ts. (28,4 L) CONTROL VALVE - BICS CONTROL CONTROL VALVE - FOR REAR 72.5 - 290 PSI SPRINGS
2 SPRING LOADED FILTER BYPASS 18 PILOT ACTIVATED DIRECTIONAL AUXILIARY - NORMALLY CLOSED 48 RESTRICTION . . . . 0.071 inch
VALVE: 45-55 PSI (311-379 kPa) CONTROL VALVE - BICS LOCK 32 FILTER - HYDRAULIC (1,80 mm)
3 DIFFERENTIAL PRESSURE SWITCH: VALVE - TILT CONTROL 33 SOLENOID ACTIVATED DIRECTIONAL 49 DA CONTROL VALVE
36-44 PSI (248-303 kPa) 19 PILOT ACTIVATED DIRECTIONAL CONTROL VALVE - BRAKE
(Normally Closed) 50 RESTRICTION . . . . . 0.217 inch
CONTROL VALVE - BICS LOCK 34 FILTER - BICS VALVE (SCREEN) (5,51 mm)
4 SOLENOID ACTIVATED DIRECTIONAL VALVE - LIFT CONTROL INTEGRATED IN CHECK VALVE
CONTROL VALVE - TWO SPEED 51 LEVER ACTIVATED CONTROLLER
20 PULL BUTTON ACTIVATED 35 FILTER - BICS VALVE (SCREEN)
5 RELIEF/REPLENISHING VALVE - HIGH DIRECTIONAL CONTROL VALVE - INTEGRATED IN SOLENOID 52 PARKING BRAKE
PRESSURE: 4640 PSI (31993 kPa) LIFT ARM BY PASS 53 DIRECTIONAL CONTROL VALVE -
6 RELIEF VALVE - CHARGE: 21 PILOT ACTIVATED DIRECTIONAL 36 CHECK VALVE - BUCKET POSITION FLUSHING
150 0 F. (65 0C.) Fluid ± Full RPM CONTROL VALVE - UNLOADING VALVE
54 DIRECTIONAL CONTROL VALVE -
N eutral - 319 PSI (2200 kPa) SPOOL 37 VARIABLE CAPACITY DISPLACEMENT TWO SPEED
7 ANTI DRAIN BACK VALVE 22 PILOT ACTIVATED DIRECTIONAL BIDIRECTIONAL HYDROSTATIC
Dealer
CONTROL VALVE - FLOW CONTROL Copy PUMP
-- Not for Resale 55 CHECK VALVE
8 HYDROSTATIC CHARGE PUMP: SPOOL
7.8 GPM (29,5 L/min.) 38 RELIEF VALVE - FLUSHING: 56 FAN PUMP
at 3525 RPM 23 FLOW DIVIDER ADJUSTMENT VALVE 260 PSI (1793 kPa) 57 SYNCHRONIZING PISTON
9 HYDRAULIC PUMP: Gear Type 24 SOLENOID ACTIVATED DIRECTIONAL 39 VARIABLE CAPACITY DISPLACEMENT
CONTROL VALVE - BLEED OFF REAR BIDIRECTIONAL HYDROSTATIC 58 SPRING LOADED FILTER BYPASS
27.9 GPM (105,6 L/min.) MOTOR VALVE: 20 PSI (138 kPa)
at 3525 RPM AUXILIARY ("SV2")
25 LOAD SHUTTLE VALVE - BLEED OFF 40 SOLENOID ACTIVATED DIRECTIONAL 59 RELIEF VALVE
10 RELIEF VALVE - MAIN (DUAL CONTROL VALVE - BUCKET POSITION
PRESSURE) AT QUICK COUPLERS: 26 PILOT ACTIVATED DIRECTIONAL VALVE (ON/OFF) 60 FAN MOTOR
3025 PSI (20857 kPa) CONTROL VALVE - FOR REAR 61 SOLENOID ACTIVATED DIRECTIONA
SECOND STAGE AUXILIARY - NORMALLY CLOSED 41 CHECK VALVE - BICS VALVE CONTROL VALVE
3375 PSI (23270 kPa) 27 PILOT ACTIVATED DIRECTIONAL 42 RESTRICTION . . . . . . 0.080 inch 62 PILOT ACTIVATED DIRECTIONAL
11 RELIEF VALVE - PORT: CONTROL VALVE - FOR REAR (2,03 mm) CONTROL VALVE
4000 PSI (27580 kPa) AUXILIARY - NORMALLY OPEN 43 RELIEF VALVE - PORT (TILT
12 ANTICAVITATION VALVE 28 PILOT ACTIVATED DIRECTIONAL 63 LOAD SHUTTLE VALVE
ROD END):
13 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - FOR REAR 3500 PSI (24133 kPa) 64 FILTER
CONTROL VALVE - AUXILIARY AUXILIARY - NORMALLY OPEN
44 RELIEF/ANTICAVITATION VALVE - 65 SHUTTLE VALVE - LOW PRESSURE
14 RELIEF VALVE - AUXILIARY PORT: 29 FILTER - DIVERTER VALVE PORT (TILT BASE END):
(Optional) 2500 PSI (17237 kPa) (SCREEN) INTEGRATED IN SOLENOID 66 HYDRAULIC PRESSURE SENSOR
3500 PSI (24133 kPa)
15 LOAD CHECK VALVE 30 SOLENOID ACTIVATED DIRECTIONAL 45 RELIEF VALVE - CHARGE:
16 ONE WAY RESTRICTOR VALVE CONTROL VALVE - TO ACTIVATE 150 0 F. (65 0 C.) Fluid ± Full RPM NOTE: Unless otherwise specified
REAR AUXILIARY ("SV1") Neutral - 406 PSI (2800 kPa) springs have NO significant
pressure value.
Printed in U.S.A.
46 RESTRICTION 0.04 inch (1,01 mm) MC 2656LE (2-1-00)
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HYDROSTATIC U
MALE
HYDRAULIC/HYDROSTATIC SCHEMATIC MOTOR -
DIVERTER VALVE (OPTIONAL)
963 (S/N 562215001 and Above) LEFT-SIDE 39 AUXILIARY
A B CASE DRAIN
(S/N 516515001 and Above) PILOT
29
PRESSURE 30
(Printed February 2000) HYDRAULIC INPUT
MC2656 FILTER
X 1
32
REAR
AUXILIARY FRONT
31 AUXILIARY
G
57 58 MALE
F2 D2
MALE
HYDRAULIC FAN 24
54 CASE 27
DRAIN
59 25
55 60 HYDRAULIC FILTER
46 32
42 53
38 26 28
2 F1 D1
FEMALE
61 FEMALE
T
P2 P1
7
BUCKET POSITION VALVE
56 3
OIL D
9 COOLER 36
HYDROSTATIC 21
PUMPS 23
A B
8 MB
A
HYDRAULIC CONTROL VALVE
S G C
PS 13 14 13 22
6 40
MA
B A
B
AUXILIARY SPOOL
BICS CONTROL VALVE
16
44
CONTROLLER
5 5 LH TILT
CYLINDERS
X2 51 51 Dealer Copy -- Not for Resale
47 48
X1 1 43
2
T P B A
TILT CYLINDER
18
SPOOL
T2 CONTROLLER
T1 1 T P 12 15
37 R 2
8
50 51 51 11 19 LIFT
S
RH CYLINDERS
B A
49 LIFT CYLINDER
YST
SPOOL
15 46
PS
10
45 G
HYDROSTATIC MOTOR -
MA MB RIGHT-SIDE 17
U
34 41 35
39
B A B DIAGNOSTICCOUPLER
LIFT ARM
5 5 BY-PASS VALVE
X2
X BRAKE/
47 48 TWO-SPEED DIAGNOSTIC 66
DIAGNOSTIC 20
X1 BLOCK COUPLER COUPLER
G RIGHT RX CPS LX LEFT
57 63
DA
55
T2
T1 54 52 65 64
A 37 R PB 62 DIAGNOSTIC
COUPLER WORKING CIRCUITS
CPX PILOT PRESSURE
42 BRK DRAIN CIRCUITS
53 CP COMPONENTS
38 DIAGNOSTIC BRKX 33
COUPLER DR1
2SP
T 4 DR2
MC2656
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HYDRAULIC SYSTEM INFORMATION
Glossary of Hydraulic/Hydrostatic Symbols for Loaders
mc-2340
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HYDRAULIC SYSTEM INFORMATION (CONT’D)
Glossary of Hydraulic/Hydrostatic Symbols for Loaders (Cont’d)
mc-2340-2
963 Bobcat Loader

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Glossary of Hydraulic/Hydrostatic Symbols for Loaders (Cont’d)
mc-2340-3
963 Bobcat Loader

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963 Bobcat Loader
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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, 5
Slow hydraulic system action. 1, 3, 4, 5, 6, 7
Hydraulic action is not smooth. 1, 3, 5, 6
Lift arms go up slowly at full engine RPM. 1, 3, 4, 5, 6, 7, 9, 10
The lift arms or Bob-Tach will move when the pedal is in neutral position. 4, 9
The lift arms come down with the pedal in the neutral position. 4, 10, 11, 12, 13
The bucket does not self-level. 14, 15, 16
The bucket will partially self-level. 14, 15
The bucket has no power to roll forward. 16
The bucket does not roll back. 15
Lift Arm By-Pass Valve stuck or stem bent/broken. 17
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has defect.
4. The pedal linkage is not adjusted correctly.
5. Drive belt is loose or broken.
6. Suction leak in the hydraulic system.
7. Fluid is cold.
8. Using the loader for more than its rated capacity.
9. Spool in the valve section is not centering or the centering spring is broken.
10. Internal leak at the lift cylinder(s).
11. External leak at the lift cylinder(s).
12. Port relief seal is leaking.
13. Load check has a defect in the valve position valve.
14. Check the flow divider in the bucket position valve.
15. Check the unloading spool in the bucket position valve.
16. Check the relief valve in the bucket position valve.
17. Replace the manual spool cartridge.
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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
Tighten Procedures
To tighten the hydraulic fittings, tubelines etc., (See

HYDRAULIC CONNECTION SPECIFICATIONS on
Page SPEC-50-1.) for the correct procedure and
torque.
WARNING
immediately.
W-2145-0290
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CYLINDER(S) Figure 20-20-2
Checking The Lift Cylinder(s)
NOTE: With the bucket attached and the boom raised 1

to maximum height. The maximum cylinder
drift allowed is 1.3 inches (33 mm) in 10
minutes. Measurement will be taken at
cylinder lift rod.
WARNING
N-15390
and possible death if proper medical treatment by a Install a cap (Item 1) [Figure 20-20-2] on the hose and
physician familiar with this injury is not received tighten.
immediately.
W-2145-0290
Engage the parking brake. Lower the seat bar. Start the
engine and push the top (toe) of the lift pedal.
Figure 20-20-1
If there is any leakage from the base end fitting, remove
the lift cylinder for repair. Repeat the procedure to check
the other lift cylinder.
1
Removal And Installation Of Lift Cylinder(s)
Figure 20-20-3
N-15389
Lower the lift arms. Stop the engine. Pull up on the lift
arm by-pass control and move the lift pedal to release the
hydraulic pressure. Raise the seat bar.
Check only one cylinder at a time. Disconnect the hose N-15391

which goes to the base end of the cylinder (Item 1)
[Figure 20-20-1].
Lower the lift arms. Stop the engine. Pull up on the lift
arm by-pass control and move the lift pedal to release the
hydraulic pressure. Raise the seat bar.
Remove the bolt (Item 1) [Figure 20-20-3] from the

tubeline clamp.
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CYLINDER(S) (CONT’D) Figure 20-20-6
Removal And Installation Of Lift Cylinder(s) (Cont'd)
Figure 20-20-4
N-15394
Remove the spacer (Item 1) [Figure 20-20-6] from the

N-15392 retainer bolt at the rod end pin.
Figure 20-20-7
Disconnect the tubeline (Item 1) [Figure 20-20-4] from
the rod end of the lift cylinder. Disconnect the hose (Item
1) [Figure 20-20-1] at the base end of the lift cylinder.
Install a cap on the tubeline and a plug in the cylinder
fitting.
Figure 20-20-5
N-15395
Use a puller and remove the rod end and base end pins
from the lift cylinder [Figure 20-20-7].
1
N-15393
Remove the retaining nut (Item 1) [Figure 20-20-5] from

the rod end of the lift cylinder pivot pin.
Installation: Tighten the nut to 16-20 ft.-lbs. (21-27 Nm)

torque.
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Removal And Installation Of Lift Cylinder(s) (Cont'd)
Figure 20-20-8
N-15413
Use a puller to remove the base end pivot pin [Figure 20-
N-15416 20-10].
Remove the lift cylinder from the loader.

Right Side Only: The lift arms will have to be raised using
a chain hoist or floor jack so there will be clearance when
removing the lift arm support device [Figure 20-20-8].
Figure 20-20-9
N-15396
Remove the retainer bolt (Item 1) [Figure 20-20-9]

spacer and nut from the base end pivot pin.
Installation: Tighten the bolt to 16-20 ft.-lbs. (21-27 Nm)

torque.
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CYLINDER(S) Figure 20-20-12
Checking The Tilt Cylinder(s)
WARNING
immediately.
W-2145-0290
N-15380
Remove any attachment from the Bob-Tach. Roll the

Bob-Tach fully back. Install a cap (Item 1) [Figure 20-20-12] on the hydraulic
hose.
Stop the engine.
Right Side engine and push the bottom (heel) of the tilt pedal. If
there is leakage from the open port, remove the tilt
Figure 20-20-11 cylinder for repair.
Left Side
Figure 20-20-13
N-15357
1
Disconnect the hose (Item 1) [Figure 20-20-11] which
goes to the base end of the tilt cylinder. N-15385
Disconnect the tubelines (Item 1) [Figure 20-20-13] from

the front hydraulic couplers.
Remove the mounting bolts (Item 2) [Figure 20-20-13]

and remove the mounting bracket and hydraulic couplers.
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CYLINDER(S) Removal And Installation Of Tilt Cylinder(s)
Checking The Tilt Cylinder(s) (Cont’d) Figure 20-20-16
Figure 20-20-14
N-15368
1
N-15386
Put the Bob-Tach on the floor [Figure 20-20-16]. Stop
the engine.
Install caps (Item 1) [Figure 20-20-14] on the tubelines
and tighten. Remove the snap ring and washer at the rod end of the
tilt cylinder (Item 1) [Figure 20-20-16].
Disconnect the hose (Item 2) [Figure 20-20-14] which
goes to the base end of the tilt cylinder.
Figure 20-20-15
N-15387
Install a cap (Item 1) [Figure 20-20-15] on the hydraulic

hose and tighten.
engine and push the bottom (heel) of the tilt pedal. If
there is leakage from the open port, remove the tilt
cylinder for repair.
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CYLINDER(S) (CONT’D) Left Side
Removal And Installation Of Tilt Cylinder(s) (Cont'd) Figure 20-20-18
Right Side
2
Figure 20-20-17
1 1
N-15374
1
N-15373 Disconnect the tubelines (Item 1) [Figure 20-20-18] from
Mark the hoses for correct installation. Remove the mounting bolts (Item 2) [Figure 20-20-18]
Disconnect both hoses (Item 1) [Figure 20-20-17] at the
tilt cylinder. Disconnect the hydraulic hose (Item 3) [Figure 20-20-18]
from the rod end of the tilt cylinder. Install a cap on the
Put plugs in the ends of the hoses. hydraulic hose and tighten.
Remove the snap ring and washer from the pivot pin
(Item 2) [Figure 20-20-17].
Remove the tilt cylinder by sliding off the pivot pins.
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Removal And Installation Of Tilt Cylinder(s) (Cont'd)
Figure 20-20-19
1 N-15366
1 Check the seal at the rod end of the tilt cylinder [Figure
N-15386 20-20-21]. Replace the seals if damaged as needed.
Tilt Cylinder Base End Pivot Pin

Install caps (Item 1) [Figure 20-20-19] on the tubelines
and tighten. Figure 20-20-22
Remove the hydraulic hose (Item 2) [Figure 20-20-19]

from the base end of the tilt cylinder. Install a cap on the
hydraulic hose and tighten.
Figure 20-20-20 1
1
N-15383
Remove the bolt at the pivot pin (Item 1) [Figure 20-20-

22]. Remove the washer.
N-15388 Installation: When installing the bolt, tighten to 220-245

ft.-lbs. (298-332 Nm) torque.
Remove the snap ring and washer (Item 1) [Figure 20-

20-20] from the pivot pin.
Remove the tilt cylinder by sliding off the pivot pins.
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CYLINDER(S) (CONT’D)
Removal And Installation Of Tilt Cylinder(s) (Cont'd)
Figure 20-20-23
N-15384
Install the bolt (without washers) into the pivot pin. Hit the
bolt with a hammer to remove the pin from the tapered
seat [Figure 20-20-23].
Figure 20-20-24
N-15382
Remove the bolt and remove the pin (Item 1) [Figure 20-
20-24] from the lift arms.
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CYLINDER(S) (CONT’D)
Lift Cylinder Parts Identification
1. Rod 7. O-ring
2. Case 8. Spacer
3. O-ring
4. Nut
5. Piston 9. O-ring
6. Ring 10. Washer
11. Head
12. Seal
13. Seal
14. Plug
8
7
1
5
14 *4
15
3
13
16 12
14 11
15 2
10
TS-01060
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CYLINDERS (CONT’D)
Tilt Cylinder Parts Identification
1. Case 11. O-ring

2. Plug 12. O-ring
3. O-ring 13. Washer
4. Tube 14. O-ring
5. Nut 15. Head
6. Clamp 16. Seal
7. Bolt 17. Seal
8. Nut 18. Rod
9. Piston 19. Seal MC-1688A
10. Seal 20. Bushing MC-1688B
3
2
4
1
6 5
15
9
10 16
11 17
12
18
13
MC-1688C
MC-1688D 19 20 19
14
TS-01233
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Disassembly 4
3
Figure 20-20-25 2
1
P-7428
Lift Cylinder: Remove the head and the rod assembly

P-7429 from the cylinder [Figure 20-20-27]. Put the rod end in a
vise.
Figure 20-20-26 Lift Cylinder: Remove the nut (Item 1) [Figure 20-20-27],
piston (Item 2) [Figure 20-20-27], spacer (Item 3)
[Figure 20-20-27] and head (Item 4) [Figure 20-20-27].
Figure 20-20-28
3
2
1
P-7435
Use the following tools to disassemble the cylinder:

P-7434
MEL1074 - O-ring Seal Hook
Spanner Wrench
Tilt Cylinder: Remove the head and rod assembly from
The lift and tilt cylinders internal components are similar, the cylinder [Figure 20-20-28]. Put the rod end in a vise.
the differences are listed below:
Tilt Cylinder: Remove the nut (Item 1) [Figure 20-20-28],
Tilt rod diameter is larger. piston (Item 2) [Figure 20-20-28] and head (Item 3)
Piston relief area is slightly different. [Figure 20-20-28].
No spacer in the tilt cylinder.
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise.
Use a spanner wrench to loosen the head [Figure 20-20-

25] & [Figure 20-20-26].
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Disassembly (Cont'd)
Figure 20-20-29
3
3
2 2
1
1
P-7422
Remove the thick O-ring (Item 1) [Figure 20-20-31], and

P-7430 the back-up washer (Item 2) [Figure 20-20-31] from the
groove in the head. Remove the thin O-ring (Item 3)
[Figure 20-20-31].
Standard Piston: Remove the seal (Item 1) [Figure 20-
20-29], and O-ring (Item 2) [Figure 20-20-29] from the Figure 20-20-32
piston (Item 3) [Figure 20-20-29].
Figure 20-20-30
2 3 1
1
P-7426
P-7439 Remove the wiper seat (Item 1) [Figure 20-20-32], and

rod seal (Item 2) [Figure 20-20-32].
Cushion Piston: Remove the seal (Item 1) [Figure 20-20- Remove the O-ring (Item 3) [Figure 20-20-32] from the
30], and O-ring (Item 2) [Figure 20-20-30] from the rod seal.
piston (Item 3) [Figure 20-20-30].
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Assembly
3
Use the following tools to assemble the cylinder:
MEL1396 - Seal Installation Tool

2
MEL1033 - Rod Seal Installation Tool
Piston Ring Compressor 1
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
P-7430
Always install new O-rings and seals during assembly.
Lubricate all O-rings and seals with hydraulic oil during Standard Piston: Install the seal (Item 1) [Figure 20-20-
installation. 34] and O-ring (Item 2) [Figure 20-20-34] on the piston
(Item 3) [Figure 20-20-34].
Figure 20-20-33
Figure 20-20-35
P-7424
P-7438
Install the new seal on the tool and slowly stretch it until it
fits the piston [Figure 20-20-33]. Cushion Piston: Install the seal and O-ring on the piston
(Item 1) [Figure 20-20-35].
Allow the seal to stretch for 30 seconds before installing it
on the piston. Use a ring compressor to compress the seal to the
correct size. Leave the piston in the compressor for about
three minutes.
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Assembly (Cont’d)
Figure 20-20-36
2
3
P-7422
Install the thin O-ring (Item 1) [Figure 20-20-38].

P-7427
Install the back-up washer (Item 2) [Figure 20-20-38]
and thick O-ring (Item 3) [Figure 20-20-38] into the
Install the rod seal on the rod seal tool [Figure 20-20-36]. groove on the head.
NOTE: During installation the O-ring side of the seal NOTE: Clean and dry the threads before install the
must be toward the inside of the cylinder. nut. Install the new nut from the kit.
Rotate the handles to collapse the rod seal [Figure 20- Figure 20-20-39
20-36].
Figure 20-20-37 1
2
3
P-7434
P-7425 Tilt Cylinder: Install the head (Item 1) [Figure 20-20-39],

and the piston (Item 2) [Figure 20-20-39]. The small
diameter of the piston goes into the cylinder tube first.
Install the rod seal in the head [Figure 20-20-37].
Tilt Cylinder: Grease the piston where the nut contacts
Install the wiper seal with the wiper toward the outside of the piston. Do not get grease on the threads.
the head.
Tilt Cylinder: Install the nut (Item 3) [Figure 20-20-39].
Tilt Cylinder: Tighten the nut to 100 ft.-lbs. (136 Nm)

torque.
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Assembly (Cont’d)
Figure 20-20-40
P-7429
Figure 20-20-43
P-10450 P-10456
Tilt Cylinder: Mark the end of the shaft and nut [Figure
20-20-40]. Tighten the nut an additional 135 degrees or
2-1/4 flats [Figure 20-20-40].
Figure 20-20-41
1
2
3
4
P-7435
Tighten the head using a spanner wrench [Figure 20-20-

42] & [Figure 20-20-43].
P-7428
NOTE: Clean and dry the threads before install the

nut. Install the new nut from the kit.
Lift Cylinder: Install the head (Item 1) [Figure 20-20-41],

and spacer (Item 2) [Figure 20-20-41].
Lift Cylinder: Install the piston (Item 3) [Figure 20-20-41],

and the nut (Item 4) [Figure 20-20-41].
Lift Cylinder: Tighten the nut (Item 4) [Figure 20-20-41]

to 400 ft.-lbs. (542 Nm) torque.
Put the base end of the hydraulic cylinder in a vise.
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MAIN RELIEF VALVE Figure 20-30-1
Checking Main Relief Valve At Front Auxiliary

Hydraulics
IMPORTANT
1
The hydraulic tester must be in the fully open
position before you start the engine.
I-2024-0284
N-15749
WARNING
Disconnect the charge tubeline (Item 1) [Figure 20-30-1]
Put jackstands under the front axles and rear corners at the main relief valve. Install a cap on the fitting and
of the frame before running the engine for service. tighten. Install a plug in the tubeline and tighten.
fall or move and cause injury or death. Lower the operator cab.
W-2017-0286
Figure 20-30-2
The tools listed will be needed to do the following
procedure:
MEL10003 - Hydraulic Tester

1
MEL10006 - Hydraulic Test Kit
The main relief valve is a two stage pressure relief valve.

When the front auxiliary hydraulics are engaged, charge
pressure will activate the second stage of main relief
valve and the pressure will increase.
Lift and block the loader. (See LIFTING AND BLOCKING 2

THE LOADER on Page 10-20-1.)
Raise the operator cab. (See Raising The Operator Cab N-16217
on Page 10-70-1.)
To check the first stage of the main relief valve, use the Connect the IN port of the hydraulic tester to the female
following procedure: quick coupler (Item 1) [Figure 20-30-2].
Connect the OUT port of the hydraulic tester to the male

quick coupler (Item 2) [Figure 20-30-2].
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MAIN RELIEF VALVE (CONT’D) Figure 20-30-5
Checking Main Relief Valve At Front Auxiliary

Hydraulics (Cont'd)
Figure 20-30-3
1
2
1
N-15749
Remove the cap and plug. Connect the charge tubeline

(Item 1) [Figure 20-30-5] to the main relief valve.
B-15551
Lower the operator cab. Start the engine.
Start the engine and run at low RPM. Push the mode Figure 20-30-6
switch (Item 1) [Figure 20-30-3] (on the instrument
panel) two times to engage the front auxiliary hydraulics,
the light (Item 2) [Figure 20-30-3] will come ON.
2
Figure 20-30-4
1 B-15551
Push the mode switch (Item 1) [Figure 20-30-6] (on the

instrument panel) two times to engage the front auxiliary
P-2152 hydraulics, the light (Item 2) [Figure 20-30-6] will come
ON.
Push the button (Item 1) [Figure 20-30-4] for fluid flow to

the quick couplers.
Watch the flow meter on the hydraulic tester to make sure

the flow is correct. Increase the engine speed to full
RPM.
There should be 26.2 GPM (99,2 L/Min.) free flow. Turn

the restrictor control, on the tester, until the main relief
opens. The correct pressure for the first stage main relief
is 3025 PSI (20857 kPa). Make record of this pressure.
Stop the engine. Raise the operator cab.
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MAIN RELIEF VALVE (CONT’D) Checking Main Relief Valve At Control Valve.
Checking Main Relief Valve At Front Auxiliary Figure 20-30-8

Hydraulics (Cont'd)
Figure 20-30-7
P-2152
Push the button (Item 1) [Figure 20-30-7] at the steering

lever for fluid flow to the quick couplers.
Run the engine at full RPM. There should be 26.2 GPM

(99,2 L/Min.) free flow. Turn the restrictor control, on the 2
tester, until the main relief valve opens. The correct
pressure for the second stage main relief valve is 3375
PSI (23270 kPa).
If the main relief valve needs to be adjusted. (20-30-6.)) N-15655 N-15727


on Page 10-70-1.)
The main relief valve is a two stage pressure relief valve.

When the front auxiliary hydraulics are engaged it will
activate the second stage of the relief valve.
Connect pressure gauge (Item 1) [Figure 20-30-8] (with

hose long enough to be read from the operator seat) to
the coupler (Item 2) [Figure 20-30-8] at the inlet port of
the control valve.
Route the pressure gauge on the outside of the loader.
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Checking Main Relief Valve At Control Valve (Cont'd)
WARNING
1
W-2017-0286
Figure 20-30-9 B-15551
Start the engine and run at low engine idle RPM. Push
the heel of the tilt pedal (Bob-Tach fully back) Increase
engine speed to full RPM. The correct pressure should
be 3025 PSI (20857 kPa). Make record of this pressure.
With no attachments connected to the front auxiliary

quick couplers. Push the mode switch (Item 1) [Figure
20-30-10] (on the instrument panel) two times to engage
the front auxiliary hydraulics, the light (Item 2) [Figure
20-30-10] will come ON.
Figure 20-30-11
N-16214 P2152
Sit the in operator seat. Lower the seat bar [Figure 20- Push the button (Item 1) [Figure 20-30-11] for fluid
30-9]. pressure to the quick couplers.
The correct pressure for the main relief is 3375 PSI

(23270 kPa). Make a record of this pressure.
Stop the engine.
If the main relief needs adjustment. (20-30-6.))
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Removal And Installation
IMPORTANT
When repairing hydrostatic and hydraulic systems, 1
damage the system.
I-2003-0888
N-15656
Figure 20-30-12
Loosen and remove the main relief valve (Item 1) [Figure

20-30-13].
Installation: Tighten the main relief valve to 35-40 ft.-lbs.

(47-54 Nm) torque.
Remove the O-rings and back-up washers from the main

2 relief valve [Figure 20-30-13].
Clean the main relief valve in clean solvent. Use air

1 pressure to dry the valve.
Install new O-rings and back-up washers. Install the main

N-15749 relief valve (Item 1) [Figure 20-30-12] and tighten.
The main relief valve (Item 1) [Figure 20-30-12] is

located at the lower front of the control valve.
Clean the area around the control valve.
Disconnect the charge tubeline (Item 2) [Figure 20-30-

12] from the main relief valve.
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Adjustment
Figure 20-30-14
1
N-15749
To adjust the second stage (high pressure setting):

N-15657
16].
If the pressure is not correct, adjust the main relief valve
using the following procedure: Figure 20-30-17
NOTE: The control valve is shown removed for photo

clarity.
To adjust the first stage (low pressure setting):

12].
1
Remove the second stage housing (Item 1) [Figure 20-
30-14].
Figure 20-30-15
N-15659
Remove the fitting (Item 1) [Figure 20-30-17].
NOTE: The control valve is shown removed for photo

clarity.
1
N-15658
Set the pressure by adjusting the set screw, using a 1/4

inch allen wrench (Item 1) [Figure 20-30-15].
One turn is equal to 490 PSI (3379 kPa). Turn clockwise

to increase the pressure.
Install and tighten the second stage housing.
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MAIN RELIEF VALVE (CONT’D)
Adjustment (Cont'd)
Figure 20-30-18
N-15660
Remove the orifice (Item 1) [Figure 20-30-18] in the end

of the second stage housing, using a standard
screwdriver.
Figure 20-30-19
N-15661
Set the pressure by adjusting the set screw, using a 1/4

inch allen wrench (Item 1) [Figure 20-30-19]. Press the
allen wrench in until the set screw is bottomed out in the
housing and turn. One turn is equal to 390 PSI (2689
kPa).
Install the orifice and fitting and tighten.
Connect the charge tubeline.
Check the main relief valve pressure again. (See

Checking Main Relief Valve At Front Auxiliary Hydraulics
on Page 20-30-1 or See Checking Main Relief Valve At
Control Valve. on Page 20-30-3)
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MAIN RELIEF VALVE (ADVANCED HAND CONTROL)
(AHC)
NOT AVAILABLE AT TIME OF PRINTING
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Figure 20-40-2
WARNING
1
the lift arms are secured by an approved lift arm
W-2059-0598
N-21092
Cut and remove the tie strap (Item 1) [Figure 20-40-2]

and move the wiring harness clear of the control valve.
Figure 20-40-3
Figure 20-40-1
1
1 1
N-21093
1 Remove the three hydraulic hoses (Item 1) [Figure 20-

N-21091
40-3].
Raise the lift arms and install an approved lift arm

support device. (See Engaging The Lift Arm Support
Device on Page 10-50-1.)
Stop the engine. Raise the seat bar.

on Page 10-70-1.)
Clean the area around the control valve.
Drain the hydraulic fluid reservoir. (See Replacing The

Hydraulic Fluid on Page 10-150-2.)
For ease of assembly, mark the five wire harness

connectors (Item 1) [Figure 20-40-1] and disconnect.
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105 of 640
(CONT’D)
Removal And Installation (Cont'd)
Figure 20-40-4
1
N-21096
N-21096
Disconnect the hydraulic hose (Item 1) [Figure 20-40-6]

and tubeline (Item 2) [Figure 20-40-6].
N-21094
Figure 20-40-7
Remove the lift and tilt linkage pins and retainer clips
(Item 1) [Figure 20-40-4].
Figure 20-40-5
1
N-21097
Remove the auxiliary tubelines (Item 1) [Figure 20-40-7].
N-21095
Disconnect the hose (Item 1) [Figure 20-40-5] that goes

from the control valve to the hydraulic cooler.
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106 of 640
(CONT’D)
Figure 20-40-8
1
N-21100
Disconnect the hydraulic hose (Item 1) [Figure 20-40-

10].
N-21098
Figure 20-40-11
Disconnect the tubeline (Item 1) [Figure 20-40-8].
Figure 20-40-9
N-21102
Loosen the two tubeline clamps (Item 1) [Figure 20-40-

N-21099 11].
NOTE: The clamp bolts and nuts may have to be

Disconnect the two hydraulic hoses (Item 1) [Figure 20- completely removed for the needed
40-9]. clearance.
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107 of 640
(CONT’D)

1
Figure 20-40-12
1
N-21104
Remove the five mount bolts (Item 1) [Figure 20-40-14]

from the access cover on the left side of the loader frame.
N-21101
Remove the cover from the loader.
Disconnect the tubeline (Item 1) [Figure 20-40-12]. Figure 20-40-15
Figure 20-40-13
2 1
N-21105
N-21103
Disconnect the auxiliary tubeline hoses (Item 1) [Figure
20-40-15] from the bulk head fittings.
Install a chain hoist on the control valve [Figure 20-40-
13] and support the valve. Loosen the bulk head fitting jam nuts (Item 2) [Figure 20-
40-15] and rotate the auxiliary tubelines away from the
Remove the left rear tire. (See TIRE MAINTENANCE on valve.
Page 10-160-1.)
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108 of 640
(CONT’D)
Figure 20-40-16
1
N-21106
Remove the two mount nuts (Item 1) [Figure 20-40-18]

and bolts.
N-21107
NOTE: Only one mount bolt and nut can be seen in
picture [Figure 20-40-18], the other mount bolt
Disconnect the tubeline (Item 1) [Figure 20-40-16] from is located at the bottom of the valve.
the rear of the control valve.
Figure 20-40-19
Figure 20-40-17
N-21109
N-21108
Raise the valve and remove the hose (Item 1) [Figure

Remove the tubeline (Item 1) [Figure 20-40-17] from the 20-40-19] from the bottom of the valve.
main relief valve.
Remove the control valve from the loader.
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(CONT’D)
BICS™ Valve, Removal And Installation
Remove the control valve. (20-40-1.))
Figure 20-40-20
1
1
1 1
2
1
1
N-21226
1
Remove the four large O-rings (Item 1) [Figure 20-40-
1
22] and the small O-ring (Item 2) [Figure 20-40-22] from
the top of the control valve and replace with new.
N-21224 Figure 20-40-23
To remove the BICS™ valve from the control valve, 6

loosen and remove the six mounting bolts (Item 1)
[Figure 20-40-20]. 3
Figure 20-40-21
1 2
4
5
N-21224
Installation: The chart below lists the correct torque

specifications and tightening sequence when reinstalling
the BICS™ valve assembly to the control valve.
Thoroughly clean and dry bolts and threads in valve. Use
N-21225 liquid adhesive LOCTITE #242 or equivalent.
Sequence [Figure
STEP TORque
Remove the BICS™ valve assembly from the top of the 20-40-23]
control valve [Figure 20-40-21]. 1 110-130in.-lbs. 1, 2, 3, 4, 5 & 6
(12,4-14,7 Nm)
2 190-210in.-lbs.
(21,5-23,7 Nm)
3 190-210in-lbs.
(21,5-23,7 Nm)
*Torque must be 190-210 in.-lbs. (21,5-23,7 Nm) for

every bolt or repeat step 3.
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(CONT’D)
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly

And Assembly
Figure 20-40-24
N-21228
2 Figure 20-40-26
N-21227
Remove the lock valve (Item 1) [Figure 20-40-24].
Installation: Tighten the lock valve to 25 ft.-lbs. (34 Nm)

torque.
Remove the fitting (Item 2) [Figure 20-40-24] from the

valve. 1
N-21229
Using a flat blade screw driver, remove the lift arm by-
pass orifice (Item 1) [Figure 20-40-25] & [Figure 20-40-
26] from the valve.
The orifice size is 0.078 inch.
Clean and inspect the orifice. Replace as needed.
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(CONT’D)
BICS™ Valve, Check Valve Disassembly And

Assembly
1
Figure 20-40-27
N-21232
1 Clean and inspect the screen (Item 1) [Figure 20-40-29]

on the end of the valve.
N-21230
Remove the check valve (Item 1) [Figure 20-40-27].
Installation: Tighten the valve to 20 ft.-lbs. (27 Nm)

torque.
Figure 20-40-28
N-21231
Remove the O-rings (Item 1) [Figure 20-40-28] and

back-up ring (Item 2) [Figure 20-40-28] from the check
valve.
Install new O-rings and back-up ring on the check valve.
The check valve has a rating of 5-10 PSI.
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(CONT’D)
BICS™ Valve, Lock Valve Disassembly And 1

Assembly
Figure 20-40-30
N-21227
1
Remove the two lock valves (Item 1) [Figure 20-40-30],
[Figure 20-40-31] & [Figure 20-40-32] from the BICS™
valve.
N-21234
Installation: Tighten the lock valves to 25 ft.-lbs. (34 Nm)
torque.
Figure 20-40-31
Figure 20-40-33
1
1
2
N-21235 2 2
N-21236

back-up rings (Item 2) [Figure 20-40-33] from both the tilt
and lift lock valves.
Install new O-rings (Item 1) [Figure 20-40-33] and back-

up rings (Item 2) [Figure 20-40-33] on the tilt and lift lock
valves.
Replace the lock valve if necessary.
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(CONT’D)
BICS™ Valve, Solenoid Disassembly And Assembly
Figure 20-40-34 1
2 N-21239
Remove the solenoid stem (Item 1) [Figure 20-40-36].
N-21237 Installation: Tighten the solenoid stem to 20 ft.-lbs. (27

Nm) torque.
Remove the mounting nut (Item 1) [Figure 20-40-34] Figure 20-40-37
from the solenoid cartridge.
Installation: Tighten the mounting nut to 53 in.-lbs. (6

Nm) torque.
Remove the solenoid (Item 2) [Figure 20-40-34]. 3

2
NOTE: The solenoid resistance is (8-10 ohms).
Figure 20-40-35
1
1 1
N-21240

back-up washers (Item 2) [Figure 20-40-37] on the stem.
Clean all parts in solvent and dry with compressed air.
Inspect all parts for wear and replace any part showing
excessive wear.
N-21238
NOTE: The screen (Item 3) [Figure 20-40-37] may be
cleaned with solvent. If it is torn or worn
Remove the O-rings (Item 1) [Figure 20-40-35] from replace the solenoid stem.
both ends of the solenoid.
Use only new O-rings and apply oil to all O-rings and
back-up washers before installation.
Install new O-rings and new back-up washers on the

solenoid stem.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Identification Chart
(CONT’D)
Figure 20-40-39
BICS™ Valve, Solenoid Testing
H2 H1
Figure 20-40-38
H3
C4
G3 B3 A3 D3
H5 C3
G2 B2 A2 E2 D2
C2
F2
G1 H4 B1 A1 E1
C1
F1
D1
MR TS-01971
P-9175
ITEM 963 Loader
Use a test meter to measure coil resistance [Figure 20- A1 Lift Cylinder Base End/Restrictor
40-38]. Coil wires do not have polarity. Correct A2 Tilt Cylinder Base End
resistance for the auxiliary pressure relief (small) coil is 7- A3 Auxiliary Hydraulics
10 ohm and the other coils 5-8 ohms. B1 Lift Cylinder Rod End
B2 Tilt Cylinder Rod End
Replace the test meter with 12 volt power. You can see
B3 Auxiliary Hydraulics
and hear the spool shift.
C1 Load Check Valve/Lift Function
C2 Load Check Valve/Tilt Function
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs
E1 Port Relief Valve - 3500 PSI
E2 Anti-Cavitation/Port Relief Valve - 2500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve - 3500 PSI
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional) - 2500 PSI
H3 Auxiliary Electric Solenoid
H4 Lift Lock Solenoid
H5 Tilt Lock Solenoid
MR Main Relief Valve - Dual Stage
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(CONT’D)
Load Check Valve
IMPORTANT 2
When repairing hydrostatic and hydraulic systems, 1

damage the system.
I-2003-0888
N-21241
Figure 20-40-40
Loosen the load check plugs (Item 1) [Figure 20-40-41]
from the lift and tilt sections of the control valve.
Installation: Always use new O-ring. tighten the plug to

35-40 ft.-lbs. (47-54 Nm) torque.
1 1 Figure 20-40-42
1 1
N-21226 3
1
Remove the BICS™ valve assembly from the control
valve. (20-40-6.)) 2
Remove the four large O-rings (Item 1) [Figure 20-40-

40] and small O-ring (Item 2) [Figure 20-40-40]. Always N-20077
replace these O-rings before installing the BICS™ valve
assembly.
Remove the load check plugs (Item 1) [Figure 20-40-42].
Mark each valve section, spool and related parts so that
they will be returned to its original valve section during Remove the spring (Item 2) [Figure 20-40-42] and
assembly. poppet (Item 3) [Figure 20-40-42].
Use bolts to fasten the control valve to a work bench for NOTE: Both load checks poppets, plugs and springs
easier disassembly and assembly procedures. are the same for the lift and tilt.
Loosen the load check plug (Item 2) [Figure 20-40-41]

from the auxiliary section of the control valve.
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116 of 640
(CONT’D)
Load Check Valve (Cont’d)
Figure 20-40-43
1 2
N-21243
Remove the fitting (Item 1) [Figure 20-40-45] and orifice

1
(Item 2) [Figure 20-40-45] from the second stage
N-20078 housing of the main relief.
Figure 20-40-46
The auxiliary section uses a load check poppet with an
orifice (Item 1) [Figure 20-40-43].
NOTE: For correct port locations and valve

component 20-40-11.)
Main Relief Valve

1
Figure 20-40-44
N-21244
Remove the second stage housing (Item 1) [Figure 20-

40-46] from the main relief valve housing.
Installation: Always use new O-rings and back-up

1 washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
N-21242
Remove the main relief valve (Item 1) [Figure 20-40-44].
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Port Relief Valve, Lift Spool (Bonnet End)
(CONT’D)
Figure 20-40-49
Port Relief Valve, Tilt Spool (Linkage End)
Figure 20-40-47
1
1
N-21245
N-21251 Remove the port relief valve (Item 1) [Figure 20-40-49]

from the control valve lift section.
Remove the port relief valve (Item 1) [Figure 20-40-47] Figure 20-40-50
from the control valve tilt section.
1. O-ring
Figure 20-40-48 2. Backup Washer
3. O-ring
1. O-ring 4. Relief Valve
2. Backup Washer 4
3. O-ring 3
4. Relief Valve 2
4
3
1
2
N-21246
N-21246 Remove the O-rings and back-up washer from the port
relief valve [Figure 20-40-50].
Remove the O-rings and back-up washer from the port Installation: Always use new O-rings and back-up
relief valve [Figure 20-40-48]. washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.

washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Anti-Cavitation Valve, Lift Spool (Linkage End)
(CONT’D)
Figure 20-40-53
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool
(Bonnet End)
Figure 20-40-51 2
N-21249
Remove the lift lock solenoid (Item 1) [Figure 20-40-53].

N-21247
Remove the anti-cavitation valve (Item 2) [Figure 20-40-
53] from the control valve lift section.
Remove the anti-cavitation/port relief valve (Item 1)
[Figure 20-40-51] from the control valve tilt section. Figure 20-40-54
Figure 20-40-52 1 2
3 4
E-01509
1 1. Anti-Cavitation Valve
2. O-ring
3. Back-up Washer
4. O-ring
N-21250
N-21248
Remove the O-rings and back-up washer from the anti-
cavitation valve [Figure 20-40-54].
Remove the O-rings (Item 1) [Figure 20-40-52] from the
anti-cavitation/port relief valve.

washers. Tighten to 35-40 ft.-lbs. (47-54 Nm) torque.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Lift And Tilt Lock Block
(CONT’D)
Figure 20-40-57
Rubber Boot
Figure 20-40-55
1 1
1
1
2
N-21252
N-21252 Figure 20-40-58
Remove the two screws (Item 1) [Figure 20-40-55] on

the rubber boot retainer.
1
Installation: Tighten the screws to 90-100 in.-lbs. (10,2-
11,3 Nm) torque.
Figure 20-40-56
2
1
2 2
2
N-21254
1 1
Remove the lock solenoids (Item 1) [Figure 20-40-57] &
[Figure 20-40-58] from the lift and tilt lock block.
Remove the rubber Boot (Item 2) [Figure 20-40-57] &

[Figure 20-40-58]. (20-40-16.))
N-21253
Remove the rubber boot (Item 1) [Figure 20-40-56] and

retainer (Item 2) [Figure 20-40-56].
963 Bobcat Loader

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(CONT’D)
Lift And Tilt Lock Block (Cont’d)
Figure 20-40-59
N-21256
Remove the bushing (Item 1) [Figure 20-40-61] and O-

ring (Item 2) [Figure 20-40-61] from the lift spool.
N-21255
Figure 20-40-62
Remove the lift and tilt lock block [Figure 20-40-59].
NOTE: The lock block must be clean and oil free. (Oil
can cause the solenoids not to function
properly.)
Lift Spool and Detent
The tool listed will be needed to do the following

procedure:
MEL1278 - Detent Tool

MEL1285 - Detent Spring Tool 1
N-21257
Figure 20-40-60
Remove the end cap (Item 1) [Figure 20-40-62].
N-21255
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
60] from the control valve. (20-40-16.))
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121 of 640
HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Lift Spool and Detent (Cont'd) IMPORTANT

Figure 20-40-63 The detent assembly has small springs and balls. Do
not lose these parts during disassembly and
assembly.
I-2012-0284
Figure 20-40-65
N-21258
Use a screwdriver to remove the snap ring (Item 1)

[Figure 20-40-63].
Remove the washer (Item 2) [Figure 20-40-63]. N-21260
Figure 20-40-64
Put a rag around the detent assembly [Figure 20-40-65].
This will prevent the detent balls and spring from being
lost when the detent sleeve is removed.
Figure 20-40-66
2
2
1
1 3
N-21259
2
Remove the screws (Item 1) [Figure 20-40-64] from the
detent bonnet.
N-21261
Remove the detent bonnet (Item 2) [Figure 20-40-64].

Remove the detent sleeve (Item 1) [Figure 20-40-66],
detent balls (Item 2) [Figure 20-40-66] and spring (Item
3) [Figure 20-40-66].
963 Bobcat Loader

122 of 640
(CONT’D)
Lift Spool and Detent (Cont'd)
Figure 20-40-67
P-08988
1 Clamp the linkage end of the spool in a vise [Figure 20-

40-69].
N-21262
Figure 20-40-70
Remove the spool assembly and seal (Item 1) [Figure
20-40-67] from the control valve. 2
Figure 20-40-68
N-18915
1
Install the spring tool (Item 1) [Figure 20-40-70] over the

centering spring.
N-21263
NOTE: Be careful when removing the detent adapter
(Item 2) [Figure 20-40-70] from the centering
Remove the spool seal (Item 1) [Figure 20-40-68] from spring, as it is under spring pressure.
the linkage end of the valve.
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(CONT’D)
Lift Spool and Detent (Cont'd) 1
Figure 20-40-71
N-19009
1 Remove spring tool (Item 1) [Figure 20-40-73] from the

2 spring assembly.
N-18916
Figure 20-40-74
Put a rag around the detent assembly [Figure 20-40-71].
This will prevent the detent balls and spring from being 2 1
lost when the detent adapter is removed. 3
Remove the detent adapter with an allan wrench.

4
Remove the back-up washer (Item 1) [Figure 20-40-71]
and spool seal (Item 2) [Figure 20-40-71].
Figure 20-40-72
N-18919
Inspect the adapter (Item 1) [Figure 20-40-74], collar

(Item 2) [Figure 20-40-74], spring (Item 3) [Figure 20-
40-74], and washer (Item 4) [Figure 20-40-74].
N-19004
Remove the detent adapter (Item 1) [Figure 20-40-72]

from the spring assembly.
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124 of 640
(CONT’D)
Figure 20-40-75 2
1
N-18961
Install the O-ring (Item 1) [Figure 20-40-77] over the

nipple on the plastic plug (Item 2) [Figure 20-40-77].
N-18918
Figure 20-40-78
Remove the stud from the end of the spool [Figure 20-
40-75].
Removal of the plastic plug:
Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
tap drill.
Figure 20-40-76
N-18963
Install the plastic plug and O-ring in the spool [Figure 20-
40-78].
N-18920
Turn a 6-32 tap (Item 1) [Figure 20-40-76] into the plug.

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

THREADS.
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(CONT’D)
Figure 20-40-79 2
O-ring
1
3
2
Plastic N-18958
Plug
0.60 inch
(15,2 mm)
Apply grease on all the detent component surfaces
before assembly [Figure 20-40-81].
B-14712
Install the spring (Item 1) [Figure 20-40-81] and detent
balls (Item 2) [Figure 20-40-81] into the adapter (Item 3)
Install the stud and tighten until the other end of the stud [Figure 20-40-81] and compress with the detent pliers.
is out about 0.600 inch (15,2 mm) from the spool [Figure
20-40-79]. Figure 20-40-82
Figure 20-40-80
N-18968
N-18967
Install the detent adapter to the collar [Figure 20-40-82].
Clamp the collar (Item 1) [Figure 20-40-80] in a vise. NOTE: The collar and the detent adapter are held
together by spring pressure when assembled
to the lift spool not the detent balls. Hold the
detent adapter and collar together to prevent
the detent balls and spring from falling out.
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(CONT’D)
Figure 20-40-83
N-19005
Install the spring assembly to the lift spool hand tight

[Figure 20-40-85].
N-19004
Remove the spring tool.
Install the spring tool (Item 1) [Figure 20-40-83] over the Check the alignment of the detent adapter and the
washer, spring, collar and detent adapter. washer.
Figure 20-40-84 Tighten the adapter to 90-100 in.-lbs. (10,2-11,3 Nm).
NOTE: The adapter must fit in the center of the

washer (Item 1) [Figure 20-40-85].
2
Figure 20-40-86
N-18917
Install the spool seal (Item 1) [Figure 20-40-84] and

back-up washer (Item 2) [Figure 20-40-84].
CD-15051
Install the detent balls and spring [Figure 20-40-86].
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(CONT’D)
Figure 20-40-87
2
N-21259
Install the lift spool assembly in the spool bore [Figure

20-40-89].
N-19007
Install the detent bonnet (Item 1) [Figure 20-40-89].
Hold the detent balls in place with the detent pliers Install the mounting screws (Item 2) [Figure 20-40-89].
[Figure 20-40-87].
Installation: Tighten the screws to 90-100 in.-lbs. (10,2-
Figure 20-40-88 11,3 Nm) torque.
Figure 20-40-90
1
2
1
N-19008
N-21258
Install the detent sleeve (Item 1) [Figure 20-40-88] to the
detent adapter.
Install the washer (Item 1) [Figure 20-40-90] and snap
ring (Item 2) [Figure 20-40-90].
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(CONT’D)
Figure 20-40-91
N-21256
Install the bushing (Item 1) [Figure 20-40-93] and O-ring

1 (Item 2) [Figure 20-40-93] on the linkage end of the lift
N-21257 spool.
Figure 20-40-94
Install the end cap (Item 1) [Figure 20-40-91].
Figure 20-40-92
1
1
N-21255
N-21263 Install the lift and tilt lock block (Item 1) [Figure 20-40-
94]. (20-40-16.))
Install the spool seal (Item 1) [Figure 20-40-92] on the

linkage end of the valve.
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(CONT’D)
Tilt Spool Removal And Installation
Figure 20-40-95
1
N-21265
1 Remove the two screws (Item 1) [Figure 20-40-97] from

the end cap.
N-21255
Installation: Tighten the bolt to 90-100 in.-lbs. (10,2-11,3
Nm) torque.
Remove the lift and tilt lock block (Item 1) [Figure 20-40-
95] from the control valve. (See Lift And Tilt Lock Block Figure 20-40-98
on Page 20-40-16.)
Figure 20-40-96
2
1
N-21266
N-21264 Remove the spool, centering spring, back-up washer and

spool seal [Figure 20-40-98].
Remove the bushing (Item 1) [Figure 20-40-96] and O- Assembly: Always use a new spool seal.
ring (Item 2) [Figure 20-40-96] from the tilt spool.
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(CONT’D)
Tilt Spool Removal And Installation (Cont'd) 1

2
3
Figure 20-40-99
4
N-18944
Inspect the adapter (Item 1) [Figure 20-40-101], collar

(Item 2) [Figure 20-40-101], spring (Item 3) [Figure 20-
N-18942 40-101], and washer (Item 4) [Figure 20-40-101].
Figure 20-40-102
Put the linkage end of the spool in the vise [Figure 20-
40-99].
2
Install the spool tool (Item 1) [Figure 20-40-99] over the 1
centering spring.
Figure 20-40-100
1
1
N-21267 N-18943
Remove the spool seal(s) (Item 1) [Figure 20-40-102]

and the back-up washer (Item 2) [Figure 20-40-102].
Assembly: Always use a new spool seal.

N-19014
Remove the bolt (Item 1) [Figure 20-40-100] holding the

centering spring to the spool.

Nm) torque.
Remove spring tool from the spring assembly.
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(CONT’D)
Auxiliary Spool Removal And Installation (Bonnet

End)
Figure 20-40-103
N-21274
1
Remove the spool (Item 1) [Figure 20-40-105].
Assembly: Put grease on all the centering spring

N-21272 component parts.
Remove the two screws (Item 1) [Figure 20-40-103]

from the end cap.

Nm) torque.
Figure 20-40-104
N-21273
Remove the end cap, O-ring, springs and spring guide

[Figure 20-40-104].
Assembly: Always use a new spool seal.
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(CONT’D)
Auxiliary Spool Removal And Installation (Linkage 1

End)
Figure 20-40-106
N-21270
1 Remove the auxiliary bleed block (Item 1) [Figure 20-40-

108] and O-ring.
N-21268 Assembly: Always use a new O-ring.
Figure 20-40-109
Remove the lock solenoid (Item 1) [Figure 20-40-106]
from the tilt lock block.
Figure 20-40-107
2
N-21271
1
Remove the spring guide (Item 1) [Figure 20-40-109]

N-21269 and springs (Item 2) [Figure 20-40-109].
Remove the spool (Item 3) [Figure 20-40-108].

Remove the screws (Item 1) [Figure 20-40-107] from the
auxiliary bleed block. Assembly: Put grease on all the centering spring
component parts.
Nm) torque.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL) Auxiliary Electric Solenoid Disassembly
(CONT’D)
Figure 20-40-112
Auxiliary Plug Removal And Installation
Figure 20-40-110 1
1
1
N-21277
N-21275 Remove the nut (Item 1) [Figure 20-40-112] from both

solenoids.
Remove the plug (Item 1) [Figure 20-40-110] auxiliary Installation: Tighten the nut to 8-12 ft.-lbs. (11-16 Nm)
section of the control valve. torque.
Figure 20-40-111 Figure 20-40-113
2
2
N-21276
N-21278
Replace the O-rings (Item 1) [Figure 20-40-111]. Remove the coil (Item 1) [Figure 20-40-113].
Check the orifice (Item 2) [Figure 20-40-111], to make Remove the solenoid stem (Item 2) [Figure 20-40-113].
sure it is not plugged.
Installation: Tighten valve to 8-12 ft.-lbs. (11-16 Nm)
torque.
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134 of 640
(CONT’D)
Plug
Auxiliary Electric Solenoid Disassembly (Cont’d)
Figure 20-40-114
2
1 1
N-21281
Figure 20-40-117
N-21279 Port Relief (Optional)
Remove the O-rings (Item 1) [Figure 20-40-114] from

2
the solenoid stem, replace as needed.
1
Check the solenoid stem and replace if needed.
Port Relief-Auxiliary Section Disassembly
Figure 20-40-115
1
N-18843
Remove the O-rings (Item 1) [Figure 20-40-116] &

[Figure 20-40-117] and back-up ring (Item 2) [Figure 20-
1 40-116] & [Figure 20-40-117] from the plug.
N-21280
Remove the plug (Item 1) [Figure 20-40-115] or optional

port relief valve from the control valve.
NOTE: Optional port relief (Item 1) [Figure 20-40-115]

is either 2500 PSI or 3000 PSI depending on
the option used.
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HYDRAULIC CONTROL VALVE (FOOT CONTROL)
(CONT’D)
Cleaning And Inspection
Clean all components with clean solvent and dry with

compressed air.
Check the spools for wear or scratches.
Check that the spools are not loose in their bore.
Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
Check the rubber boots and retainers.
Replace the parts as needed.
Use new O-rings and back-up rings.
Apply oil to all new O-rings and back-up rings before

installation.
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HYDRAULIC CONTROL VALVE (ADVANCE HAND
CONTROL) (AHC)
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963 Bobcat Loader
138 of 640
LIFT ARM BY-PASS CONTROL VALVE Figure 20-50-2
WARNING 1

W-2059-0598
N-20742
Remove the jam nut and rubber washer (Item 1) [Figure

20-50-2].
Figure 20-50-3

1
Raise the operator cab. (See Raising The Operator Cab 2
on Page 10-70-1.)
Figure 20-50-1 3
N-20743
1
Disconnect the hydraulic tubeline (Item 1) [Figure 20-50-

3] from the lift arm by-pass valve.
At the control valve, disconnect the hydraulic hose (Item

2) [Figure 20-50-3], that goes to the lift arm by-pass
valve.
Remove the two mount bolts (Item 3) [Figure 20-50-3].

N-20741
Installation: Tighten the mounting bolts to 180-200 in.-
lbs. (21-23 Nm) torque.
Remove the lift arm by-pass knob (Item 1) [Figure 20-50-
1]. Remove the lift arm by-pass valve from the loader.
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LIFT ARM BY-PASS CONTROL VALVE (CONT’D) Disassembly And Assembly
Removal And Installation (Cont’d)
Figure 20-50-4
IMPORTANT
damage the system.
I-2003-0888
1
Figure 20-50-5
N-20744
1
Remove the hose (Item 1) [Figure 20-50-4] from the

valve.
P-7939
Remove the by-pass valve (Item 1) [Figure 20-50-5] from

the valve block. Inspect the by-pass valve for damage
and replace if necessary.
Installation: Tighten the valve to 33-37 ft.-lbs. (45-50

Nm) torque.
Inspect the hydraulic fittings on the valve block for

damage and replace if necessary.
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HYDRAULIC PUMP Figure 20-60-1
Checking the Output of the Pump
WARNING
W-2059-0598 1
N-21371
Disconnect the OUTLET hose (Item 1) [Figure 20-60-1]

from the pump.
Connect the INLET hose from the tester to the OUTLET

of the pump. Connect the OUTLET hose from the tester
to the hose which was disconnected from the pump.
The tools listed will be needed to do the following Start the engine and run at low idle RPM. Make sure the
procedure: tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong. With the hoses
MEL10003 - Hydraulic Tester connected correctly, increase the engine speed to full
MEL10006 - Hydraulic Test Kit RPM.
NOTE: Make sure all the air is removed from the Warm the fluid to 140°F. (60°C.) by turning the restrictor
hydraulic system before beginning the test. control on the tester to about 1000 PSI (6895 kPa). DO
Air in the system can give an inaccurate test. NOT exceed system relief pressure. Open the restrictor
control and record the free flow (GPM) at full RPM.
*Relief pressure must be per specification before the
test is done. Turn the restrictor down to system operating pressure.
DO NOT EXCEED SYSTEM RELIEF PRESSURE. The
Lift and block the loader. (See LIFTING AND BLOCKING highest pressure flow must be at least 80% of free flow.
% = HIGH PRESSURE FLOW (GPM) X 100
Raise the lift arms and install an approved lift arm FREE FLOW (GPM)
Device on Page 10-50-1.) A low percentage may indicate a pump problem.

on Page 10-70-1.)
Connect the remote start switch. (See REMOTE START

on Page 10-90-1.)
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141 of 640
HYDRAULIC PUMP (CONT’D) Figure 20-60-4
Figure 20-60-2
N-21371
1
Remove the hose (Item 1) [Figure 20-60-4] from the rear
N-21369 of the pump.
Remove the left rear tire. (See TIRE MAINTENANCE on

Remove the two hoses (Item 1) [Figure 20-60-2]. Page 10-160-1.)
Figure 20-60-3 Figure 20-60-5
1
2
N-21370 N-21372
Remove the hose (Item 1) [Figure 20-60-3] and tubeline Remove the five mounting bolts (Item 1) [Figure 20-60-
(Item 2) [Figure 20-60-3]. 5].
Remove access cover from the loader.
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142 of 640

1
Figure 20-60-6
1
1
N-21375
Remove pump mount bolts (Item 1) [Figure 20-60-8].

N-21373
Installation: Tighten the pump mounting bolts to 30 ft.-
lbs. (40 Nm) torque.
Remove the hose (Item 1) [Figure 20-60-6] from the rear
of the pump. Access the hose through the access hole on Figure 20-60-9
the left side of the loader frame.
Figure 20-60-7
N-21376
N-21374 Remove the two pump brace mount bolts (Item 1)

[Figure 20-60-9].
Remove top split flange from rear of pump [Figure 20- Remove pump and brace assembly from the loader.
60-7]. Access bolts through left side of frame.
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143 of 640
HYDRAULIC PUMP (CONT’D) Disassembly and Assembly
Removal And Installation (Cont'd) Figure 20-60-12
Figure 20-60-10
N-21728
N-21377
Mark the pump housing for proper assembly [Figure 20-
60-12].
Remove the O-ring (Item 1) [Figure 20-60-10] from the
hydrostatic pump, and replace with a new O-ring before Remove the two bolts (Item 1) [Figure 20-60-12].
installing the hydraulic pump.
Remove the two nuts (Item 2) [Figure 20-60-12] from the
Figure 20-60-11 pump stud bolts.
Assembly: Tighten the bolts and nuts to 78 ft.-lbs. (106

Nm) torque.
NOTE: If the long studs are loose in the pump

mounting flange, replace the assembly or
remove the studs, clean the threads, apply
LOCTITE to the threads. Install the studs in
1
the mounting flange and let set for 10-15
minutes before assembling the pump. If the
studs turn, the correct torque can not be
apply to the nuts when the pump is
assembled.
N-21378
Remove the two nuts (Item 1) [Figure 20-60-11] and

remove the brace.
Installation: Tighten the nuts at the mounting bracket to

70 ft.-lbs. (95 Nm) torque.
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Disassembly and Assembly (Cont’d)
Figure 20-60-13
1
2
N-21702
Remove the rear bearing housing (Item 1) [Figure 20-60-

N-21700 15] from the pump.
Assembly: The pump seal and back-up seal (Item 2)

Slide the two pump sections apart [Figure 20-60-13]. [Figure 20-60-15] must be installed toward the pressure
side of the pump [Figure 20-60-15].
Figure 20-60-14
N-21701
Remove the end cap (Item 1) [Figure 20-60-14] from the

front pump housing.
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145 of 640
Disassembly and Assembly (Cont'd)
Figure 20-60-16
N-21703
Remove the gears (Item 1) [Figure 20-60-18] from the

N-21704 pump housing.
Figure 20-60-19
pump.
Assembly: Always install a new O-ring.
Figure 20-60-17
3
N-21710
1
Check the gears [Figure 20-60-19] for wear. If the gears

2 are worn replace the complete pump.
N-21705
Remove the back-up seal (Item 1) [Figure 20-60-17] and

seal (Item 2) [Figure 20-60-17] from the bearing
housing.
Assembly: Replace the seals with new. If the bearing

housing (Item 3) [Figure 20-60-17] is worn replace the
complete pump.
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146 of 640
Figure 20-60-20
3
1
1 2
N-21705
Remove the back-up seal (Item 1) [Figure 20-60-22] and

N-21706 seal (Item 2) [Figure 20-60-22] from the bearing
housing.
Remove the pump housing (Item 1) [Figure 20-60-20] Assembly: Replace the seals with new. If the bearing
from the pump flange. housing (Item 3) [Figure 20-60-22] is worn replace
complete the pump.
Check the pump housing for wear, scratches etc. If worn
replace the complete pump. Figure 20-60-23
Figure 20-60-21
N-21708
N-21707
Remove the snap ring (Item 1) [Figure 20-60-23] from
the outer end of the pump mounting flange.
Remove the front bearing housing (Item 1) [Figure 20-
60-21] from the pump housing.
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147 of 640
Figure 20-60-24
3
1
1
N-21714
Assembly: Replace the O-ring (Item 1) [Figure 20-60-

N-21709 26] with new from the kit. Check the coupling (Item 2)
[Figure 20-60-26] for wear and replace as needed.
Remove the seal (Item 1) [Figure 20-60-24] from the Figure 20-60-27
pump mounting flange.
Assembly: Use the correct size seal driver tool and

install a new seal into the pump mounting flange. Install
the snap ring into the pump mounting flange.
1
Figure 20-60-25
2
1
2
N-21715
Remove the gears and holders (Item 1) [Figure 20-60-

27] from the pump.
Assembly: The pump seal and back-up seal (Item 2)

N-21713 [Figure 20-60-27] must be installed toward the pressure
side of the pump (Item 3) [Figure 20-60-26].

rear pump.
Remove the pump drive coupling (Item 2) [Figure 20-60-

25] from the rear pump.
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Figure 20-60-28
1
N-21738
1
Remove the back-up seal and seal (Item 1) [Figure 20-
N-21716 60-30] from the bearing housings.
Figure 20-60-31
Remove the bearing housings (Item 1) [Figure 20-60-
28] from the gears.
Figure 20-60-29
1
1
N-21739
1
2 Assembly: Replace the seals and back-up seal (Item 1)
N-21737 [Figure 20-60-31] with new.
Inspect the gears (Item 1) [Figure 20-60-29] and the

bearing housings (Item 2) [Figure 20-60-29] for wear. If
parts are worn replace the complete pump.
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963 Bobcat Loader
150 of 640
HYDRAULIC PUMP Figure 20-61-2
Disassembly And Assembly
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1 1
damage the system.
I-2003-0888
N-15715
Figure 20-61-1
Install the bolts (Item 1) [Figure 20-61-2] in the next set

of holes in the pulley. Turn the bolts in evenly to remove
the pulley from the hub.
1
Figure 20-61-3
1
1 3
N-15714
2 1
Mark the pump sections for correct assembly.
Remove the three bolts (Item 1) [Figure 20-61-1] from

the pulley. N-15716
Remove the pulley (Item 1) [Figure 20-61-3] and hub

(Item 2) [Figure 20-61-3].
Remove the key (Item 3) [Figure 20-61-3] from the shaft.
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151 of 640
Disassembly And Assembly (Cont'd)
Figure 20-61-4
3 1
1 2
N-15719
2
Remove the bearing housing (Item 1) [Figure 20-61-6].
N-15717
Remove the back-up seal/O-ring seal (Item 2) [Figure
20-61-6] from the bearing housing.
Remove the two bolts (Item 1) [Figure 20-61-4].
Remove the large O-ring (Item 3) [Figure 20-61-6] from
Remove the two nuts (Item 2) [Figure 20-61-4]. the pump housing.
Assembly: Tighten the bolts and nuts to 78 ft.-lbs. (106 Figure 20-61-7
Nm) torque.
NOTE: If the long threaded studs are loose in the

pump mounting flange, replace the pump 1
assembly or remove the studs, clean the
threads, apply LOCTITE to the threads. Install
the studs in the mounting flange and let set
for 10-15 minutes before assembling the
pump. If the studs turn, the correct torque can
not be apply to the nuts when the pump is
assembled.
Figure 20-61-5
N-16079
Assembly: The O-ring and back-up washer (Item 1)

[Figure 20-61-7] must be installed toward the pressure
side of the pump.
N-15718
Remove the end housing (Item 1) [Figure 20-61-5].
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Figure 20-61-8
2
4
1
N-15721
3 Remove the drive gear (Item 1) [Figure 20-61-10] and

2
N-15720 idler gear (Item 2) [Figure 20-61-10] from the pump
housing.
Remove the drive end housing (Item 1) [Figure 20-61-8]. Figure 20-61-11

the pump housing.
Remove the bearing housing (Item 3) [Figure 20-61-8].
Remove the back-up seal/O-ring seal (Item 4) [Figure

20-61-8] from the bearing housing.
Figure 20-61-9
2
1 1
N-15725
Remove the snap ring (Item 1) [Figure 20-61-11] and

seal (Item 2) [Figure 20-61-11] from the pump end
housing.
N-16078
Assembly: The O-ring and back-up washer (Item 1)

[Figure 20-61-9] must be installed toward the pressure
side of the pump.
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Figure 20-61-12
1
N-15723
Check the pump housing (Item 1) [Figure 20-61-14].

N-15726 Check the surface in the gear area for scratches, wear,
etc.
Remove the snap ring (Item 1) [Figure 20-61-12] and Figure 20-61-15
seal (Item 2) [Figure 20-61-12] from the pump mounting
flange.
Assembly: Use the correct size driver tool to install the

shaft seals into the housings.
Inspection
Wash all parts in clean solvent. Use air pressure to dry

them.
1
Make a visual inspection, those parts which show wear,
or damage must be replaced.
Figure 20-61-13 N-15724
Check the bushings (Item 1) [Figure 20-61-15] in the

bearing housing. If the bushings are worn, scratched,
and etc. Replace the parts as needed.
N-15722
Check the drive and idler gears [Figure 20-61-13]. If

excessive wear is visible on the journals, side or face of
the gears, they must be replaced. If the splines are worn,
replace the gears.
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HYDRAULIC/HYDROSTATIC FILTER Figure 20-70-3
Figure 20-70-1
1
1
N-21337
Remove two hydraulic hose (Item 1) [Figure 20-70-3]

N-21335 from the right side of the filler housing.
Figure 20-70-4
Disconnect the two electrical connectors (Item 1) [Figure
20-70-1] from the filter housing.
Figure 20-70-2 1
N-21338
1
Remove the four mounting bolts (Item 1) [Figure 20-70-
N-21336 4] from the filter head.
Remove the filter and filter head from the loader.

Remove the two hydraulic hoses (Item 1) [Figure 20-70-
2] from left side of the filter housing. Installation: Tighten the mounting bolts to 25 ft.-lbs. (34
Nm) torque.
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HYDRAULIC/HYDROSTATIC FILTER (CONT’D)
Figure 20-70-5
N-21339
Remove the two mounting bolts (Item 1) [Figure 20-70-5]

from the filter mount bracket.
Remove the mount bracket from the loader.
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COOLING FAN FILTER Figure 20-71-3
Figure 20-71-1
N-21351
1
Remove the hydraulic hose (Item 1) [Figure 20-71-3] that
N-21349 goes from the filter housing to the hydraulic reservoir at
the reservoir.
Remove the filter element (Item 1) [Figure 20-71-1] from Remove the two bolts (Item 2) [Figure 20-71-3] and
the filter housing. remove the filter mount and hydraulic hose from the
loader.
Figure 20-71-2
N-21350

from the front of the filter housing.
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HYDRAULIC FLUID RESERVOIR Figure 20-80-1
IMPORTANT
1
damage the system.
I-2003-0888
N-21357
WARNING Disconnect the lift arm linkage (Item 1) [Figure 20-80-1].
Figure 20-80-2
W-2059-0598
N-20790

support device. (See Engaging The Lift Arm Support Disconnect the brake wire harness (Item 1) [Figure 20-
Device on Page 10-50-1.) 80-2].
Stop the engine.

on Page 10-70-1.)
Remove the control panel. (See Removal And Installation

on Page 30-20-1.)
Drain the reservoir. (See Replacing The Hydraulic Fluid

on Page 10-150-2.)
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HYDRAULIC FLUID RESERVOIR (CONT’D) Figure 20-80-5
Figure 20-80-3
N-21359
2 Remove the three bolts (Item 1) [Figure 20-80-5] and

1 1 remove the front left panel.
N-20789
Figure 20-80-6
Remove the two bolts (Item 1) [Figure 20-80-3] and
remove the floor plate (Item 2) [Figure 20-80-3] from the
loader.
Figure 20-80-4
1
1
N-20831
Remove the clevis pin (Item 1) [Figure 20-80-6] and

retainer from the tilt linkage.
N-21358
Remove the three bolts (Item 1) [Figure 20-80-4] and

remove the left panel.
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Removal and Installation (Cont'd)
Figure 20-80-7
1 N-20834

N-20832 the front of the loader frame.
Remove the floor board.

remove the right panel. Figure 20-80-10
Figure 20-80-8
1
1
N-21360
N-20833
Remove the two mount bolts and nuts (Item 1) [Figure
20-80-10] from the Bobcat Controller. Reposition the
Remove the three bolts (Item 1) [Figure 20-80-8] and Bobcat Controller to allow clearance for the reservoir
remove the right front panel. removal.
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Figure 20-80-11
1
N-21362
Remove the hydraulic fluid fill hose (Item 1) [Figure 20-

N-21364 80-13] from the reservoir.
Figure 20-80-14
Remove the mount bolt and nut (Item 1) [Figure 20-80-
11].
Figure 20-80-12 2
2 1
1
1
N-21363
3 Loosen the two hose clamps (Item 1) [Figure 20-80-14]

N-21361 and remove the hose from the reservoir.
Remove the mount bolt and nut (Item 2) [Figure 20-80-

Remove the two hydraulic hoses (Item 1) [Figure 20-80- 14] from the bottom of the reservoir.
12] from the reservoir.

and 90° fitting (Item 3) [Figure 20-80-12] from the
reservoir.
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Figure 20-80-15
1 N-21367
Slide the reservoir forward and remove the reservoir from

N-21366 the loader [Figure 20-80-17].
Remove the hose (Item 1) [Figure 20-80-15] from the

pump and reposition the hose for clearance.
Figure 20-80-16
N-20830
Remove the two mount bolts (Item 1) [Figure 20-80-16]

and the mount.
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CONTROLS Control Pedal Adjustment
Control Pedal Removal And Installation After installing the pedal, adjust so there is clearance
under the rear of the pedal and the valve spool must
Figure 20-90-1 travel full stroke without hitting the floor panel.
1 WARNING
Adjust locking tabs on control linkage so that lift and
tilt control pedals or (Mechanical Hand Controls) are
locked in neutral when the seat bar is up.
W-2104-0199
Control Pedals Mounting Panel Removal And

Installation
N-20850
Figure 20-90-3
Remove the bolt and nut (Item 1) [Figure 20-90-1] from

the pedal linkage.
Installation: Tighten the bolt and nut to 21-25 ft.-lbs. (28-

34 Nm) torque.
1
Check the rubber bushing in the pedal for wear and
replace as needed.
Figure 20-90-2
N-21357
Remove the loader control panel/steering lever assembly.

(See Removal And Installation on Page 30-20-1 and See
1
Lever Removal And Installation on Page 30-30-1)
1 Remove the bolt and nut (Item 1) [Figure 20-90-3] at the

lift pedal linkage and crossbar.
N-20851
Remove the two mounting bolts (Item 1) [Figure 20-90-

2].
Remove the pedal assembly from the loader.
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CONTROLS (CONT’D) Figure 20-90-6

Installation (Cont'd)
Figure 20-90-4
1
N-20789
1
Remove the lower front panel mounting bolts (Item 1)
[Figure 20-90-6].
N-20831
Remove the lower front panel.
Disconnect the tilt pedal linkage (Item 1) [Figure 20-90- Figure 20-90-7
4] from the control valve spool.
Figure 20-90-5
N-20791
N-20790 Remove the three mounting bolts (Item 1) [Figure 20-90-

7] from the left side panel.
Disconnect the parking brake wire harness (Item 1) Remove the panel.
[Figure 20-90-5].
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CONTROLS (CONT’D) Figure 20-90-10

Figure 20-90-8
1
N-20833
Remove the three mounting bolts (Item 1) [Figure 20-90-

10] from the right front side panel.
N-20792
Remove the panel.
Remove the three mounting bolts (Item 1) [Figure 20-90- Figure 20-90-11
8] from the left front side panel.
Remove the panel.
Figure 20-90-9
2 2
1
1
N-20834

11] from the control pedals mounting panel.
N-20832
Remove the panel.
Remove the three mounting bolts (Item 1) [Figure 20-90- NOTE: Remove the two lower cover mounting bolts
9] from the right side panel. (Item 2) [Figure 20-90-11] to ease panel
removal.
Remove the panel.
Remove the control pedal mounting panel from the
loader.
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BUCKET POSITION VALVE Figure 20-100-3
Figure 20-100-1
1 N-21353
Remove the four hydraulic hoses (Item 1) [Figure 20-

N-21349 100-3] from the bucket position valve.
Figure 20-100-4
Remove the cooling fan filter (Item 1) [Figure 20-100-1].
Figure 20-100-2
N-21354
N-21352 Remove the two tubelines (Item 1) [Figure 20-100-4]

from the bucket position valve.
Disconnect the wire harness (Item 1) [Figure 20-100-2]

from the bucket position valve.
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BUCKET POSITION VALVE (CONT’D) Disassembly And Assembly
Figure 20-100-5
1
P-6568
N-21355
Loosen the unloading spool (Item 1) [Figure 20-100-7].
Remove the hose (Item 1) [Figure 20-100-5] from the Figure 20-100-8
bottom of the valve.
Figure 20-100-6
P-6569
N-21356 Remove the plug, O-ring, spring and spool [Figure 20-
100-8].
Remove the bolts (Item 1) [Figure 20-100-6] from the

valve.
Installation: Tighten the mounting bolts and nuts to 15

ft.-lbs. (20 Nm) torque.
Remove the valve.
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BUCKET POSITION VALVE (CONT’D) Figure 20-100-11
Figure 20-100-9
1
P-6572
Loosen the flow adjustment valve (Item 1) [Figure 20-

P-6570 100-11].
Figure 20-100-12
Use a drag link socket and loosen the plug for the flow
control spool (Item 1) [Figure 20-100-9].
Figure 20-100-10
P-6573
Remove the flow adjustment valve and O-ring [Figure

P-6571 20-100-12].
NOTE: Always install new O-rings before any parts

Remove the plug, O-ring and flow control spool [Figure are installed into the valve. Check the parts
20-100-10]. for wear or damage and replace as needed.
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TILT JUNCTION BLOCK Left Side
Removal And Installation Figure 20-110-3
Figure 20-110-1
1
1
N-15379
1
3
Remove any attachment from the Bob-Tach. Roll the
Bob-Tach fully out.
Stop the engine.
Use a floor jack and raise the lift arms.

3
Install jackstands (Item 1) [Figure 20-110-1] under the lift
arms.
Pull up on the lift arm by-pass control and move the lift
pedal to release the hydraulic pressure.
Figure 20-110-2
N-15374
Disconnect the tubelines (Item 1) [Figure 20-110-3] from


Remove the front step mounting bolts (Item 3) [Figure

20-110-3].
N-15375
Remove the tilt junction block mounting bolts (Item 1)

[Figure 20-110-2].
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TILT JUNCTION BLOCK (CONT’D) Figure 20-110-5
Right Side
WARNING 1
2
sufficient force to enter a person’s body by 3
4
N-15378
immediately.
W-2145-0290
Installation: The cork washer (Item 1) [Figure 20-110-

Figure 20-110-4 5] goes between the step and the loader lift arms. The
spacer (Item 2) [Figure 20-110-5] fits into the mounting
hole in the step and is tightened into place with the
mounting bolt and washer (Items 3 & 4) [Figure 20-110-
5].
Mark the hydraulic hoses for the correct installation.
Figure 20-110-6
1
N-15377
Disconnect the hoses from the junction block (Item 1)

1 [Figure 20-110-6].
Remove the junction block.

N-15373
Put plugs in the ends of the hoses.
Remove the front step mounting bolts (Item 1) [Figure

20-110-4].
Remove the front step from the loader.
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REAR AUXILIARY DIVERTER Figure 20-120-3
Figure 20-120-1 1
N-21870
Remove the tubeline (Item 1) [Figure 20-120-3] that

N-21884 goes from the diverter block to the control valve.
Figure 20-120-4
Remove the left side motor cover, and drain the hydraulic
reservoir [Figure 20-120-1].
1
Figure 20-120-2
N-21869
Remove the tubeline (Item 1) [Figure 20-120-4] that

N-21871 goes from the diverter block to the control valve.
Disconnect the two electrical connectors (Item 1) [Figure

20-120-2] from the diverter valve.
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REAR AUXILIARY DIVERTER (CONT’D) Figure 20-120-7
Figure 20-120-5
2 N-21892
1
Remove the two hydraulic hoses (Item 1) [Figure 20-
N-21868 120-7] from the T-fittings on the diverter block.
Figure 20-120-8
Remove the two bucket position valve mount bolts (Item
1) [Figure 20-120-5].
Remove the bucket position mount plate mounting bolts,

and remove the mount plate (Item 2) [Figure 20-120-5]
1
from the loader.
Figure 20-120-6
2
N-21891

120-8] from the hydraulic tubelines going to the bucket
position valve.
1
N-21866 120-8] from the diverter valve.
Remove the two tubelines (Item 1) [Figure 20-120-6]

from the diverter block.
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1
Figure 20-120-9
1 N-21885
Remove the two diverter valve mounting bolts (Item 1)

N-21889 [Figure 20-120-11].
Remove the diverter block from the loader.

Loosen the tubelines (Item 1) [Figure 20-120-9] from the
bucket position valve to allow clearance for removal of the Figure 20-120-12
diverter valve.
Figure 20-120-10
N-21882
N-21886 Remove the two diverter valve mount bracket mounting

bolts (Item 1) [Figure 20-120-12] and remove the mount
bracket from the loader.
Disconnect the drain hose (Item 1) [Figure 20-120-10]
that goes from the diverter block to the hydraulic
reservoir, at the hydraulic reservoir.
The drain hose (Item 1) [Figure 20-120-10] will be

removed with the diverter block.
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Disassembly
IMPORTANT
damage the system. 1
I-2003-0888 2
N-0529
Figure 20-120-13
Remove the pilot check valves from block ports PC1 and
PC2 (Item 1) [Figure 20-120-14].
Remove the shuttle check valve from block port SH1

(Item 2) [Figure 20-120-14].
Figure 20-120-15
4
1
2
1
N-0527 3
5
2
Clean the diverter block to remove dirt before
disassembly. Block ports are labeled for correct 2
assembly.
Remove the logic cartridge valves from block ports LC1 3

2 1
and LC2 (Item 1) [Figure 20-120-13]. N-0528
Remove the nuts (Item 1) [Figure 20-120-15], seal

washers (Item 2) [Figure 20-120-15], and solenoid valve
coils (Item 3) [Figure 20-120-15].
Remove the diverter control solenoid valve (Item 4)

[Figure 20-120-15] from port SV1. Remove the pressure
relieving solenoid valve (Item 5) [Figure 20-120-15] from
block port SV2.
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REAR AUXILIARY DIVERTER (CONT’D)
Inspection
Inspect cartridges, check valves, solenoid valves and

sealing washers for contamination or damage. Wash all
parts in clean solvent. Use air pressure for drying them.
Install new O-rings and back-up washers.
Inspect diverter block cavities for contamination. Wash

block in clean solvent. Use air pressure to dry.
Solenoid Testing
Figure 20-120-16
P-9137
Use a test meter to measure coil resistance [Figure 20-

120-16]. Coil wires do not have polarity. Correct
resistance is 6-9 ohms.
Assembly
Put oil on O-rings and back-up washers.
Tighten the Logic cartridge valves (Item 1) [Figure 20-

120-13] to 65 ft. lbs. (88 Nm) torque.
Tighten the pilot check valves (Item 1) [Figure 20-120-

14], and shuttle check valve (Item 2) [Figure 20-120-14]
to 35 ft. lbs. (47 Nm) torque.
Tighten the solenoid valves (Items 4 and 5) [Figure 20-

120-15] to 12 ft. lbs. (16,3 Nm) torque. Install the sealing
washers (Item 2) [Figure 20-120-15] and coils (Item 3)
[Figure 20-120-15]. Tighten the nuts (Item 1) [Figure 20-
120-15] to 10 in. lbs. (1,13 Nm) torque.
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HYDROSTATIC SYSTEM
CHARGE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-50-1

Checking The Charge Pressure. . . . . . . . . . . . . . . . . . . . . 30-50-1
SAFETY &
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1 MAINTENANCE
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-1 HYDROSTATIC

Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2 SYSTEM
Idler Pulley Removal And Installation . . . . . . . . . . . . . . . . 30-70-6
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-2
Shield Removal And Installation . . . . . . . . . . . . . . . . . . . . 30-70-1 DRIVE
Tensioner Pivot Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-5 SYSTEM
Tensioner Pulley Disassembly And Assembly . . . . . . . . . . 30-70-4
Tensioner Pulley Removal And Installation . . . . . . . . . . . . 30-70-3
Tensioner Tension Spring. . . . . . . . . . . . . . . . . . . . . . . . . . 30-70-4
HYDROSTATIC MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-10
Cover Removal And Installation. . . . . . . . . . . . . . . . . . . . 30-40-15 ELECTRICAL
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-5 SYSTEM &
Flushing Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-4 ANALYSIS
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-8
Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-15
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-1 ENGINE
Throttle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-40-3 SERVICE
HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-1

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-14
Charge Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-3 SPECIFICATIO
DA Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-3
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-4
Hydrostatic Pump Start-Up . . . . . . . . . . . . . . . . . . . . . . . 30-60-24
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-12
Replenishing/High Pressure Relief Valve . . . . . . . . . . . . . 30-60-2
Timing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-60-27
HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . . . . . . . 30-10-1

Replenishing Valve Function . . . . . . . . . . . . . . . . . . . . . . . 30-10-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-80-1

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HYDROSTATIC SYSTEM (CONT’D)
STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 30-30-1
Lever Removal And Installation . . . . . . . . . . . . . . . . . . . . . 30-30-1
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HYDROSTATIC SYSTEM INFORMATION
WARNING
assistance in locating and correcting problems which are Check for correct function after adjustments, repairs
most common. Many of the recommended procedures or service. Failure to make correct repairs or
must be done by authorized Bobcat Service Personnel adjustments can cause injury or death.
only. W-2004-1285
problem Cause
No drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2, 3, 4, 5
The loader does not move in a straight line. 2, 3, 5, 6, 7
The hydrostatic system is overheating. 8, 9, 10, 11
Warning light comes ON. 8, 11, 12, 13, 14
Key to correct the cause

1. The hydrostatic pump replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The temperature sending switch is not operating correctly.
11. The loader is not being operated at the correct RPM.
12. The sender is defective.
13. Pump is defective or worn hydrostatics.
14. Hydraulic filter is plugged.
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HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function
IMPORTANT
damage the system.
I-2003-0888
Figure 30-10-1
CHARGE OIL
FUNCTION 1 Valve Moves for Charge

Oil Replacement
Hold High Pressure for Drive

Valve Stays on Seat to
FUNCTION 2
B-2804
The functions of the replenishing valves are:
1. To give replacement fluid to the low pressure side of

the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the controlled
flow to the oil cooler for cooling; 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].
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CONTROL PANEL Figure 30-20-2
WARNING 1
W-2017-0286
N-20752
WARNING Disconnect the right steer lever harness (Item 1) [Figure

30-20-2].
Figure 30-20-3
W-2059-0598
Figure 30-20-1
1
N-20753
Disconnect the left steer lever harness (Item 1) [Figure

30-20-3].
N-20740


on Page 10-70-1.)
Remove the engine speed control (Item 1) [Figure 30-

20-1]. (See Removal And Installation on Page 70-20-1.)
Remove the lift arm by-pass knob (Item 2) [Figure 30-20-

1].
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CONTROL PANEL (CONT’D) Figure 30-20-6
Figure 30-20-4
1
2
1
N-20756
2 2
N-20754 one bolt and nut (Item 2) [Figure 30-20-6].
Figure 30-20-7
and remove the fuse cover.

4] from the control panel.
1
Figure 30-20-5
N-20757
1
Tilt the control panel forward and remove the nut & bolt
(Item 1) [Figure 30-20-7], two bolts (Item 2) [Figure 30-
20-7] from the control panel brace.
N-20755 Remove the brace (Item 3) [Figure 30-20-7] from the

control panel.
Remove the five bolts (Item 1) [Figure 30-20-5] on the

left side of the panel.
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CONTROL PANEL (CONT’D) Figure 30-20-10
Figure 30-20-8
1
1
1 1
1
N-20760
Mark the five hydraulic hoses (Item 1) [Figure 30-20-10]

N-20759 for the correct installation.
Disconnect them from the right steering lever control

Remove the bolt (Item 1) [Figure 30-20-8] from the valve.
wiring harness clamp and reposition the wire harness.
Remove the control panel.
Figure 30-20-9
N-20758
Mark the four hydraulic hoses (Item 1) [Figure 30-20-9]

for the correct installation.
Disconnect them from the left steering lever control valve.
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STEERING Disassembly And Assembly
Lever Removal And Installation Figure 30-30-3
Figure 30-30-1
1 1
N-21432
N-21429
right side steering shock.
Figure 30-30-2
Remove the shock from the control panel.
Figure 30-30-4
1
1
1
N-21430
Remove the control panel. (See Removal And Installation

N-21433
on Page 30-20-1.)
Remove the four mounting bolts (Item 1) [Figure 30-30- Remove the three mounting bolts (Item 1) [Figure 30-30-
1] & [Figure 30-30-2] from the steering cross shaft block. 4] from the control panel brace.
Mark the wiring harness connectors for proper Remove the brace from the panel.
installation and remove the wiring connectors from the
steering lever harness.
Remove the steering lever (both sides).
Installation: The steering lever must be flush with the

back of the mounting plate on the steering cross shaft.
Tighten the mounting bolts to 25-28 ft.-lbs. (34-38 Nm)

torque.
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STEERING (CONT’D) Figure 30-30-7

2 1
Figure 30-30-5 2
N-21438
Remove the nut (Item 1) [Figure 30-30-7] and remove

N-21435 the decal plate from the panel.
Remove the two mount nuts, washers and bolts (Item 2)

Remove the two nuts (Item 1) [Figure 30-30-5] from the [Figure 30-30-7].
left side steering shock.
Figure 30-30-8
Remove the shock from the control panel.
Figure 30-30-6
N-21442
N-21436 Remove the steering lever centering spring assembly

[Figure 30-30-8] from the control panel.

6] from the control panel brace.
Remove the brace from the panel.
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Figure 30-30-9
1 1
1
1
N-21439
1
Figure 30-30-12
N-21427 N-21428
Remove the six mounting bolts (Item 1) [Figure 30-30-9]

from the front side of the control panel.
Figure 30-30-10
N-21440
Drill out the four pop rivets (Item 1) [Figure 30-30-11] &
[Figure 30-30-12] and remove the steering lever boot.
Replace the steering lever boot and pop rivet (Item 1)

N-21445 [Figure 30-30-12] the boot to the control panel.
Remove the bellcrank/steering controller assembly

[Figure 30-30-10] from the control panel.
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Figure 30-30-13
1
1
1 2
1 N-21444
Remove the nut and bolt (Item 1) [Figure 30-30-15] from

N-21442 the angle bracket, and remove the centering bracket
(Item 2) [Figure 30-30-15].
Remove the bolt and nut (Item 1) [Figure 30-30-13] from Inspect all parts and replace as needed.
the steering centering plate.
Figure 30-30-16
Figure 30-30-14
N-21445
N-21443
Slide the bellcrank halves apart [Figure 30-30-16], so

Remove the centering spring (Item 1) [Figure 30-30-14] the steering shaft clears the left and right steering
and washers (Item 2) [Figure 30-30-14], check for wear bracket/controller assemblies.
and replace as needed.
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Figure 30-30-17 1
N-21448
For proper assembly, note the location of the plastic

N-21446 washers (Item 1) [Figure 30-30-18] & [Figure 30-30-19]
and of the wave washer (Item 2) [Figure 30-30-18].
Remove the steering bracket/controller assemblies (Item Figure 30-30-20

1) [Figure 30-30-17] from the bellcranks.
Figure 30-30-18
N-21449
2
N-21447 Remove the bellcranks (Item 1) [Figure 30-30-20] from
the steering shaft (Item 2) [Figure 30-30-20]. Inspect all
parts for wear and replace as needed.
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1
Figure 30-30-21
N-21469
1
Remove the steering cam/roller bearing assembly (Item
N-21450 1) [Figure 30-30-23] from the bellcrank.
Figure 30-30-24
Remove the needle bearings (Item 1) [Figure 30-30-21]
from each end of the bellcrank. Check for wear and
replace as needed.
Figure 30-30-22
N-21470
1
Check all parts and replace as needed [Figure 30-30-

24].
N-21467
NOTE: Install the needle bearings with the O-ring

(Item 1) [Figure 30-30-22] toward the outer end
of the bellcrank.
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STEERING (CONT’D) Remove the steering controller and mount plate from the
steering bracket.
Figure 30-30-27
Figure 30-30-25
1 1
N-21472
2 N-21471
Remove the mount bolt (Item 1) [Figure 30-30-27] from

Loosen and remove the jam nut (Item 1) [Figure 30-30- the steering controller.
25] from the steering stops.
Installation: Tighten the mount bolt to 30 ft.-lbs. (41 Nm)
Remove the steering stops (Item 2) [Figure 30-30-25] torque.
from the bellcranks.
Figure 30-30-28
NOTE: The steering stops are threaded into the
bellcrank, and must be unscrewed to remove.
The steering stops must be set after the
control panel is installed in the loader. (30-30-
12.) for proper procedure.) 3 2
Figure 30-30-26
N-21473
Remove the steering controller mount plate (Item 1)

1 [Figure 30-30-28] from the steering controller block (Item
2) [Figure 30-30-28].
N-20994 Remove the spacer washer (Item 3) [Figure 30-30-28]

from the controller block.
Remove the two hydraulic fittings (Item1) [Figure 30-30-

26] from the steering controller.

from the steering controller mount plate.
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Figure 30-30-29
1
2
3
N-21474A
1
1
Remove the plunger (Item 1) [Figure 30-30-31] and O-
N-21817 ring (Item 2) [Figure 30-30-31] from the plunger guide
(Item 3) [Figure 30-30-31].
Remove the rubber boots (Item 1) [Figure 30-30-29] Check for wear and replace as needed.
from the plunger guide.
Figure 30-30-32
Figure 30-30-30
1
N-21815
N-21816
Remove the wiper ring (Item 1) [Figure 30-30-32] from

Remove the plunger guide assemblies (Item 1) [Figure the inside of the plunger guide.
30-30-30] from the controller plate.
Replace the wiper ring.
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Disassembly and Assembly (Cont'd) 1 2 1
Figure 30-30-33
2 Correct Incorrect
B-15683
1
NOTE: The spring retainer (Item 2) [Figure 30-30-34]
N-21477 & [Figure 30-30-35], must be installed on the
spool with the shoulder side (Item 3) [Figure
30-30-35] toward the springs. The locking
Remove the spool assemblies (Item 1) [Figure 30-30-33] disks (Item 1) [Figure 30-30-34] & [Figure 30-
from the controller. 30-35] must be installed with the square edge
toward the springs [Figure 30-30-35].
Remove the return springs (Item 2) [Figure 30-30-33]
from the controller.
Figure 30-30-34
2
5
1
4
3
N-21475
Remove the two locking disks (Item 1) [Figure 30-30-34]

from the spring retainer (Item 2) [Figure 30-30-34].
Remove the spring (Item 3) [Figure 30-30-34], shim

(Item 4) [Figure 30-30-34], and retaining washer (Item 5)
[Figure 30-30-34] from the spool (Item 6) [Figure 30-30-
34].
NOTE: The spool (Item 6) [Figure 30-30-34] cannot be

replaced as a separate part, if damaged, the
complete controller must be replaced.
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Figure 30-30-36
4
1
1
3
N-21816
Install the plunger guide assemblies (Item 1) [Figure 30-

N-21477 30-38] in the controller mount plate.
Figure 30-30-39
Install the return spring (Item 1) [Figure 30-30-36], the
spool assembly (Item 2) [Figure 30-30-36].
Install the spacer washer (Item 3) on the controller at the

location shown (Item 4) [Figure 30-30-36].
Figure 30-30-37
N-21817
1
Install the plunger boots (Item 1) [Figure 30-30-39] on
the plunger guide and piston.
Install the mount plate assembly to the controller. (30-30-

N-21479 7.))
Install the controllers on the steering brackets. (30-30-7.))

Remove the bushings (Item 1) [Figure 30-30-37] from
the controller mount plate. Check for wear and replace as
needed.
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Figure 30-30-40 1
N-21666
Install the washers and nuts (Item 1) [Figure 30-30-42]

N-21446 and lightly tighten the bolts to hold the spring assembly in
place.
Install the steering controller/bracket assemblies (Item 1) Figure 30-30-43

[Figure 30-30-40] on the bellcrank assembly.
Install the bellcrank/steering controller assembly to the

control panel. (30-30-3.))
Install the steering levers. (30-30-1.)) 1

2
Figure 30-30-41
1 2
2
N-21667
Install the steering cams (Item 1) [Figure 30-30-43] in

the bellcranks, and finger tighten the nuts.
N-21665
Install the centering spring assembly (Item 1) [Figure 30-

30-41] on the control panel.
Position the centering spring assembly so the mount

bolts (Item 2) [Figure 30-30-41] are at the bottom of the
mounting slots.
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Neutral Adjustment
Figure 30-30-44
4 1
1
N-21668
2
3 Measure the distance from the controller plate to the top

N-21670 of the bellcranks (Item 1) [Figure 30-30-45] & [Figure
30-30-46].
Loosen the jam nuts (Item 1) [Figure 30-30-44] from the Move the steering lever forward or backward to make the
top of the steering stops (Item 2) [Figure 30-30-44]. distance on the front side and back side the same.
Turn the steering stops away from the controller to allow When the distance is equal tighten the nut on the
for clearance. steering cam.
The distance (Item 3) [Figure 30-30-44] from the top of Repeat the procedure for the other lever.
the bellcrank to the controller plate, on the front and rear
side of the bellcrank, is adjusted by moving the steering Figure 30-30-47
cams (Item 4) [Figure 30-30-44] forward or back in the
slot.
2
Figure 30-30-45
1
1
N-21438
Move the centering spring assembly (Item 1) [Figure 30-

N-21669 30-47] so the centering spring lever (Item 2) [Figure 30-
30-47] has equal pressure on both the steering cams.
Tighten the two mounting bolts.
Install the decal mount. (30-30-2.))
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STEERING (CONT’D)
Neutral Adjustment (Cont'd)
Figure 30-30-48
N-21792
Install the steering brace and shocks on the control

panel. (See Disassembly And Assembly on Page 30-30-
1.)
Install the control panel in the loader. (See Removal And

Installation on Page 30-20-1.)


Connect the remote start tool to the loader. (See

REMOTE START on Page 10-90-1.)

on Page 10-70-1.)
Start the loader and run the engine at an idle.
Adjust the rear steering stop (Item 1) [Figure 30-30-48]

down until it lightly contacts the controller plunger,
without causing the wheel to creep in reverse.
Adjust the front steering stop (Item 2) [Figure 30-30-48]

down until it lightly contacts the controller plunger,
without causing the wheel to creep forward.
Lock the jam nuts (Item 3) [Figure 30-30-48].
Repeat the procedure for the other lever.
NOTE: The steering stop adjustment, may need to be

repeated to get the steering the same for both
levers and for forward and reverse.
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HYDROSTATIC MOTOR Figure 30-40-1
Removal and Installation
2
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
N-15496
WARNING Disconnect the hose (Item 1) [Figure 30-40-1] at the

bottom of the motor.
Never work on a machine with the lift arms up unless Disconnect the hose (Item 2) [Figure 30-40-1] at the top
the lift arms are secured by an approved lift arm of the motor.
support device can allow the lift arms or attachment Figure 30-40-2
W-2059-0598
Lift and block the loader. (See LIFTING AND BLOCKING 1

THE LOADER on Page 10-20-1.) 1


on Page 10-70-1.)
Drain the hydraulic fluid reservoir. (See Replacing The

Hydraulic Fluid on Page 10-150-2.) N-15497
Remove the hydrostatic motor cover. (See Cover

Removal And Installation on Page 30-40-15.) Loosen the four mounting bolts at the high pressure hose
collar (Item 1) [Figure 30-40-2] (front and rear).
Mark all the hoses for correct installation.
Remove only two bolts and one collar (Item 1) [Figure
30-40-2] and disconnect the high pressure hose.
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HYDROSTATIC MOTOR CONT’D) Figure 30-40-5
Figure 30-40-3
1 1
N-15500
Remove the hydrostatic motor from the gearcase

N-15498 housing [Figure 30-40-5].
Installation: Install the rear collar (Item 1) [Figure 30-

40-3] and connect the high pressure hose behind the
collar and then install the other collar and tighten the
bolts to 25 ft.-lbs. (34 Nm) torque.
Figure 30-40-4
N-15499

4] from the motor mounting flange.
Installation: Tighten the mounting bolts to 65-70 ft.-lbs.

(88-95 Nm) torque.
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HYDROSTATIC MOTOR (CONT’D) Remove the bottom throttle seat (Item 3) [Figure 30-40-
7].
Throttle Control
Inspect all the parts and replace as needed.
Shuttle Check Valve

IMPORTANT Remove the plug (Item 2) [Figure 30-40-6].
When repairing hydrostatic and hydraulic systems, Figure 30-40-8
I-2003-0888
5
6
Figure 30-40-6
1
3
2
1 3
N-16082
4 Remove the top shuttle check valve plug (Item 1) [Figure

30-40-8].
Remove the shuttle check valve (Item 2) [Figure 30-40-

N-16080 8].
Remove the shuttle check valve seat (Item 3) [Figure 30-

Remove the plug (Item 1) [Figure 30-40-6]. 40-8].
Figure 30-40-7 Remove the plug (Item 3) [Figure 30-40-6].
Remove the top shuttle check valve plug (Item 4) [Figure

30-40-8].
Remove the shuttle check valve (Item 5) [Figure 30-40-

8].
Remove the shuttle check valve seat (Item 6) [Figure 30-

40-8].
1 Inspect all the parts and replace as needed.

2
Remove the plug (Item 4) [Figure 30-40-6].
3
N-16081
Use a allen wrench and remove the top throttle seat (Item
1) [Figure 30-40-7].
Remove the double coned throttle pin (Item 2) [Figure

30-40-7].
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HYDROSTATIC MOTOR (CONT’D) Figure 30-40-11
Shuttle Check Valve (Cont’d)
Figure 30-40-9
1
2
2 1
N-16085
Remove the flushing relief valve spring (Item 1) [Figure

N-16083 30-40-11].
Remove the flushing relief valve (Item 2) [Figure 30-40-

Remove the spring (Item 1) [Figure 30-40-9]. 11].
Remove the spool (Item 2) [Figure 30-40-9]. Inspect all the parts and replace as needed.
Inspect all the parts and replace as needed. Remove the plugs (Item 2) [Figure 30-40-10].
Assembly: Always use new O-rings before installing Figure 30-40-12

plugs.
Flushing Valve 1
2
Figure 30-40-10
2
2 3 1
2
N-16086
Remove the flushing spool springs (Item 1) [Figure 30-

40-12] and washers (Item 2) [Figure 30-40-12].
N-16084
Remove the flushing spool (Item 3) [Figure 30-40-12].
Remove the plug (Item 1) [Figure 30-40-10]. Inspect all the parts and replace as needed.
Assembly: Always use new O-rings when installing

plugs.
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Disassembly
1
IMPORTANT
I-2003-0888
N-16089
Figure 30-40-13
Remove the three O-rings (Item 1) [Figure 30-40-15]

from the end plate housing.
Figure 30-40-16
1
1
1
1
N-16084
1
Remove the four mounting bolts (Item 1) [Figure 30-40- 1
13] at the flushing valve housing.
N-16090
Figure 30-40-14

end plate housing.
Remove the end plate housing.
N-16088
Remove the flushing valve housing (Item 1) [Figure 30-

40-14] from the motor end plate housing.
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Figure 30-40-17
1
1
N-16095
Remove the tamper proof cap (Item 1) [Figure 30-40-19]

N-16091 from the adjustment screw.
Figure 30-40-20
Remove the control lens (Item 1) [Figure 30-40-17] from
the end plate housing.
Figure 30-40-18
1
1
N-16096
Measure the adjustment screw (Item 1) [Figure 30-40-

N-16093 20]. Make a record of this measurement for correct
assembly.
Remove the plug (Item 1) [Figure 30-40-18] and control Remove the adjustment screw from the motor housing.
piston (Item 2) [Figure 30-40-18] from the end plate
housing. Remove the O-ring (Item 2) [Figure 30-40-20] from the
housing.
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Figure 30-40-21
3
1
1
N-16100
Remove the snap ring (Item 1) [Figure 30-40-23],

N-16097 washer (Item 2) [Figure 30-40-23] and seal (Item 3)
[Figure 30-40-23] from the motor housing.
Install a 5 mm bolt (Item 1) [Figure 30-40-21] and Figure 30-40-24

washer into the center pin in the rotating group to hold it
together.
Figure 30-40-22
N-16103
Remove the bolt (Item 1) [Figure 30-40-24] and washer

N-16098 from the rotating group.
Install a bearing puller (Item 1) [Figure 30-40-22] around

the motor housing. Press the rotating group/shaft
assembly from the housing.
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HYDROSTATIC MOTOR (CONT’D) Inspection
Disassembly (Cont'd) Figure 30-40-27
Figure 30-40-25
1 3
N-16108
N-16105
Check the pistons (Item 1) [Figure 30-40-27] for no
scoring and no pitting at the ball socket and piston body.
Remove the rotating group cylinder block from the
pistons [Figure 30-40-25]. Check the piston retainer plate (Item 2) [Figure 30-40-
27] for scoring and no evidence of wear.
Figure 30-40-26
Check the piston rings (Item 3) [Figure 30-40-27] for
wear.
Figure 30-40-28
N-16106
Remove the center pin spring from the center pin [Figure
30-40-26].
N-16109
Check the main shaft driver bearings (Item 1) [Figure 30-

40-28] that they are free of corrosion, erosion and with no
damage to the splines.
If any of the parts on the rotating group or drive shaft

show wear or damage, they must be replaced as an
assembly.
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Inspection (Cont'd)
1
Figure 30-40-29 2
1
1
N-16111
2 Check the cylinder block (Item 1) [Figure 30-40-31] and

2
N-16113A N-16112A control lens (Item 2) [Figure 30-40-31] mating surfaces
for being smooth faces and even, and free of cracks or
scoring.
Remove the pin (Item 1) [Figure 30-40-29] from the
control lens (Item 2) [Figure 30-40-29]. Check the face of If any of the parts on the rotating group/drive shaft
the control lens for being smooth and even, free of cracks assembly show wear or damage they must be replaced
and scoring. as an assembly.
Check the pin for wear. Figure 30-40-32
Figure 30-40-30
N-16102
N-16110
Check the housing at the bearing seats (Items 1 & 2)
[Figure 30-40-32] for scoring and no evidence of wear.
Check the cylinder block bores (Item 1) [Figure 30-40-
30] that they are free of scoring and no evidence of wear.
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Assembly
IMPORTANT
damage the system.
I-2003-0888
Figure 30-40-33
N-16115
N-16106
For easier installation of the piston/piston rings into the
cylinder block, come straight down into the cylinder block
Install the center spring into the center pin. Put grease on bores [Figure 30-40-35].
the washer and install it in the cylinder block center bore
[Figure 30-40-33]. Make sure all the parts are fitted together correctly.
Figure 30-40-34
N-16105
Install the cylinder block on the pistons [Figure 30-40-

34].
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Assembly (Cont'd)
Figure 30-40-36
1
1
N-16099
Install the washer and snap ring (Item 1) [Figure 30-40-

N-16116 38] into the housing.
Figure 30-40-39
Swivel the cylinder block to the minimum angle (straight
up and down) and install the 5 mm bolt (Item 1) [Figure
30-40-36] and washer to hold the rotating group together. 1
Figure 30-40-37
2 3
N-16119
A sleeve (Item 1) [Figure 30-40-39] (Example: MEL1399

Tool), two bolts (Item 2) [Figure 30-40-39] and washers
N-16101 (Item 3) [Figure 30-40-39] will be needed to install the
rotating group/drive shaft assembly into the motor
housing.
Install a new drive shaft seal using a seal driver tool
[Figure 30-40-37]. The correct bolts sizes are as follows:
7/16 x 3 inch NC 14
7/16 x 2-3/4 inch NC 14
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Assembly (Cont'd)
1
Figure 30-40-40
N-16120
1 Remove the bolt and washer (Item 1) [Figure 30-40-42]

N-16117 from the rotating group center pin.
Figure 30-40-43
Start the drive shaft bearing/rotating group assembly into
the motor housing making sure the bearings and shaft
(Item 1) [Figure 30-40-40] are centered in the housing. 2
1
Figure 30-40-41
1
N-16113
2
Install the pin (Item 1) [Figure 30-40-43] into the control
lens (Item 2) [Figure 30-40-43].
N-16118
Install the tool (Item 1) [Figure 30-40-41], bolt and

washer(s) (Item 2) [Figure 30-40-41] on the end of the
drive shaft.
Make sure the drive shaft bearing is being pulled straight

into the motor housing with no binding, pull the assembly
into the housing by turning the bolt until it bottoms on the
end of the drive shaft. Remove the bolt and install the
shorter bolt and continue to install the drive shaft bearing
until it is fully seated in the motor housing.
Remove the bolt, washer and tool from the drive shaft.
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Assembly (Cont'd)
1
Figure 30-40-44
N-16091
2
Install the control lens (Item 1) [Figure 30-40-46] into the
N-16092 end plate housing with the pin going into the control
piston.
Install the control piston (Item 1) [Figure 30-40-44] into Figure 30-40-47
the end plate housing.
Install the plug (Item 2) [Figure 30-40-44] and tighten.
Figure 30-40-45
N-16122
Install the end plate housing (Item 1) [Figure 30-40-47]

on the motor housing and rotating group.
N-16121
Install the end plate housing bolts.
Put grease on the control lens [Figure 30-40-45]. Tighten the bolts evenly until there is a small amount of
pre-load on the rotating group cylinder block and control
lens.
This pre-load is necessary so the adjustment screw can

be installed.
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Assembly (Cont'd)
1
Figure 30-40-48
1
N-16089
Install the new O-rings (Item 1) [Figure 30-40-50].

N-16123
Figure 30-40-51
Install the adjustment screw (Item 1) [Figure 30-40-48]

into the housing. 1
Adjust the adjustment screw to the correct dimension

recorded when the screw was removed. (See
Disassembly on Page 30-40-5.) [Figure 30-40-20].
2
Replace the tamper proof cap on the adjustment screw. 2
Figure 30-40-49
N-16087
1
1 Install the flushing valve (Item 1) [Figure 30-40-51].
Install the bolts (Item 2) [Figure 30-40-51] and tighten to

85 in.-lbs. (9,6 Nm) torque.
Pour about 1 qt. (0,9 L.) of hydraulic fluid into the

1 1 hydrostatic motor case before installation.
N-16090
Tighten the bolts (Item 1) [Figure 30-40-49] at the end

plate housing to 36 ft.-lbs. (48 Nm) torque.
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HYDROSTATIC MOTOR (CONT’D) Neutral Adjustment
Cover Removal And Installation Figure 30-40-54

Figure 30-40-52
N-15881
N-15872 With a second person in the operator seat, seat belt

fasten, and seat bar down.
Remove the wheel nuts and remove the tire/wheel Start the engine.
assembly from the hub [Figure 30-40-52].
Engine at full RPM and two speed switch in high range,
Installation: Tighten the wheel nuts to 320-350 ft.-lbs. check the wheel RPM. Move the steering lever fully
(434-475 Nm) torque. forward with a hand held tachometer (Item 1) [Figure 30-
40-54], on each side of the loader.
Figure 30-40-53
If the wheel speeds are different the hydrostatic motor
must be adjusted.
Remove the motor access cover (both sides). ((See

Cover Removal And Installation on Page 30-40-15.))
1
1 1
N-15873

from the motor access cover.
Installation: Tighten the mounting bolts to 220-245ft.-

Remove the access cover from the loader frame.
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HYDROSTATIC MOTOR (CONT’D)
Neutral Adjustment (Cont’d)
Figure 30-40-55
P-10536
Remove the tamper proof cap and loosen the set screw
jam nut on the bottom of the motor (Item 1) [Figure 30-
40-55].
Turn the set screw out or in matching the wheel speed

from one side of the loader to the other side. About 1/4
turn on the set screw will equal one RPM for wheel
speed.
Factory specification is 92 wheel RPM (full engine RPM

and high range). DO NOT exceed this wheel RPM.
Install the new tamper proof cap after the adjustment is

done.
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CHARGE PRESSURE Figure 30-50-2
Checking The Charge Pressure
Figure 30-50-1
1
N-21836
2
The diagnostic coupler (Item 1) [Figure 30-50-2] at the
N-21838 left side of the brake/two-speed block, checks the
controller pressure. Run the engine at full RPM and
transmission not stroked. Connect a gauge to the coupler
Check the charge pressure with the engine at full RPM and the normal operating pressure should be 406 PSI
and the hydraulic fluid temperature at about 150°F. (65° (2868 kPa).
C.).
Connect a gauge to the diagnostic coupler (Item 1)

[Figure 30-50-1] located on the back side of the brake/
two speed block, to check the left charge pump. The
pressure reading should be 319 PSI (2200 kPa).
Connect a gauge to the diagnostic coupler (Item 2)

[Figure 30-50-1] located on the back side of the brake/
two speed block, to check the right charge pump. The
pressure reading should be 406 PSI (2868 kPa).
If the pressure is not correct, adjust the charge relief

valve. (See Charge Relief Valve on Page 30-60-3.)
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HYDROSTATIC PUMP Figure 30-60-3
Figure 30-60-1
N-15834

N-15832 pump mounting bracket.
Installation: Tighten the mounting bolts to 65-70 ft.-lbs.

Remove the hydrostatic pump/engine assembly from the (88-95 Nm) torque.
loader. (See Removal And Installation on Page 70-80-1.)
Figure 30-60-4
Remove the drive belt from the pump pulley. (See
Replacement on Page 30-70-2.)
Remove the nut (Item 1) [Figure 30-60-1] and washer

from the hydrostatic pump drive shaft.
Installation: Tighten the nut to 200 ft.-lbs. (271 Nm)

torque.
1
Figure 30-60-2
N-15837
Remove the mounting bolts (Item 1) [Figure 30-60-4] at

1
the hydraulic pump mounting bracket.
Lift the hydrostatic pump with the chain hoist and remove
from the engine mounting bracket.
Remove the hydraulic pump from the hydrostatic pumps.

N-15833
Use a puller (Item 1) [Figure 30-60-2] to remove the

pulley from the pump drive shaft.
Connect a chain hoist to the hydrostatic pump.
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HYDROSTATIC PUMP (CONT’D) Figure 30-60-6
Replenishing/High Pressure Relief Valve
IMPORTANT
I-2003-0888
N-16126
Figure 30-60-5
Remove the plug(s) (Item 1) [Figure 30-60-6].
Figure 30-60-7
1 1
1
2
N-16050
There are four replenishing/high pressure relief valves

(Item 1) [Figure 30-60-5] in the hydrostatic pump N-16125
assembly.
Two are located at the top of the pumps and two are Remove the spring (Item 1) [Figure 30-60-7] and high
located at the bottom of the pumps. pressure relief valve (Item 2) [Figure 30-60-7] from the
pump.
Check for damage and replace as needed.
Installation: Tighten the main relief plug to 30 ft.-lbs. (41

Nm) torque.
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Charge Relief Valve
IMPORTANT 4
3

tubelines and ports to keep dirt out. Dirt can quickly 1
damage the system.
I-2003-0888
N-16127
Figure 30-60-8
Remove the charge relief (Item 1) [Figure 30-60-9], seat

(Item 2) [Figure 30-60-9], shims (Item 3) [Figure 30-60-
9] and spring (Item 4) [Figure 30-60-9].
Installation: Tighten the charge relief valve to 30 ft.-lbs.

(41 Nm) torque.
1 DA Controller
2 Loosen the DA controller (Item 2) [Figure 30-60-8].
Figure 30-60-10
N-16126
Loosen the charge relief valve (Item 1) [Figure 30-60-8].
N-16128
Remove the DA controller assembly (Item 1) [Figure 30-

60-10] from the port block.
The DA controller can not be adjusted and must be

replaced as an assembly.
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Disassembly
1
IMPORTANT
damage the system.
I-2003-0888
1
N-16132
Figure 30-60-11
Loosen the two replenishing/high pressure relief valves

(Item 1) [Figure 30-60-13].
Figure 30-60-14
N-16129 1
Remove the bolt (Item 1) [Figure 30-60-11] from both

sides of the hydrostatic pump assembly.
N-16133
Figure 30-60-12
Remove the replenishing/high pressure relief valves

(Item 1) [Figure 30-60-14] from the port block.
N-16130
Separate the two pump halves [Figure 30-60-12].
Remove the large O-ring (Item 1) [Figure 30-60-12].
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Figure 30-60-15
N-16135
3
1
2 Remove the four mounting bolts (Item 1) [Figure 30-60-
N-16134 17] from the charge pump.
Figure 30-60-18
Remove the charge relief valve (Item 1) [Figure 30-60-
15], seat (Item 2) [Figure 30-60-15] and spring (Item 3)
[Figure 30-60-15] from the port block.
Figure 30-60-16
N-16138
Remove the charge pump (Item 1) [Figure 30-60-18]

from the port block.
N-16143
Use a punch and hammer to mark the charge pump

housing and port block housing for correct installation of
the charge pump [Figure 30-60-16].
Mark the port block to the pump housing for correct

installation.
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Figure 30-60-19
2
1
1
N-16142

N-16139 the charge pump housing.
Figure 30-60-22
Remove the coupler (Item 1) [Figure 30-60-19] and key
from the pump shaft.
Remove the large O-ring (Item 2) [Figure 30-60-19].
Figure 30-60-20
1
1 1
N-16146
Remove the four mounting bolts (item 1) [Figure 30-60-

22] from the port block.
N-16141
Remove the charge pump wear plate (Item 1) [Figure

30-60-20].
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Figure 30-60-23
2
1
N-16152

N-16149 the pump housing.
Remove the tamper proof cap (Item 2) [Figure 30-60-25]

Remove the port block (Item 1) [Figure 30-60-23] from from the adjustment screw.
the pump housing.
Figure 30-60-26
Figure 30-60-24
1
1
N-16153
N-16150
Put a mark (Item 1) [Figure 30-60-26] on the pump

Remove the valve plate (Item 1) [Figure 30-60-24] from housing in alignment with the notch (Item 2) [Figure 30-
the port block. 60-26] on the adjustment screw. This mark is needed for
correct installation of the adjustment screw.
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Figure 30-60-27
N-16159
Remove the swashplate/bearing assembly from the

N-16154 pump housing [Figure 30-60-29].
Figure 30-60-30
Push down on the rotating group and remove the
eccentric adjustment screw from the housing [Figure 30-
60-27].
Figure 30-60-28
1
N-16160
Remove the bearing races (Item 1) [Figure 30-60-30]

from the pump housing.
N-16155
Remove the rotating group assembly from the pump

housing [Figure 30-60-28].
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Figure 30-60-31
1 1
N-16168
Turn the servo piston cover counterclockwise to remove it

N-16166 from the servo piston adjustment screw [Figure 30-60-
33].
Remove the four bolts (Item 1) [Figure 30-60-31] from Figure 30-60-34
the servo piston cover.
Figure 30-60-32
1
N-16169
N-16167 Remove the servo piston (Item 1) [Figure 30-60-34] from

the pump housing bore.
Remove the lock nut at the servo piston adjustment

screw [Figure 30-60-32].
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Figure 30-60-35
N-16173
1
Left Pump: Remove the snap ring (Item 1) [Figure 30-60-
N-16170 37] at the pump drive shaft seal.
Figure 30-60-38
Check the piston servo bushing(s) (Item 1) [Figure 30-
60-35] for wear and damage, if they need replacement,
remove the snap ring (Item 2) [Figure 30-60-35].
Figure 30-60-36
N-16174
Left Pump: Use a puller with a screw tip and remove the
shaft seal from the pump housing [Figure 30-60-38].
N-16172
Remove the snap ring, bushing and snap ring from the
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Figure 30-60-39
N-16175
1
Left Pump: Remove the snap ring (Item 1) [Figure 30-60-
39] at the drive shaft bearing.
Figure 30-60-40
N-16195
Right Pump: Remove the snap ring (Item 1) [Figure 30-

60-41] from the drive shaft seal.
N-16176
Left Pump: Remove the drive shaft from the pump

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2
Figure 30-60-42
N-16150
Check the valve plate (Item 1) [Figure 30-60-44], the

N-16196 surface must be smooth and free of scratches. If
scratches can be felt with a fingernail, replace the parts.
Right Pump: Use a puller with a screw tip and remove the Check the port block bearing (Item 2) [Figure 30-60-44]
seal from the pump housing [Figure 30-60-42]. for wear, replace as needed.
Right Pump: Repeat the procedure from the left pump to Figure 30-60-45
remove the drive shaft ([Figure 30-60-19] & [Figure 30-
60-20]; (See Disassembly on Page 30-60-4.)
2
Inspection
Figure 30-60-43 1
N-16184
Check the swashplate (Item 1) [Figure 30-60-45], the

surface must be smooth and free of scratches.
N-16144 Check the servo piston (Item 2) [Figure 30-60-45] for

wear or damage.
Clean all the parts in solvent and use air pressure to dry Replace the parts as needed.
them. DO NOT use cloth or paper because small pieces
of material can get into the system and cause damage.
Check the charge pump gears for wear and damage

[Figure 30-60-43].
Check the pump housing for wear and damage [Figure

30-60-43].
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Inspection (Cont'd)
Figure 30-60-46
1
N-16156
Check that each piston move freely in its bore [Figure

N-16179 N-16181 30-60-48].
Check each piston and piston shoe for wear or scratches.

Check the swashplate bearing (Item 1) [Figure 30-60-46]
for wear and damage, replace as needed. Check the shoe plate, the shoe plate must be flat with no
signs of cracks or wear.
Figure 30-60-47
Check the end of the cylinder block, the surface must be
smooth and free of scratches.
1
2 Figure 30-60-49
2
1
N-16180 N-16183
1
Check the swashplate bearing (Item 1) [Figure 30-60-47]

and servo piston block (Item 2) [Figure 30-60-47] for
N-16157
wear and damage. Replace the parts as needed.
Check the cylinder block bores for wear and scratches

[Figure 30-60-49].
Check the spherical washer (Item 1) [Figure 30-60-49]

for wear or damage.
Check the pins (Item 2) [Figure 30-60-49], the pins must

not be bent and the same length.
If there is any defect in the rotating group, the complete

unit must be replaced.
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HYDROSTATIC PUMP (CONT’D) Assembly
Inspection (Cont'd)
Figure 30-60-50
IMPORTANT
damage the system.
I-2003-0888
Figure 30-60-52
N-16177
Check the shaft for wear or damaged in the spline and

bearing areas [Figure 30-60-50]. 2
1
Check the bearing for correct operation. Remove the
bearing from the shaft only if it is necessary to replace
the bearing [Figure 30-60-50].
Figure 30-60-51
N-16175
Right Pump: Install the drive shaft (Item 1) [Figure 30-

60-52] into the pump housing.
Install the snap ring (Item 2) [Figure 30-60-52].
Figure 30-60-53
N-16172
Check the servo piston busing for wear or damage

[Figure 30-60-51].
Check the snap rings for not being bend [Figure 30-60-
51]. Replace the parts as needed.
N-16178
Right Pump: Install the drive shaft seal using a bearing

driver tool [Figure 30-60-53].
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Assembly (Cont'd)
Figure 30-60-54
N-16173
Right Pump: Install the snap ring (Item 1) [Figure 30-60-

54] into the pump housing.
Left Pump: Install the drive shaft and snap ring into the
pump housing.
Figure 30-60-55 N-16195
Left Pump: Install the snap ring (Item 1) [Figure 30-60-

56] into the housing.
N-16197
Left Pump: Install the drive shaft seal using a bearing

driver tool [Figure 30-60-55].
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Assembly (Cont'd)
Figure 30-60-57
N-16169
Install the servo piston (Item 1) [Figure 30-60-58] into

the pump housing.
Figure 30-60-59
3 1
N-16171
Install the snap ring (Item 1) [Figure 30-60-57] into the N-16168
housing.
Install the servo piston cover by turning it clockwise
Install a new O-ring on the servo bushing (Item 2)
[Figure 30-60-59].
[Figure 30-60-57].
HYDROSTATIC PUMP (CONT’D)
Install the servo bushing (Item 2) [Figure 30-60-57] into
the pump housing.
Assembly (Cont'd)
Install the other snap ring (Item 3) [Figure 30-60-57] into
the housing.
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Figure 30-60-60 Install the bearing, servo block and linkage rod on the
swashplate [Figure 30-60-62].
Put grease on all the parts to hold them together.
Figure 30-60-63
1 1
N-16166
1
Install the four mounting bolts (Item 1) [Figure 30-60-60]
and tighten to 85 in.-lbs. (9,6 Nm) torque.
N-16179
Figure 30-60-61
Install the bearing (Item 1) [Figure 30-60-63] and linkage

rod (Item 2) [Figure 30-60-63] on the swashplate.
1 Put grease on all the parts to hold them together.
N-16161
Install the bearing races (Item 1) [Figure 30-60-61] into

the pump housing.
Figure 30-60-62
N-16182
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Assembly (Cont'd)
2
Figure 30-60-64
N-16158 N-16184
1
2
After the swashplate is installed, make sure the servo
N-16186 block (Item 1) [Figure 30-60-66] is engaged in the slot in
the servo piston (Item 2) [Figure 30-60-66].
Remove the plug (Item 1) [Figure 30-60-64] and locating Figure 30-60-67
pin (Item 2) [Figure 30-60-64] from the housing.
Figure 30-60-65
1 2
N-16185 N-16187
N-16159 At the other side of the swashplate, align the linkage rod
(Item 1) [Figure 30-60-67] so when the slotted locating
pin (Item 2) [Figure 30-60-67] is installed it will go over
Install the swashplate/bearing assembly into the pump the linkage rod. Install and tighten the plug.
To set neutral at the servo piston and swashplate, do the
following procedure:
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Assembly (Cont'd)
Figure 30-60-68
2
N-16167
1 Hold the adjustment screw and tighten the lock nut

[Figure 30-60-69].
Figure 30-60-70
N-16188
Put a straight edge (Item 1) [Figure 30-60-68] across the

pump housing.
N-16189
Use a calipers (Item 2) [Figure 30-60-68] and measure
the distance on one side of the swashplate. Then
measure the other side of the swashplate. Put a rubber band around the pistons to hold them in
position [Figure 30-60-70].
Turn the servo piston adjustment screw (Item 3) [Figure
30-60-68] until both sides of the swashplate measure the
same distance.
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Assembly (Cont'd)
Figure 30-60-71
N-16191
Put grease on the valve plate and install it on the port

block [Figure 30-60-72].
Figure 30-60-73
N-16190
Install the rotating group assembly into the pump housing N-16192
[Figure 30-60-71].
When the rotating group is seated on the swashplate, Install the port block/valve plate assembly (Item 1)
release the rubber band and remove it from the pistons. [Figure 30-60-73] on the pump housing and rotating
group.
Install the four bolts into the port block and tighten evenly
until a small amount of space (Item 2) [Figure 30-60-73]
is left between the pump housing and port block.
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Assembly (Cont'd)
Figure 30-60-74
2
N-16150
N-16194
1
Install the eccentric adjustment screw into pump housing
[Figure 30-60-75].
As the eccentric adjustment screw is installed, you will

feel, no resistance and small amount of resistance as the
screw is turned into the valve plate.
Figure 30-60-76
1
N-16193
Using a small screwdriver (Item 1) [Figure 30-60-74],

make alignment of the slot (Item 2) [Figure 30-60-74] in
the valve plate with the hole the eccentric adjustment
screw will turn into housing. The adjustment screw will
turn into the slot in the valve plate. N-16153
Turn the adjustment screw until it bottoms in the valve

plate slot, then turn the adjustment screw back out until
the marks (Item 1) [Figure 30-60-76] are aligned.
Tighten the lock nut [Figure 30-60-76].
Install a new tamper proof cap on the eccentric

adjustment screw.
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Assembly (Cont'd)
Figure 30-60-77 1
N-16141
Figure 30-60-80
N-16147
Tighten the bolts at the port block to 85 ft.-lbs. (118 Nm)

torque [Figure 30-60-77].
Figure 30-60-78
N-16140
Install the wear plate with the large opening (Item 1)

[Figure 30-60-79] toward the intake and pressure side of
1 the charge pump [Figure 30-60-80].
N-16142
Install the large O-ring (Item 1) [Figure 30-60-78] on the

charge pump housing.
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Assembly (Cont'd)
Figure 30-60-81
1
N-16136
2
Tighten the charge pump mounting bolts to 34 ft.-lbs. (46
N-16145 Nm) torque [Figure 30-60-83].
Figure 30-60-84
Install the coupler (Item 1) [Figure 30-60-81] and key
into the pump drive shaft.
Install the large O-ring (Item 2) [Figure 30-60-81] on the

pump housing.
Figure 30-60-82
1
N-16131
1
Install the large O-ring (Item 1) [Figure 30-60-84] into the
charge pump.
N-16137
Install the charge pump into the port block [Figure 30-60-
82].
Install the four mounting bolts (Item 1) [Figure 30-60-82].
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Assembly (Cont'd)
Figure 30-60-85
N-16130
3
2
1 Install the two hydrostatic pump halves together [Figure
N-16134 30-60-87].
Figure 30-60-88
Install the spring (Item 1) [Figure 30-60-85], seat (Item 2)
[Figure 30-60-85] and charge relief valve (Item 3)
[Figure 30-60-85] into the port block.
Tighten the charge relief valve to 30 ft.-lbs. (41 Nm)

torque.
Figure 30-60-86
N-16129
1 Install the bolt (Item 1) [Figure 30-60-88] and tighten to

75 ft.-lbs. (102 Nm) torque (both sides).
Hydrostatic Pump Start-Up
N-16133 Disconnect the fuel shut-off solenoid at the fuel injection

pump.
Install the replenishing/high pressure relief valves (Item Crank the engine, with the starter, for 15-20 seconds.
1) [Figure 30-60-86] into the port block.
Connect the fuel shut-off solenoid.
Tighten the valves to 30 ft.-lbs. (41 Nm) torque.
Start the engine and run at idle speed for 5-7 minutes
before operating the loader. Do Not run the engine above
idle speed while doing the above procedure.
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Neutral Adjustment
Figure 30-60-89 1
1 N-21627
Install a hydraulic hose between the two hydrostatic

N-21537 fittings (Item 1) [Figure 30-60-90] and tighten.
Figure 30-60-91
After the hydrostatic pumps have been disassembled and
assembled, the servo pistons (Item 1) [Figure 30-60-89]
must be adjusted to find neutral.


on Page 10-70-1.)

on Page 10-90-1.)
1
NOTE: Mark all the hoses before disconnecting them
for correct installation. N-21628
Disconnect and cap the two hydraulic hoses (Item 2)

[Figure 30-60-89] from the top of the right hydrostatic With a deep-well socket loosen the jam nut (Item 1)
pump servo. [Figure 30-60-91].
Start the loader and run the engine at an idle.
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Neutral Adjustment (Cont'd)
WARNING
servicing machine. Read and understand the
Operation & Maintenance Manual, Handbook and
instructions in the manuals when making repairs, 1
N-15496C
injury or death.
W-2003-0199
With an allan wrench turn the adjustment screw (Item 1)
[Figure 30-60-93] counterclockwise until the wheels start
Figure 30-60-92 to creep in the opposite direction, mark the cap [Figure
30-60-94].
Turn the adjustment screw (Item 1) until it is half way

between the two marks.
Lock the jam nut.

1
Repeat the procedure for the opposite pump.
N-15496A
With an allan wrench turn the adjustment screw (Item 1)

[Figure 30-60-92] clockwise until the wheels start to
creep, mark the cap [Figure 30-60-92].
Figure 30-60-93
N-15496B
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Timing Procedure
Figure 30-60-95
1
2
1
P-16135
Install a tee-fitting (Item 1) [Figure 30-60-96] and re-

N-20758 connect the hose to the bottom of the tee-fitting [Figure
30-60-96].
Lift and block the loader. (See LIFTING AND BLOCKING Disconnect the hose (Item 2) [Figure 30-60-96] at left
THE LOADER on Page 10-20-1.) hydrostatic controller, from the port marked 1 on the
controller block.
on Page 10-70-1.) Figure 30-60-97

on Page 10-90-1.)
After the hydrostatic pumps have been disassembled and

assembled, you need to set the output pressure between
the pumps so they are equal, use the following
1
procedure.
NOTE: Mark all the hoses before disconnecting them

for correct installation.
Disconnect the hose (Item 1) [Figure 30-60-95] at left

hydrostatic controller, from the port marked 2 on the
controller block. P-16136
Install a tee-fitting (Item 1) [Figure 30-60-97] and re-

connect the hose to the bottom of the tee-fitting [Figure
30-60-97].
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Timing Procedure (Cont'd)
Figure 30-60-98
P-16139
Connect the hose that was remove from the right

P-16137 controller, to the T-fitting at the left controller (Item 1)
[Figure 30-60-100], at the port marked 2 and tighten.
Disconnect the hose (Item 1) [Figure 30-60-98] at right Figure 30-60-101

hydrostatic controller, from the port marked 1 on the
controller block.
Figure 30-60-99
P-16138
1
Disconnect the hose (Item 1) [Figure 30-60-101] at right

P-16138 hydrostatic controller, from the port marked 2 on the
controller block.
Install a cap (Item 1) [Figure 30-60-99] and tighten.
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Figure 30-60-102
P-16142
Disconnect the hydraulic hose (Item 1) [Figure 30-60-

P-16140 104] that comes from the hydrostatic pump to the DA
fitting on the brake/two speed block.
Install a cap (Item 1) [Figure 30-60-102] and tighten. Figure 30-60-105
Figure 30-60-103
P-16143
P-16141
that connects to the P port on the left side controller.
Connect the hose that was removed from the right
controller, to the T-fitting at the left controller (Item 1) Plug the hydraulic hose.
[Figure 30-60-103], at the port marked 1 and tighten.
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Figure 30-60-106
N-15496
Figure 30-60-109
P-16144
Connect and tighten the hydraulic hose (Item 1) [Figure

30-60-106] (that was disconnected earlier (Item 1)
[Figure 30-60-104] from the DA port on the brake/two 1
speed block), to the P port on the left controller.
Figure 30-60-107
N-16080
At the hydrostatic motor (Item 1) [Figure 30-60-108]

(both sides), remove the G port plug (Item 1) [Figure 30-
1 60-109], connect a 10000 PSI (68950 kPa) gauge.
Start the engine and run at full RPM.
P-16145 NOTE: Do not stroke the hydrostatic pump for more

than 20 seconds at a time when checking the
pressure.
Install a cap (Item 1) [Figure 30-60-107] on the fitting
and tighten. Push the left hydrostatic controller forward and note the
pressure on both gauges at the motors. If the pressures
The pressure used to actuate the pumps will be are different, the pump timing needs to be adjusted.
controlled by the DA controller in the hydrostatic pump
and the output of the left controller is actuating both
pumps evenly while the right controller is not connected.
Remove the hydrostatic motor cover (both sides). (See

Cover Removal And Installation on Page 30-40-15.)
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Figure 30-60-110
1 N-16153
NOTE: A small adjustment makes a large difference

N-15847 in the output pressure. This adjustment screw
(Item 1) [Figure 30-60-111] has an adjustment
range from 12 o'clock to 6 o'clock with 3
Remove the tampered proof caps (Item 1) [Figure 30-60- o'clock being the nominal. Do not turn the
110] to turn the adjustment screws. adjustment screw beyond the 12 or 6 o'clock
position.
With the engine at full RPM and the pump stroked
pressure should be approximately 3400 PSI (23443 kPa). To raise the pressure turn the adjustment screw (Item 1)
Be more concerned with the pressure being the same [Figure 30-60-111] toward the 6 o'clock position. To
than with the 3400 PSI (23443 kPa) pressure. lower the pressure turn the screw toward the 12 o'clock
position.
Depending on the situation one or both pumps may need
adjusting. The pump that is furthest from the nominal Install new tamper proof caps on the adjustment screw
3400 PSI (23443 kPa) should be adjusted first. after the procedure is completed.
For example; one pump is at 3600 PSI (24882 kPa) and

the other pump is at 3300 PSI (22753 kPa). The 3600
PSI (24882 kPa) pump should be lowered to 3300 PSI
(22753 kPa). If the pump does not drop enough to match,
raise the pressure on the other pump. Try to equal the
pressure on both pumps as close to 3400 PSI (23443
kPa) as possible.
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DRIVE BELT Figure 30-70-2
Shield Removal And Installation
Figure 30-70-1
N-16236
2
Remove the bolt (Item 1) [Figure 30-70-2] at the wire
harness clip.
1
Figure 30-70-3
N-15765
Open the rear door. N-15766

at the belt shield. Remove the belt shield from the loader [Figure 30-70-3].
Remove the three mounting bolt (Item 2) [Figure 30-70-

1] at the top of the belt shield.
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DRIVE BELT (CONT’D) Figure 30-70-6
Replacement
Figure 30-70-4
2
3
N-15822
Remove the drive belt shield. (30-70-1.))
The drive belt idler arm stop (Item 1) [Figure 30-70-4] is

located on the right side of the engine mounting bracket.
Loosen the bolt (Item 2) [Figure 30-70-4].
Remove the bolt (Item 3) [Figure 30-70-4] and spacer.

N-15773
Slide the idler arm stop toward the front of the loader.
Figure 30-70-5 Remove the drive belt from the loader [Figure 30-70-6].
Adjustment
There is no adjustment for the spring, just make sure the

spring bolt (Item 1) [Figure 30-70-5] is tight.
Loosen the two bolts (Items 2 & 3) [Figure 30-70-4] and

slide the stop (Item 1) [Figure 30-70-4] against the idler
arm. Tighten the bolts.
1
N-15772
Loosen the spring tension bolt (Item 1) [Figure 30-70-5].
Remove the drive belt from the hydrostatic pump pulley

and the flywheel pulley.
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Tensioner Pulley Removal And Installation
Remove the drive belt shield. (See Shield Removal And 2

Installation on Page 30-70-1.) 1
Figure 30-70-7
N-15824
1 Remove the bolt (Item 1) [Figure 30-70-9] and spacer.

2
Remove the idler arm stop (Item 2) [Figure 30-70-9].
N-15822 Figure 30-70-10
Loosen the bolt (Item 1) [Figure 30-70-7] on the drive

belt idler stop.
Remove the bolt (Item 2) [Figure 30-70-7] and spacer 1

and slide the idler arm stop toward the front of the loader.
Figure 30-70-8
N-15825
Remove the end cap (Item 1) [Figure 30-70-10] from the

tension pulley arm.
Installation: Fill the end cap with grease to lubricate the

pivot shaft.
N-15823
Loosen the spring tension bolt (Item 1) [Figure 30-70-8].
Remove the spring tension bolt.
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DRIVE BELT (CONT’D) Tensioner Pulley Disassembly And Assembly
Tensioner Pulley Removal And Installation (Cont'd) Figure 30-70-13
Figure 30-70-11
1
2
1
N-15851
N-15827
Remove the arm seal (Item 1) [Figure 30-70-13] and arm
bushing (Item 2) [Figure 30-70-13]. Check for wear and
Remove the bolt (Item 1) [Figure 30-70-11] from the replace if needed.
drive belt tension pulley arm and remove the assembly.
Figure 30-70-14
Tensioner Tension Spring
Figure 30-70-12
1 2
N-15852
4 3
5
N-15842 Disassemble the pulley and bearings as shown in figure
[Figure 30-70-14]. Check the parts for wear and replace
if needed.
Remove the tension spring assembly from the tension
pulley assembly by removing the snap ring and washer
(Items 1 & 2) [Figure 30-70-12].
Remove the end blocks (Item 3) [Figure 30-70-12] from

the spring and check for wear, replace if needed.
Remove the spring pivot pin (Item 4) [Figure 30-70-12]

from the end block by loosening the nut (Item 5) [Figure
30-70-12].
Check the pin for wear and replace if needed.
Check the spring for wear and replace if needed.
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DRIVE BELT (CONT’D) Tensioner Pivot Shaft
Tensioner Pulley Disassembly And Assembly Figure 30-70-16

(Cont’d)
Figure 30-70-15
1 1
N-15836
N-15853 Remove the pivot shaft (Item 1) [Figure 30-70-16] from

the engine mounting bracket.
Remove the pulley mounting bolt (Item 1) [Figure 30-70- Figure 30-70-17
15] from the pulley spindle (Item 2) [Figure 30-70-15]
and remove the spindle from the arm. Check the pulley
spindle for wear and replace if needed.
N-15845
Remove the bushing (Item 1) [Figure 30-70-17] from the

pivot shaft. Check for wear and replace if needed.
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Idler Pulley Removal And Installation
Figure 30-70-18
N-15840
Disassemble the pulley and bearings as shown in figure

P10512 [Figure 30-70-20]. Check the parts for wear and replace
if needed.
Remove the end cap (Item 1) [Figure 30-70-18] from the Figure 30-70-21
drive belt idler pulley.
Figure 30-70-19
N-15835
P10513 Check the idler shaft (Item 1) [Figure 30-70-21] for wear.
The idler shaft can be replaced by removing the

Remove the mounting bolt and washer (Item 1) [Figure mounting bolt located on the backside of the mounting
30-70-19] from the idler pulley. bracket.
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OIL COOLER Figure 30-80-2
2
1
IMPORTANT
damage the system.
I-2003-0888
N-15794
Figure 30-80-1
Remove the two nuts at the bolts (Item 1) [Figure 30-80-

2].
1 Remove the oil cooler mounting bracket (Item 2) [Figure

30-80-2].
Raise the oil cooler and lift from the loader frame.
N-15793
Open the rear door.
Remove the rear grill. (See REAR GRILL on Page 50-60-

1.)
Disconnect the hose (Item 1) [Figure 30-80-1] at the oil

cooler (both sides).
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DRIVE SYSTEM
BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1
Parking Brake Disassembly And Assembly . . . . . . . . . . . 40-10-10
Parking Brake Removal And Installation . . . . . . . . . . . . . . 40-10-9 SAFETY &
Pedal Disassembly And Assembly . . . . . . . . . . . . . . . . . . 40-10-2 MAINTENANCE
Pedal Removal And Installation . . . . . . . . . . . . . . . . . . . . . 40-10-1
Two Speed Block Disassembly And Assembly . . . . . . . . . 40-10-4
Two Speed Block Removal And Installation. . . . . . . . . . . . 40-10-3
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 40-30-1
Front Chaincase Cover Removal And Installation . . . . . . . 40-30-1 DRIVE
Rear Chaincase Cover Removal and Installation . . . . . . . 40-30-1 SYSTEM
Reduction Gearcase Disassembly And Assembly. . . . . . . 40-30-6
Reduction Gearcase Removal And Installation . . . . . . . . . 40-30-2
Removing The Oil From The Chaincase . . . . . . . . . . . . . 40-30-14
DRIVE COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

Axle, Bearings And Sprocket Removal And Installation. . . 40-20-4
Axle Seal Removal And Installation . . . . . . . . . . . . . . . . . . 40-20-1 ELECTRICAL
Drive Chains Removal And Installation . . . . . . . . . . . . . . . 40-20-9 SYSTEM &
ANALYSIS
ENGINE
SERVICE
SPECIFICATIO
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BRAKE Figure 40-10-3
Pedal Removal And Installation
Figure 40-10-1
1 2
N-15454
Open the front clean-out cover (Item 1) [Figure 40-10-3].

N-15453
Pull the wire harness tube (Item 2) [Figure 40-10-3]
through the opening to remove it from under the front
Raise the operator cab. (See Raising The Operator Cab panel. Remove the parking brake pedal bracket/wire
on Page 10-70-1.) harness assembly from the loader.
Disconnect the wire harness connector (Item 1) [Figure

40-10-1] for the parking brake.
Figure 40-10-2
N-15452

from the parking brake pedal mounting bracket.
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BRAKE (CONT’D) Figure 40-10-5
Pedal Disassembly And Assembly

1
Figure 40-10-4
5
6
2
1
4 P-4156
Remove the harness mounting clamp (Item 1) [Figure

3 2 40-10-5] from the pedal mounting bracket (Item 2)
P-4189
[Figure 40-10-5].
Loosen and remove the mounting bolt (Item 1) [Figure Remove the sensor harness from the pedal mounting
40-10-4] and nut from the spring mounting bracket (Item bracket.
2) [Figure 40-10-4].
Remove the pedal mounting bolt (Item 6) [Figure 40-10-
Remove the brake pedal spring (Item 3) [Figure 40-10-4] 4], plastic spacers and bushing nut from the brake pedal.
from the tension spring mounting bracket (Item 2)
[Figure 40-10-4] and from the brake pedal mounting Remove the pedal from the pedal mounting bracket.
bracket (Item 4) [Figure 40-10-4].
Photo [Figure 40-10-5] shows the parking brake
Remove the two mounting bolts, washers and nuts (Item disassembled to identify the existing parts in the brake
5) [Figure 40-10-4] from the brake pedal sensor. assembly.
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Two Speed Block Removal And Installation
Figure 40-10-6
3
1
1
2 2
3 2 N-20785
Disconnect the three hydraulic hoses (Item 1) [Figure

N-20784 40-10-7] from the rear of the valve.

Lift and block the loader. (See LIFTING AND BLOCKING 40-10-7] from the right side of the valve.
Raise the operator cab. (See Raising The Operator Cab from the front of the valve.
on Page 10-70-1.)
Figure 40-10-8
Remove the loader control panel. (See Removal And

from the charge pressure sender.

from the brake solenoid.
2
from the two speed solenoid.
Mark all hydraulic hoses for proper installation.

1
N-20786
Disconnect the two hydraulic hoses (Item 1) [Figure 40-

10-8] from the left side of the valve.

from the valve.
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Two Speed Block Removal And Installation (Cont’d)
Figure 40-10-9
1
N-21839
Loosen the electrical solenoid nut (Item 1) [Figure 40-10-

N-20787 11] from the two speed solenoid.
Assembly: Tighten the nut to 9-12 in.-lbs. (1,02-1,36

Remove the valve from the loader [Figure 40-10-9]. Nm) torque.
Two Speed Block Disassembly And Assembly Figure 40-10-12
Figure 40-10-10
1 N-21840
N-20787
Remove the solenoid valve (Item 1) [Figure 40-10-12]
from the block.
Mark all hydraulic hoses and fittings for proper
installation. Assembly: Always install new O-rings and back-up
washers. Tighten the solenoid valve to 96-144 in.-lbs.
Remove the hydraulic hoses (Item 1) [Figure 40-10-10] (10,8-16 Nm) torque.
from the block.
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Two Speed Block Disassembly and Assembly

(Cont'd)
Figure 40-10-13
1
N-21841
1
2
Remove the solenoid valve (Item 1) [Figure 40-10-15]
4 from the block.
N-21863
Assembly: Always install new O-rings and back-up
washers. Tighten the solenoid valve to 96-144 in.-lbs.
Remove the solenoid nut (Item 1) [Figure 40-10-13], O- (10,8-16 Nm) torque.
rings (Item 2) [Figure 40-10-13], and solenoid coil (Item
3) [Figure 40-10-13]. Figure 40-10-16
Remove and replace the O-rings and back up washer

(Item 4) [Figure 40-10-13] on the solenoid stem.
Figure 40-10-14
1 N-21864
Check the O-rings and back-up washers (Item 1) [Figure

40-10-16] and replace as needed.
N-21839
Remove the brake solenoid nut (Item 1) [Figure 40-10-

14].
Assembly: Tighten the nut to 9-12 in.-lbs. (1,02-1,36

Nm) torque.
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(Cont'd)
Figure 40-10-17
2
N-21842
Remove the shuttle valve (Item 1) [Figure 40-10-19] from

the block.
N-21842
Figure 40-10-20
Remove the charge pressure sender (Item 1) [Figure 40-

10-17] and the adapter snubber (Item 2) [Figure 40-10-
17] from the block. 2
Figure 40-10-18
1
N-21860
Remove the three O-rings (Item 1) [Figure 40-10-20]

from the shuttle valve.
1
N-21843 Remove the two back-up washers (Item 2) [Figure 40-
10-20] from the shuttle valve.
Remove the O-rings (Item 1) [Figure 40-10-18] and Replace the O-rings and back-up washers with new parts
replace with new. from the seal kit.
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(Cont'd)
Figure 40-10-21
N-21842
Remove the pilot operated directional valve (Item 1)

[Figure 40-10-23].
N-21842
Figure 40-10-24
Remove the cartridge screen (Item 1) [Figure 40-10-21]

from the block.
1 1
Figure 40-10-22
1
N-21861
2
3
Remove and replace the O-rings and back-up washers
2
(Item 1) [Figure 40-10-24].
1
N-21859
Check the vent (Item 2) [Figure 40-10-24] to be sure it is
open.
Remove and replace the back-up washer (Item 1)
[Figure 40-10-22], O-rings (Item 2) [Figure 40-10-22]
and screen (Item 3) [Figure 40-10-22] from the cartridge.
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(Cont'd)
Figure 40-10-25
N-21834
With an allen wrench remove the plug (Item 1) [Figure

1 40-10-27] from the block.
N-21835
With the same allen wrench remove the load shuttle
valve, located below the plug.
Remove the check valve (Item 1) [Figure 40-10-25] from
the block. Figure 40-10-28
Figure 40-10-26
2
2
2 1
1
N-21862
N-21844
Remove and replace the O-rings (Item 1) [Figure 40-10-
28] and back-up washers (Item 2) [Figure 40-10-28]
Remove and replace the O-rings (Item 1 [Figure 40-10- from the load shuttle valve and the plug.
26] and back-up washer (Item 2) [Figure 40-10-26] from
the check valve.
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Parking Brake Removal And Installation

1
Figure 40-10-29
1
2
1
N-15589

N-15643 31] and (Item 1) [Figure 40-10-31].
Installation: Tighten the mounting bolts to 70 ft.-lbs. (95

Lift and block the loader. (See LIFTING AND BLOCKING Nm) torque.
Figure 40-10-32
on Page 10-70-1.)
Remove the brake/two speed block from the center cover

on the chaincase. (See Two Speed Block Removal And
Remove the bolts from the center cover (Item 1) [Figure

40-10-29] on the chaincase.
Figure 40-10-30
1
2
N-15494
1
2 Remove the parking brake (Item 1) [Figure 40-10-32]
from the reduction gearcase housing.
Installation: Cap the T-fitting (Item 2) [Figure 40-10-31].

Connect a Port-a-Power to the hose (Item 2) [Figure 40-
10-32]. Pump the Port-a-Power until the pressure
releases the brake discs so they can be aligned on the
reduction gearcase splined shaft.
P-9670
Disconnect the cross-over hose (Item 1) [Figure 40-10-

30] at the fitting on the brake housing.
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Parking Brake Disassembly And Assembly
Figure 40-10-33 1
N-21822
1
Remove the brake housing end cover (Item 1) [Figure

N-21913 40-10-35].
Figure 40-10-36
Remove the four bolts (Item 1) [Figure 40-10-33] from
the brake housing.
Assembly: Put LOCTITE #242 and tighten the bolt to 55 1

ft.-lbs. (75 Nm) torque.
Figure 40-10-34
1
2
N-21824
2
Use low air pressure at the fitting to remove the piston

(Item 1) [Figure 40-10-36] from the brake housing.
3
Check the O-rings and back-up washers (Item 2) [Figure
N-21914 40-10-36].
NOTE: The brake housing (Item 1) [Figure 40-10-

34]will have a plug installed at this location.
The plug may look like either (Item 2) or (Item
3) [Figure 40-10-34]. Both are correct and act
only as a plug, and each may be used in place
of the other.
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Figure 40-10-37 BRAKE (CONT’D)
Parking Brake Disassembly And Assembly (Cont'd)
Figure 40-10-38
N-21825
Remove and replace the O-rings and back-up washers 1

from the brake piston (Item 1) [Figure 40-10-37]. N-21826
Assembly: Install the back-up washers (Item 1) [Figure

40-10-38] above the O-rings on the piston as shown in
[Figure 40-10-38].
Figure 40-10-39
N-21827
Remove the brake discs (Item 1) [Figure 40-10-39] from

the brake housing.
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Figure 40-10-40 BRAKE (CONT’D)
Parking Brake Disassembly And Assembly (Cont'd)
Figure 40-10-42
1
2
2
1
N-21832
Check the stationary discs (Item 1) [Figure 40-10-40], 1

the rotating discs (Item 2) [Figure 40-10-40] and the N-21831
primary disc (Item 3) [Figure 40-10-40] for wear and
replace as needed.
Inspect the springs (Item 1) [Figure 40-10-42] and pin
Figure 40-10-41 (Item 2) [Figure 40-10-42] for wear and replace as
needed.
Figure 40-10-43
1
1
N-21828
Remove the eleven compression spring assemblies (Item N-21829

1) [Figure 40-10-41] from the brake housing.
Remove the two pins (Item 2) [Figure 40-10-41] from the Remove the compression spring retainer (Item 1) [Figure
brake housing. 40-10-43] from the brake housing.
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Figure 40-10-44
1
N-21830
Inspect the compression spring retainer (Item 1) [Figure

40-10-44] and replace as needed.
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DRIVE COMPONENTS Figure 40-20-2
Axle Seal Removal And Installation
Figure 40-20-1
N-15488
Remove the end plate from the hub [Figure 40-20-2].

N-15487
Figure 40-20-3

procedure:
MEL1242 - Port-a-Power
MEL1255 - Axle Seal Tool 1

1
Remove the wheel assembly.
Installation: Tighten the wheel nuts to 320-350 ft.-lbs.

(434-475 Nm) torque. N-15489
Remove the three bolts from the hub end plate (Item 1)
[Figure 40-20-1]. Install a wheel nut (Item 1) [Figure 40-20-3] on two
wheel studs straight across from each other.
Installation: Put LOCTITE on the bolts and tighten to
210-230 ft.-lbs. (285-311 Nm) torque. Use a hammer and remove the wheel studs.
Installation: After the hub has been removed, use a

hammer and install the wheel studs in the hub.
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DRIVE COMPONENTS (CONT’D) Figure 40-20-6
Axle Seal Removal And Installation (Cont'd)
WARNING
NEVER STAND IN-LINE OF THE HUB WHEN
REMOVING A HUB FROM AN AXLE. The hub has a
tapered fit on the axle end and can come off the axle
with great force and cause serious injury.
W-2186-0395
Figure 40-20-4 N-15492
Use a drill to drill a hole in the axle seal [Figure 40-20-6].

1
Figure 40-20-7
2
N-15490
Install two long puller bolts into the hub. Install the puller
cross-bar (Item 1) [Figure 40-20-4]. Install a spacer on
the end of the axle and against the Port-a-Power ram jack N-15493
(Item 2) [Figure 40-20-4].
Remove the hub from the axle. Install a puller into the drilled hole and remove the axle
seal [Figure 40-20-7].
Figure 40-20-5
NOTE: Inspect the wear ring, if the ring is worn, use
the following procedure to remove it.
N-15491
Remove the key (Item 1) [Figure 40-20-5] from the axle.
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Axle Seal Removal And Installation (Cont'd)
Figure 40-20-8
1
N-15555
Install the wear ring/seal assembly or seal on the axle

N-15553 seal tool (Item 1) [Figure 40-20-10].
Figure 40-20-11
Use a hammer and chisel and split the wear ring [Figure
40-20-8]. Be careful not to damage the axle surface.
Remove the wear ring from the axle.
Figure 40-20-9
N-15556
Install the wear ring/seal or seal into the axle tube

[Figure 40-20-11].
N-15554
If the wear ring was removed from the axle, install a new
wear ring (Item 1) [Figure 40-20-9] into the axle seal.
Put LOCTITE on the inside diameter of the wear ring.
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Axle, Bearings And Sprocket Removal And

Installation

procedure:
MEL1202D - Axle Tools

MEL1242 - Port-a-Power 1
NOTE: The procedure shown for removal and

installation of the axle, bearings and sprocket
is for a front axle. This procedure will also be
the same for the rear axle.
N-15501
Loosen the three bolts (Item 1) [Figure 40-20-13] at the
Raise the operator cab. (See Raising The Operator Cab axle sprocket before removing the axle hub.
on Page 10-70-1.)
Remove the axle hub and seal. (See Axle Seal Removal
Remove the control panel. (See Removal And Installation And Installation on Page 40-20-1.)
on Page 30-20-1.)
Remove the bolts (Item 1) [Figure 40-20-13] and end
Remove the parking brake pedal assembly. (See Parking plate from the axle sprocket.
Brake Removal And Installation on Page 40-10-9.)
Installation: Put LOCTITE on the bolts and tighten to
Remove the control pedals mounting panel. (See Control 210-230 ft.-lbs. (285-311 Nm) torque.
Pedals Mounting Panel Removal And Installation on
Page 20-90-1.) Figure 40-20-14
Figure 40-20-12
1 1
N-15503
N-15485
Remove the end plate (Item 1) [Figure 40-20-14] and
shim (Item 2) [Figure 40-20-14].
Remove the front cover (Item 1) [Figure 40-20-12] from
the chaincase by removing the eight bolts. Installation: The correct end play for the axle is between
0.00-0.006 inch (0,152 mm). Add or replace the shim(s)
Remove the fluid from the chaincase. (See Removing (Item 2) [Figure 40-20-14] on the end of the sprocket to
The Oil From The Chaincase on Page 40-30-14.) get the correct end play.
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1
Figure 40-20-15
N-15506
Remove the drive chain from the sprocket. Remove the

sprocket (Item 1) [Figure 40-20-17] from the chaincase.
N-15504
Figure 40-20-18
Install the Port-a-Power ram jack between the two front

sprockets [Figure 40-20-15]. 1
Push the axle out until the ram jack is at the end of the
stroke. Retract the ram, add spacer and push axle out
again. Repeat this procedure until axle is out of the
sprocket.
Figure 40-20-16
1
N-15507
Remove the bearing (Item 1) [Figure 40-20-18] from the

inside of the chaincase.
Installation: Pack the bearing with grease before

installing in the cup.
N-15505
Remove the axle (Item 1) [Figure 40-20-16] from the

axle tube.
Installation: Pack the bearing with grease before

installing the axle.
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Installation (Cont'd) 1
Figure 40-20-19
N-15510
Using the long driver tool handle, install the bearing cup
tool (Item 1) [Figure 40-20-21] (MEL1202-13).
N-15508
Figure 40-20-22
Install the bearing cup puller tool (Item 1) [Figure 40-20-

19] (MEL1201-13) into the axle tube behind the bearing
cup.
Figure 40-20-20
N-15511
Remove the inner bearing cup from the axle tube [Figure
40-20-22].
N-15509
Pull the bearing cup from the axle tube [Figure 40-20-
20].
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Figure 40-20-23
1
N-15549
Installation: Inside the chaincase, start the inner bearing

cup into the axle tube. Install a bearing cup driver tool
N-15512 (Item 1) [Figure 40-20-25] (MEL1202-12). Install the nut
and washer.
Installation: Using the correct size driver tool (Item 1) Figure 40-20-26
[Figure 40-20-23] (MEL1202-12), install the outer
bearing cup.
Figure 40-20-24
1
1
N-15550
Installation: Install a wrench (Item 1) [Figure 40-20-26]

N-15547 on the nut and have a second person hold the wrench.
Installation: Install the long threaded bolt into the axle

tube. Install the correct size bearing cup driver tool (Item
1) [Figure 40-20-24] (MEL1202-11). Install the nut and
washer on the threaded bolt.
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DRIVE COMPONENTS (CONT’D) A bearing puller (Item 1) [Figure 40-20-28] is needed to
do the following procedure.
Installation (Cont'd) Be sure the bearing puller makes good contact with the
inner race and press the bearing off the mounting surface
Figure 40-20-27 of the axle [Figure 40-20-28].
NOTE: Hold the axle during removal because it will

slide freely after the bearing is removed from
the mounting surface.
Figure 40-20-29
N-15548
Installation: Turn the nut on the outside of the axle tube

until the inner bearing cup is on its seat [Figure 40-20-
27].
Figure 40-20-28
N-15551
Installation: Install the bearing puller making sure it has

good contact with the inner race of the bearing [Figure
40-20-29]. Press the bearing onto the mounting surface
until the bearing is fully seated.
N-15552
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Drive Chains Removal And Installation FRONT DRIVE

CHAIN

WARNING
REAR DRIVE
the lift arms are secured by an approved lift arm CHAIN
N-15562
W-2059-0598
NOTE: It is necessary to remove the rear axle and
drive chain if the front chain has to be
Lift and block the loader. (See LIFTING AND BLOCKING removed [Figure 40-20-30].

on Page 10-70-1.)
Remove the front panel/steering lever assembly. (See

Lever Removal And Installation on Page 30-30-1.)
Remove the brake/two speed block assembly. (See

Parking Brake Removal And Installation on Page 40-10-9
and See Two Speed Block Removal And Installation on
Page 40-10-3)
Remove the front cover on the chaincase. (See Front

Chaincase Cover Removal And Installation on Page 40-
30-1.)
Remove the rear cover from the chaincase.
Remove the center cover from the chaincase.
Remove the fluid from the chaincase. (See Removing

The Oil From The Chaincase on Page 40-30-14.)
Remove the rear axle. (See Axle, Bearings And Sprocket

Removal And Installation on Page 40-20-4.)
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963 Bobcat Loader
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CHAINCASE Front Chaincase Cover Removal And Installation
Checking And Adding Oil Remove the front steering panel/steering levers
assembly. (See Lever Removal And Installation on Page
Figure 40-30-1 30-30-1.)
Remove the parking brake pedal assembly. (See Parking

Brake Removal And Installation on Page 40-10-9.)
Remove the control pedals mounting panel. (See Control

Pedals Mounting Panel Removal And Installation on
Page 20-90-1.)
1 Figure 40-30-2
N-16243
The chaincase contains the final drive sprockets and

chains and uses the same type of oil as the hydraulic/
hydrostatic system. (See HYDRAULIC/HYDROSTATIC
FLUID SPECIFICATIONS on Page SPEC-60-1.)
To check the chaincase oil level, use the following

procedure: 1
N-15485
Drive the loader on a level surface. Stop the engine.

Remove the eight bolts from the front cover (Item 1)
Remove the plug (Item 1) [Figure 40-30-1] from the front [Figure 40-30-2].
of the chaincase housing.
Remove the front cover.
If oil can be reached with the tip of the your finger through
the hole the oil level is correct. Rear Chaincase Cover Removal and Installation
If the level is low, add oil through the check plug hole until Figure 40-30-3
the oil flows from the hole. Install and tighten the plug.
N-16071
Remove the bolts at the rear cover [Figure 40-30-3].
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CHAINCASE (CONT’D) Reduction Gearcase Removal And Installation
Rear Chaincase Cover Removal and Installation

(Cont’d)
Figure 40-30-4
WARNING
W-2059-0598
Figure 40-30-5
1 1
N-16064
The rear two bolts (Item 1) [Figure 40-30-4], also attach

the front of the fuel tank shield. The fuel tank shield will
have to be lifted a small amount so the rear cover can be
removed from the chaincase.
N-15485



on Page 10-70-1.)
Remove the front panel/steering lever assembly. (See

Lever Removal And Installation on Page 30-30-1.)
Remove the hydraulic foot pedals mounting panel. (See

Control Pedals Mounting Panel Removal And Installation
on Page 20-90-1.)
Remove the brake/two speed block. (See Parking Brake

Removal And Installation on Page 40-10-9 and See Two
Speed Block Removal And Installation on Page 40-10-3)
Remove the hydraulic/hydrostatic filter. (See Removal

And Installation on Page 20-70-1.)
Remove the front cover from the chaincase [Figure 40-

30-5].
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CHAINCASE (CONT’D) Figure 40-30-8
Reduction Gearcase Removal And Installation

(Cont’d)
Figure 40-30-6
N-15559
Left Side Only: Disconnect the wiring harness connectors

(Item 1) [Figure 40-30-8] from the PWM module harness
N-15643 connectors.
Left Side Only: Remove the hose clamp (Item 2) [Figure

Remove the center cover from the chaincase [Figure 40- 40-30-8].
30-6].
Figure 40-30-9
Remove the fluid from the chaincase. (See Removing
The Oil From The Chaincase on Page 40-30-14.)
Figure 40-30-7
1
1
2
N-15560
Left Side Only: Disconnect the hose (Item 1) [Figure 40-

N-15481 30-9] from the bucket position valve.

Disconnect the cross-over hose (Item 1) [Figure 40-30- 30-9].
7] between the parking brakes.
Remove the hydrostatic motor. (See Removal and

Remove the front axle. (See Axle, Bearings And

Sprocket Removal And Installation on Page 40-20-4.)
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(Cont'd)
1
Figure 40-30-10
N-15563
1 Connect a chain (Item 1) [Figure 40-30-12] to the top

cover bolts on the reduction gearcase.
N-15561

30-10] from the bucket position valve.
Right Side Only: Remove the lift lock valve. (See Lift And
Tilt Lock Block on Page 20-40-16.)
Right Side Only: Remove the hydraulic control valve.

(See Removal And Installation on Page 20-40-1.)
Figure 40-30-11
N-15638
Right Side Only: Remove the front fuel tank bracket (Item
1) [Figure 40-30-11] from the reduction gearcase.
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(Cont'd)
Figure 40-30-13
1 1
1
N-15562
Loosen and remove the ten mounting bolts (Item 1)

[Figure 40-30-14] from the reduction gearcase.
Installation: Tighten the reduction gearcase mounting

bolts to 220-245 ft.-lbs. (298-332 Nm) torque.
Lift the gearcase a small amount and slide to the rear of

the loader. Remove the rear drive chain. Remove the
front drive chain.
Installation: When installing the gearcase, put grease on

the O-ring to keep it from falling off the gearcase housing.
Move the gearcase away from the chaincase and start to

lift until the gearcase has enough clearance over the
fender [Figure 40-30-13]. Remove from the loader.
N-15564
Put the gearcase on a work bench and disconnect the

Connect the lifting bar (Item 1) [Figure 40-30-13] to the lifting chains.
chain on the gearcase.
Connect the chain hoist (Item 2) [Figure 40-30-13] to the

lifting bar.
NOTE: The lifting bar is needed so there will be

clearance for the chain hoist along side the lift
arms and operator cab.
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Reduction Gearcase Disassembly And Assembly
Figure 40-30-15
1
1
N-15626
1 Assembly: Put R.T.V. sealant (Item 1) [Figure 40-30-

N-15589 17] on the cover surface on the gearcase.
Figure 40-30-18
Remove the parking brake mounting bolts (Item 1)
[Figure 40-30-15].
Remove the parking brake from the gearcase. 1
To disassemble and assemble the parking brake, (See

Parking Brake Disassembly And Assembly on Page 40-
10-10.)
1 1
Assembly: Tighten the parking brake mounting bolts to
Figure 40-30-16
1 1
N-15591
Remove the four bolts from the cover (Item 1) [Figure

40-30-18].
N-15629
Remove the bolts from the cover (Item 1) [Figure 40-30-

16]. Remove the cover.

(Cont'd)
963 Bobcat Loader

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(Cont'd)
Figure 40-30-19
1
N-15628
1
Assembly: Put R.T.V. sealant (Item 1) [Figure 40-30-

21] on the cover before installation.
N-15627
Figure 40-30-22
Assembly: Put R.T.V. sealant (Item1) [Figure 40-30-19]

on the cover before installation.
1
Figure 40-30-20
N-15624

1
the input/brake shaft.
N-15592
Using a chisel and hammer remove the idler shaft cover

(Item 1) [Figure 40-30-20].
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(Cont'd)
Figure 40-30-23
N-15622
1
Assembly: Tighten the three bolts to 65-70 ft.-lbs. (88-95
Nm) torque [Figure 40-30-25].
N-15623
Figure 40-30-26
Remove the input/brake shaft (Item 1) [Figure 40-30-23]

and bearing from the housing. 1
Figure 40-30-24
N-15594
1
Use a press or install a Port-a-Power ram jack (Item 1)

[Figure 40-30-26] on the drive gear shaft. Push the drive
N-15593 shaft out of the bearing.

plate at the drive gear shaft.
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(Cont'd)
Figure 40-30-27
N-15621
Assembly: Install the spacer. Support the drive shaft.

Install the bearing using a hammer [Figure 40-30-29].
N-15595
Figure 40-30-30
Remove the bearing [Figure 40-30-27].
Figure 40-30-28
N-15618
Remove the drive shaft (Item 1) [Figure 40-30-30] and

N-15619 spacer (Item 2) [Figure 40-30-30] from the gearcase
housing.
Remove the spacer [Figure 40-30-28]. The tool listed will be needed to do the following
procedure:
MEL1557 - Spanner Nut Socket
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(Cont'd)
Figure 40-30-31
1
2
3
N-15615
2
Remove the bearing (Item 1) [Figure 40-30-32] and

1 spacer (Item 2) [Figure 40-30-32].
N-15850
Figure 40-30-33
Loosen and remove the outside locking spanner nut

(Item 1) [Figure 40-30-31].
Remove the tab washer (Item 2) [Figure 40-30-31] from

the shaft.
Remove the inside spanner nut (Item 3) [Figure 40-30-

31].
Remove the large washer from the shaft.
Assembly: Install the large washer. Install the second

spanner nut (Item 3) [Figure 40-30-31] with the flat face
toward the large washer. Taper part of the nut is toward N-15614
the outside. Tighten the nut to 35 ft.-lbs. (47 Nm) torque.
Assembly: Install the tab washer (Item 2) [Figure 40-30- Remove the idler shaft from the gear and gearcase
31] with the tabs toward the inside spanner nut. If a tab housing [Figure 40-30-33].
does make alignment with the inside spanner nut, tighten
the nut a small amount until a tab is aligned. Bend the tab Assembly: Put LOCTITE #262 on the idler shaft
toward the inside nut. (according to manufacturer's instructions) before
installing it into the gear.
Assembly: Put LOCTITE on the outside spanner nut.
Install the nut (Item 1) [Figure 40-30-31] and tighten to
963 Bobcat Loader

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(Cont'd)
Figure 40-30-34
N-15605
Install a bearing puller tool under the bearing and press

the bearing from the shaft [Figure 40-30-36].
N-15598
Figure 40-30-37
Remove the large gear and idler gear from the gearcase
Figure 40-30-35
N-15604
Assembly: Press the new bearing onto the shaft using a

press and bearing tool [Figure 40-30-37].
N-15608
Check the bearing (Item 1) [Figure 40-30-35] for wear or

damage and replace as needed.
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Reduction Gearcase Disassembly and Assembly

(Cont'd)
Figure 40-30-38
1
N-15601

output shaft.
Figure 40-30-39
N-15603
Assembly: Install the bearing tool (Item 1) [Figure 40-

30-40] so it will support the inside diameter of the
bearing. Press the new bearing on the output shaft.
N-15602
Install the bearing puller tool (Item 1) [Figure 40-30-39]

under the bearing and press the bearing from the output
shaft.
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(Cont'd)
Figure 40-30-41
N-15625
Assembly: Check the backlash between the gears

[Figure 40-30-43]. The correct specifications is 0.005-
N-15607 0.010 inch (0,13-0,28 mm).
Install a bearing puller tool under the bearing and press

the bearing from the shaft [Figure 40-30-41].
Figure 40-30-42
N-15606
Assembly: Use a sleeve (Item 1) [Figure 40-30-42] to

press the new bearing onto the shaft.
Reverse the above procedure to assemble the reduction

gearcase.
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Removing The Oil From The Chaincase

Figure 40-30-44
P-1619
Remove the drain plug (Item 1) [Figure 40-30-44] and

drain the oil into a container.
Check the drain plug and replace if necessary.

N-15743
Use the following procedure if the chaincase covers are
removed for other repair procedures: (Example; Removal
and Installation of Axle) Use a pump to remove the chaincase fluid [Figure 40-
30-45].
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MAIN FRAME
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1
Bob-Tach Lever And Wedge . . . . . . . . . . . . . . . . . . . . . . . 50-40-3
Bob-Tach Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-4 SAFETY &
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 50-40-1 MAINTENANCE
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-1

Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-80-1
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-2
Pick-up Tube Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-80-5
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-80-3
DRIVE
LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-50-1 SYSTEM
OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-20-1

Gas Cylinder Bracket Disassembly And Assembly . . . . . . 50-20-2 MAIN FRAME
Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . 50-20-1
OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-30-1

Back Removal And Installation . . . . . . . . . . . . . . . . . . . . . 50-30-3
Cushion Removal And Installation . . . . . . . . . . . . . . . . . . . 50-30-2
Shock Removal And Installation . . . . . . . . . . . . . . . . . . . . 50-30-3
Slide Rail Removal And Installation . . . . . . . . . . . . . . . . . . 50-30-1
POWER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-41-1
REAR DOOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-70-1

Adjusting The Rear Door Latch . . . . . . . . . . . . . . . . . . . . . 50-70-2
Door Brace Removal And Installation . . . . . . . . . . . . . . . . 50-70-3
Door Latch Removal And Installation. . . . . . . . . . . . . . . . . 50-70-3
REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-60-1

Gas Cylinder Removal And Installation . . . . . . . . . . . . . . . 50-60-1
SEAT BAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-1

Assembling Components . . . . . . . . . . . . . . . . . . . . . . . . . . 50-10-2
Compression Spring Disassembly And Assembly . . . . . . . 50-10-4
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SEAT BAR Figure 50-10-3
Figure 50-10-1
N-18572
Raise the loader operator cab. (See Raising The

N-19225 Operator Cab on Page 10-70-1.)
Remove the seat bar mounting nuts (Item 1) [Figure 50-

Raise the seat bar (Item 1) [Figure 50-10-1]. 10-3] (both sides).
Figure 50-10-2 Installation: Tighten the nuts to 28 ft.-lbs. (38 Nm)

torque.
Lower the operator cab. (See Lowering The Operator

Figure 50-10-4
N-18463
Disconnect the seat bar sensor (Item 1) [Figure 50-10-2]

from the cab harness.
Lower the seat bar.

N-19224
Remove the seat bar (Item 1) [Figure 50-10-4] from the

operator cab.
Reverse the above procedure to install the seat bar into

the operator cab.
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SEAT BAR (CONT’D) Assemble the parts as shown for the left side of the seat
bar pivot assembly [Figure 50-10-5] & [Figure 50-10-6].
Assembling Components
Seat Bar Mount (Item 1)
Figure 50-10-5 Mounting Bolt (Item 2)
Keyed Plastic Bushing (Item 3)
6 Seat Bar (Item 4)
4 5
Magnetic Bushing Assembly (Item 5)
7 Pivot Bushing (Item 6)
Sensor Bracket (Item 7)
3 Sensor Mounting Nut (Item 8)
Sensor Mounting Bolt (Item 9)
Mounting Nut (Item 10)
2
9 8 Installation: Tighten the mounting bolt (Item 2) [Figure
1 50-10-5] & [Figure 50-10-6] to 50-70 in.-lbs. (5,6-7,9
10 Nm) torque.
N-19383
Figure 50-10-6
4 9 8
5
3 6
2
10
N-19219
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SEAT BAR (CONT’D) Assemble the parts as shown for the right side of the seat
bar pivot assembly [Figure 50-10-7] & [Figure 50-10-8].
Assembling Components (Cont'd)
Seat Bar Mount (Item 1)
Figure 50-10-7 Mounting Nut (Item 2)
Pivot Bushing (Item 3)
5 Spacer Bushing (Item 4)
4 Seat Bar (Item 5)
6
Keyed Plastic Bushing (Item 6)
3 Mounting Bolt (Item 7)
Installation: Tighten the mounting bolt (Item 7) [Figure

2 7 50-10-7] & [Figure 50-10-8] to 50-70 in.-lbs. (5,6-7,9
Nm) torque.
N-19340
Figure 50-10-8
4
5
2 3
6
N-19220
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SEAT BAR (CONT’D) Figure 50-10-10
Compression Spring Disassembly And Assembly 6 7
Figure 50-10-9
1
5
6
4
3
2
1 N-19384
Disassemble and assemble the seat bar compression

spring and parts as shown in [Figure 50-10-10].
Bolt (Item 1)
Bushing (Item 2)
Spring (Item 3)
Clevis (Item 4)
Retaining Pin (Item 5)
Pin (Item 6)
Bushing (Item 7)
N-19222
Turn the bolt (Item 1) [Figure 50-10-9] & [Figure 50-10-

10] out of the clevis.
Assembly: Apply LOCTITE #518 adhesive to the bolt

threads. Adjust the compression spring by turning the
bolt in past the end of the clevis three turns.
NOTE: For procedures requiring the use of LOCTITE

#518 adhesive, thoroughly clean and dry
affected parts before the application of
LOCTITE #518.
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OPERATOR CAB Figure 50-20-2
Gas Cylinder Removal And Installation
Figure 50-20-1
N-20927
Remove the retainer pin (Item 1) [Figure 50-20-2].
Figure 50-20-3
N-20926
Raise the operator cab (See Raising The Operator Cab N-20928
on Page 10-70-1.) and install a chain hoist [Figure 50-

20-1].
Remove the pivot pin (Item 1) [Figure 50-20-3] at the top
of the gas cylinder.
NOTE: Make sure to support the operator cab with a
chain hoist when the gas cylinder is removed
so that the operator cab cannot tip forward.
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OPERATOR CAB (CONT’D) Gas Cylinder Bracket Disassembly And Assembly
Gas Cylinder Removal And Installation (Cont'd) Upper Mounting Bracket:
Figure 50-20-4 Figure 50-20-6
N-20929 N-20931
Remove the retainer pin (Item 1) [Figure 50-20-4] at the Remove the nuts (Item 1) [Figure 50-20-6] and bolts,
bottom of the gas cylinder. and remove the mounting bracket.
Replace the bracket as needed.
WARNING Lower Mounting Bracket:
Figure 50-20-7
Cylinder contains high pressure gas. Do not open.
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 50-20-5 1
N-20932
1 Remove the nuts (Item 1) [Figure 50-20-7] and bolts.

Remove the mounting bracket.
N-20930 Replace the bracket as needed.
Remove the pivot pin (Item 1) [Figure 50-20-5] at the

bottom mounting bracket.
Remove the gas cylinders.
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Figure 50-20-8
1
2
2
1 3
N-20934
Cut and remove the tie strap (Item 1) [Figure 50-20-10]

P-10162 disconnect the wire harness (Item 2) [Figure 50-20-10]
and remove the nut (Item 3) [Figure 50-20-10] from the
harness clamp.
Remove the nut (Item 1) [Figure 50-20-8] and hold down
plate (Item 2) [Figure 50-20-8] (both sides) from the Figure 50-20-11
operator cab.

torque.
Figure 50-20-9
1 N-20935
Disconnect the two wire connectors (Item 1) [Figure 50-

20-11].
N-20933
Disconnect the operator cab ground wire (Item 1) [Figure

50-20-9].
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Figure 50-20-12
1 N-20936
1
Remove the nut (Item 1) [Figure 50-20-13] from the pivot

bolt (both sides).
Installation: Tighten the pivot bolt and nut to 25-35 ft.-

Remove the pivot bolt (both sides).
Figure 50-20-14
N-20926
Install a sling (Item 1) [Figure 50-20-12] on the grab

handles of the operator cab. Connect a chain hoist to the
sling. 1
Remove both gas cylinders. (See Gas Cylinder Removal

N-20937
After the gas cylinders are removed, lower the operator

cab using the chain hoist [Figure 50-20-12].
Move the operator cab forward a small amount for
clearance at the pivot mounting brackets [Figure 50-20-
14].
Install the pivot bolt, washer (one on each side) and nut
(Item 1) [Figure 50-20-14] (both sides).
Install the sling under the pivot bolt and pivot of the
operator cab (Item 2) [Figure 50-20-14].
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OPERATOR CAB (CONT’D)
Figure 50-20-15
N-20938
Connect the slings to a chain hoist and remove the

operator cab from the loader [Figure 50-20-15].
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963 Bobcat Loader
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OPERATOR SEAT Figure 50-30-2
Figure 50-30-1
1 1
1
1 2
2
1
1
N-18587
1 1
Remove the two slide rail mounting bolts (Item 1) [Figure

N-20925 50-30-2].
Remove the slide rail (Item 2) [Figure 50-30-2] from the

Raise the operator cab. (See Raising The Operator Cab bottom of the seat frame.
on Page 10-70-1.)
Reverse the removal procedure to install the operator
Remove the four seat mounting nuts (Item 1) [Figure 50- seat slide rail.
30-1] and washers from the operator seat mounting
studs.
Installation: Tighten the mounting nuts to 20 ft.-lbs. (27

Nm) torque.
Lower the cab remove the operator seat.
NOTE: With the seat removed the cab will raise.

seat.
Slide Rail Removal And Installation

on Page 10-70-1.)
Remove the operator seat. (50-30-1.))
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OPERATOR SEAT (CONT'D) Figure 50-30-5
Cushion Removal And Installation
Figure 50-30-3 1
N-18581
Remove the cushion (Item 2) [Figure 50-30-4] from the

N-18579 seat frame (Item 1) [Figure 50-30-5].
Figure 50-30-6
Figure 50-30-4
1 1
N-18580
N-18582
Inspect the seat ride adjustment [Figure 50-30-6].

Press the two buttons (Item 1) [Figure 50-30-3] &
[Figure 50-30-4] and lift the seat cushion. Reverse the removal procedure to install the operator
seat back.
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OPERATOR SEAT (CONT'D) Shock Removal And Installation
Back Removal And Installation Figure 50-30-9
Figure 50-30-7
1
2
N-18584
N-18583
Figure 50-30-10
Pull the seat back adjustment lever (Item 1) [Figure 50-

30-7] and tilt the seat back all the way forward.
1
Figure 50-30-8
2
1 1
N-18585

on Page 10-70-1.)
N-18578
Remove the operator seat. (See Removal And
Remove the two mounting screws (Item 1) [Figure 50-
30-8] from the seat back and remove the back. Remove the seat shock retaining pin (Item 1) [Figure 50-
30-9] & [Figure 50-30-10] (Both ends.)
seat back. Remove the seat shock (Item 2) [Figure 50-30-9] &
[Figure 50-30-10].
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OPERATOR SEAT (CONT'D)
Shock Removal And Installation (Cont’d)
Figure 50-30-11
N-18586
NOTE: The seat block mounting studs (Item 1)

[Figure 50-30-11]are replaceable.

seat shock.
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BOB-TACH Figure 50-40-3
Figure 50-40-1
N-15360
1
Hit the bolt with a hammer [Figure 50-40-3] to remove

N-15358 the pivot pin from the Bob-Tach frame (both sides).
Figure 50-40-4
Put the Bob-Tach on the floor.
Remove the bolt and washer (Item 1) [Figure 50-40-1] at

the pivot pin of the rod end of the tilt cylinder (both sides).
Installation: Tighten the bolt to 125-140 ft.-lbs. (170-190

Nm) torque. Hit the bolt with a hammer, then re-torque
the bolt to 125-140 ft.-lbs. (170-190 Nm) torque.
Figure 50-40-2
N-15363
Remove the bolt at the pivot pin. Remove the pivot pin
from the rod end of the tilt cylinder [Figure 50-40-4] (both
sides).
1
N-15359
Install the bolt (Item 1) [Figure 50-40-2] (without washer)

in the pivot pin.
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BOB-TACH (CONT’D) Figure 50-40-7
Figure 50-40-5
N-15364
1
Installation: Make sure the shims (Item 1) [Figure 50-
N-15361 40-7] are installed when the Bob-Tach is installed on the
lift arms.
Remove the retainer bolt (Item 1) [Figure 50-40-5] at the Figure 50-40-8
Bob-Tach pivot pin (both sides).
Installation: Tighten the retainer bolt to 16-20 ft.-lbs.

(21-27 Nm) torque.
Figure 50-40-6
N-15365
Check the bushings in the lift arms for wear and damage,
replace as needed [Figure 50-40-8].
1
N-15362
Remove the Bob-Tach pivot pin (Item 1) [Figure 50-40-6]

(both sides).
Remove the Bob-Tach from the lift arms.
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BOB-TACH (CONT’D) Figure 50-40-11
Bob-Tach Lever And Wedge
Figure 50-40-9 5 1
3
2
N-15369
1
Remove the bolt (Item 1) [Figure 50-40-11], nut (Item 2)

N-15367 [Figure 50-40-11], washer (Item 3) [Figure 50-40-11]
and spring (Item 4) [Figure 50-40-11].
Use the following procedure to remove and install the Remove the Bob-Tach lever (Item 5) [Figure 50-40-11].
Bob-Tach lever, spring and wedge.
Remove the spring/clevis assembly.
NOTE: The removal procedure shown is on the right
side, the left side procedure is the same. Figure 50-40-12
Use a punch and hammer, remove the roll pin (Item 1)

[Figure 50-40-9] from the clevis and wedge.
1
Start the engine and tilt the Bob-Tach frame forward so it
is parallel to the floor. Stop the engine.
Figure 50-40-10
1
N-15370
Remove the Bob-Tach wedge (Item 1) [Figure 50-40-12]

from the Bob-Tach frame.
Check for bent, broken or worn wedge, replace as

needed.
N-15368
Loosen the mounting nut (Item 1) [Figure 50-40-10] at

the lever.

torque.
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BOB-TACH (CONT’D) Bob-Tach Stops
Bob-Tach Lever And Wedge (Cont'd) Figure 50-40-15
Figure 50-40-13
N-15422
N-15371
Remove and replace the Bob-Tach stop (Item 1) [Figure
50-40-15] (both sides) if worn or damaged.
Put the spring/clevis assembly in a vise [Figure 50-40-
13]. NOTE: The Bob-Tach stop (Item 1) [Figure 50-40-15]
must contact the lift arm at the same time the
Remove the bolt (Item 1) [Figure 50-40-13] and tilt cylinders reaches full extension. Use
disassemble the spring and clevis. available shims to adjust the Bob-Tach stop
and tilt cylinder sequence as closely as
Figure 50-40-14 possible.
N-15372
Check all parts for wear or damage. Replace the parts as

needed [Figure 50-40-14].
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POWER BOB-TACH
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LIFT ARMS Left Side:
Removal And Installation Figure 50-50-2
IMPORTANT 1
damage the system.
I-2003-0888
Figure 50-50-1
N-20256
Remove the nut (Item 1) [Figure 50-50-2], washer and

spacer from the pivot pin retainer plate.

torque.
Figure 50-50-3
1
1
N-20939
Put the Bob-Tach on the floor. Remove the Bob-Tach

from the lift arms. (See Removal And Installation on Page
50-40-1.)
Remove the the tilt cylinders. (See Removal And

Installation Of Tilt Cylinder(s) on Page 20-20-5.)
Remove the top tubeline clamp (Item 1) [Figure 50-50-1] N-20940

from the lift arms (both sides).
Pull the tubelines down for clearance. Disconnect the Remove the pivot pin (Item 1) [Figure 50-50-3] with a
hoses from the tubelines (both sides). slide hammer puller.
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LIFT ARMS (CONT’D) Figure 50-50-6
Right Side:
Figure 50-50-4 1
N-20262
Remove the nut (Item 1) [Figure 50-50-4], washer and

spacer from the pivot pin retainer plate.

torque.
N-20942
Figure 50-50-5
Install a sling (Item 1) [Figure 50-50-6] and chain hoist
on the lift arms.
Raise the lift arms so there will be clearance for removal

of the lift arm support device.
Figure 50-50-7
N-20941
Remove the pivot pin (Item 1) [Figure 50-50-5].
N-20944
Remove the lift arm support device from the lift arms
[Figure 50-50-7].
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LIFT ARMS (CONT’D) Figure 50-50-10
Removal And Installation (Cont`d)
Figure 50-50-8
1
N-20946
Remove the bolt (Item 1) [Figure 50-50-10], washer,

N-20943 spacer & nut from the retainer plate pivot pin (both sides).
Installation: Tighten the bolt to 16-20 ft.-lbs. (21-27 Nm)

Installation: Be sure to install the washers (Item 1) torque.
[Figure 50-50-8] (if so equipped) on both sides of the rod
end of the lift cylinder. Figure 50-50-11
Figure 50-50-9
1 N-20947
Remove the lift arm pivot pin (both sides) [Figure 50-50-
11].
N-20945
Install a sling (Item 1) [Figure 50-50-9] under the lift arm

as shown. Connect the chain hoist to the sling.
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LIFT ARMS (CONT’D)
Figure 50-50-12
N-20978
Remove the lift arms from the loader frame [Figure 50-
50-12].
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REAR GRILL Removal And Installation
Gas Cylinder Removal And Installation Remove the gas cylinder.
Figure 50-60-2
WARNING
Cylinder contains high pressure gas. Do not open. 1
Opening cylinder can release rod and cause injury or
death.
W-2113-0288
Figure 1
1
N-21481
Remove the bolt and nut (Item 1) [Figure 50-60-2] (both

sides).
Remove the rear grill from the loader frame.

1
Figure 50-60-3
N-21480
Lift the rear grill [Figure 1]. Add a support to prevent the
grill from closing when the gas cylinder is removed.
Remove the retainer clips (Item 1) [Figure 1] at both of

the ball joints ends. Remove the ball joints from the ends.
Remove the gas cylinder.
N-21482
Remove the bushing from both sides of the grill [Figure

50-60-3].
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REAR DOOR Figure 50-70-3
Open the rear door. 1
Figure 50-70-1
N-21517
1
Remove the light housing (Item 1) [Figure 50-70-3].
Figure 50-70-4
N-21514
2
Disconnect the wiring harness connector (Item 1)
[Figure 50-70-1].
Figure 50-70-2 1
N-21516
Remove work light (Item 1) [Figure 50-70-2] from the

light housing.
N-20845
Install a nylon sling (Item 1) [Figure 50-70-4] through the

holes for the light housings.
Connect a chain hoist (Item 2) [Figure 50-70-4] to the

nylon sling.
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REAR DOOR (CONT’D) Adjusting The Rear Door Latch
Figure 50-70-5
1
3
P-16367
2 1
N-21379
The door catch (Item 1) [Figure 50-70-6] can be adjusted

side to side for alignment with the door latch.
Figure 50-70-7
N-21518
1
Remove the nuts from the top and bottom hinge bolts
(Item 1) [Figure 50-70-5] and remove the hinge bolts. N-20243
Installation: Tighten the mounting bolts and nuts to 25-

28 ft.-lbs. (34-38 Nm) torque. The door stop (Item 2) The door latch (Item 1) [Figure 50-70-7] can be adjusted
[Figure 50-70-5] is installed in the top hinge bolt, above forward or backward for alignment with the door catch.
the stop retainer (Item 3) [Figure 50-70-5].
Remove the rear door from the loader frame and lay it flat
on the floor.
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REAR DOOR (CONT’D) Figure 50-70-10
Door Latch Removal And Installation
Figure 50-70-8
N-21381
1 Remove two bolts and nuts (Item 1) [Figure 50-70-10]

N-21379 and remove bracket from the loader.
Door Brace Removal And Installation

Remove the nut (Item 1) [Figure 50-70-8].
Figure 50-70-11
Figure 50-70-9
2
1
N-21382
N-21380
Remove the bolt (Item 1) [Figure 50-70-11] and

Slide out the bolt (Item 1) [Figure 50-70-9] and remove reposition the cables.
the spacer (Item 2) [Figure 50-70-9].
Remove the battery. (See Removal And Installation on
Page 60-20-1.)
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REAR DOOR (CONT’D) Figure 50-70-14
Door Brace Removal And Installation (Cont'd)
Figure 50-70-12
1
1
N-21383

N-21384 bottom of the loader frame.
Figure 50-70-15
Remove the two bolts (Item 1) [Figure 50-70-12].
Remove the battery tray.
Figure 50-70-13
2
1
1
N-21386

spacers (Item 2) [Figure 50-70-15] and door brace from
N-21385 the loader.
Remove the two spacers (Item 1) [Figure 50-70-13].
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FUEL TANK Figure 50-80-2
Front Removal And Installation
WARNING 1

W-2059-0598
2
N-15638A
Figure 50-80-1
Loosen the two hose clamps (Item 1) [Figure 50-80-2]

from the hose that connects the front fuel tank with the
rear fuel tank.
Disconnect the hose from the fuel tank.
Remove the two bolts (Item 2) [Figure 50-80-2] from the

1
gearcase and remove the bracket.
Figure 50-80-3
P1619
Remove the drain plug (Item 1) [Figure 50-80-1].
Drain the fuel into a container.
Check the drain plug and replace if necessary.

1
N-20847
Raise the lift arm and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-50-1.) Disconnect the wire harness connector at the fuel sender
(Item 1) [Figure 50-80-3].
Stop the engine.

on Page 10-70-1.)
Remove the front panel/steering levers assembly. (See

Removal And Installation on Page 30-20-1 and See Lever
Removal And Installation on Page 30-30-1)
Remove the hydraulic foot pedals and foot pedal

mounting plate. (See CONTROLS on Page 20-90-1.)
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FUEL TANK (CONT’D) Figure 50-80-6
Front Removal And Installation (Cont’d)
Figure 50-80-4
N-20851

N-20848 remove the pedal.
Figure 50-80-7
Disconnect the vent hose (Item 1) [Figure 50-80-4].
Remove the front fuel tank from the loader frame.
Loosen the fuel lever sender in the fuel tank. Remove the
sender (Item 2) [Figure 50-80-4]. from the tank.
NOTE: The fuel level sender can be removed without

removing the control panel and foot pedal
mounting plate. 50-80-2.) for Fuel Level
Sender Removal. 1
Fuel Level Sender
Figure 50-80-5 N-20852

remove the access cover.
N-20850
Remove the tilt linkage bolt (Item 1) [Figure 50-80-5].
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FUEL TANK (CONT’D) Rear Removal And Installation
Fuel Level Sender (Cont'd)
Figure 50-80-8
WARNING
W-2059-0598
Figure 50-80-10
N-20853

1
Figure 50-80-9
P-1619
Raise the lift arm and install an approved lift arm support
device. (See Engaging The Lift Arm Support Device on
Page 10-50-1.)

1
N-20854 Remove the drain plug (Item 1) [Figure 50-80-10].
Drain the fuel into a container.

Remove the sender (Item1) [Figure 50-80-9] from the
tank. Check the drain plug and replace if necessary.
Stop the engine.

on Page 10-70-1.)
Remove the engine/hydrostatic assembly from the

loader. (See Removal And Installation on Page 70-80-1.)
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FUEL TANK (CONT’D) Figure 50-80-13
Rear Removal and Installation (Cont'd)
Figure 50-80-11
1
2 2
N-21599
Remove the bolt (Item 1) [Figure 50-80-13] from the rear

N-21595 of the fuel tank shield.
Remove the fuel tank shield (Item 2) [Figure 50-80-13].

Disconnect the fuel fill hose (Item 1) [Figure 50-80-11]
from the fuel tank. Figure 50-80-14
Disconnect the vent hose (Item 2) [Figure 50-80-11],

from the fuel tank. 1
Figure 50-80-12
N-21596
1
At the lower right side (Item 1) [Figure 50-80-14], of the

rear fuel tank, disconnect the hose for the cross-over
N-21598 tube to the front fuel tank.
Remove the fuel tank from the loader frame.

Remove the two bolts (Item 1) [Figure 50-80-12] from
the front of the fuel tank shield.
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FUEL TANK (CONT’D)
Pick-up Tube Screen
Figure 50-80-15
N-15887
Remove the fitting (Item 1) [Figure 50-80-15] with the

pick-up tube from the fuel tank.
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ELECTRICAL SYSTEM & ANALYSIS
ADVANCED HAND CONTROL (A.H.C.) SYSTEM . . . . . . . . . . . . . . . . . . .60-120-1

Actuators Disassembly and Assembly. . . . . . . . . . . . . . . . . . . . . . . . . .60-120-9
A.H.C. Controller Removal And Installation . . . . . . . . . . . . . . . . . . . . . .60-120-4 SAFETY &
Components Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-120-1 MAINTENANCE
Handle Control Unit Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-120-5
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-120-3
Switch Handle Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . .60-120-6
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-120-2
ALTERNATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1
Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-5 DRIVE
Alternator Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1 SYSTEM
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-2
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-8
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-6
Rectifier Continuity (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-7
Rectifier (Diode) Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-3
Rotor Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-7 ELECTRICAL
Rotor Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-7 SYSTEM &
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-6 ANALYSIS
Stator Ground Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-30-6
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-1
Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-20-3
Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . .60-20-4
BICS™ SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-1

Additional Inspection For Loaders With Advanced Hand Controls (AHC) .60-90-
2
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED
- Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-1
Inspecting The BICS™ Controller (Engine STOPPED - Key ON) . . . . . .60-90-1
Inspecting The Lift Arm By-Pass Control . . . . . . . . . . . . . . . . . . . . . . . . .60-90-1
Inspecting The Seat Bar Sensor (Engine RUNNING) . . . . . . . . . . . . . . .60-90-1
Inspecting The Traction Lock (Engine RUNNING) . . . . . . . . . . . . . . . . .60-90-1
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-3
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-90-4
BOBCAT CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-70-1

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-70-1
DIAGNOSTICS SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1

Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-80-1
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ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE . . . . . . . . . 60-140-1

Controls Identification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-140-1
ELECTRICAL SYSTEM INFORMATION. . . . . . . . . . . . . . . . . . . . . . .60-10-1

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-4
Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-6
Relay Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-6
Solenoid Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-7
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-10-3
INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-1

Deluxe Panel Removal And Installation (Right Side) . . . . . . . . . . 60-50-10
Left Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-1
Option And Field Accessory Panels. . . . . . . . . . . . . . . . . . . . . . . .60-50-8
Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-50-6
Right Panel - (Deluxe) (With Keyless Start) . . . . . . . . . . . . . . . . . .60-50-3
Right Panel Set Up Display Options (Deluxe) . . . . . . . . . . . . . . . .60-50-5
Right Panel - Standard Instrument Panel (With Key Switch) . . . . .60-50-2
Standard And Deluxe Panel Removal And Installation (Left Side)60-50-11
Standard Panel Removal And Installation (Right Side) . . . . . . . . .60-50-9
LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-60-1
Front Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .60-60-1
Rear Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .60-60-2
PROPORTIONAL CONTROL (PWM) . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1

Control Handle Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
Electric Solenoid Coil Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-130-1
SEAT BAR SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1

BICS™ Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-4
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-3
Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-2
Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-100-1
STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-1
Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-4
External Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-6
Inspection And Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-7
Magnetic Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-10
No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-40-11
Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-3
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60-40-1
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ELECTRICAL SYSTEM & ANALYSIS (CONT’D)
TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1

Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-110-1
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963 Bobcat Loader
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CAB FRONT LIGHT
2750
963 WIRING SCHEMATIC
ACCESSORY 2740
CONNECTORS 2760
BATTERY FEED 1000-1999 RED, RED/WHT, RNG
RED = RED
HARNESS 6718870
S/N 562215001-15434 GROUND 2000-2999 BLK
RNG = ORANGE
LEFT FRONT WORKLIGHTS
C435
MONITORING 3000-3999 LBL 2750 B B 2750
BLK = BLACK
S/N 516515001-15999 WIRES CONNECT BY LETTER
HYDRAULIC 4000-4999 LGN LBL = LIGHT BLUE 6110 A A 6110 2750
DBL = DARK BLUE
(PRINTED APRIL 2001) ACROSS CONNECTORS ATTACHMENT CONTROLS 5000-5999 YEL
LGN = LIGHT
RIGHT
C434
A B LIGHTS 6000-6999 PNK 6120 A A 6120 2760
V-0013 ACCESSORIES 7000-7999 WHT
GREEN
2760 B B 2760
B A DGN = DARK
ENGINE 8000-8999 TAN GREEN LEFT PANEL
SOME CONNECTOR COMMUNICATION 9000-9999 PUR YEL = YELLOW
BODIES NOT SHOWN PNK = PINK
FOR DRAWING CLARITY WHT = WHITE 9340 D HEADLIGHTS
BRN = BROWN
TAN = TAN
2910 G GROUND
FUSE 5 FUSE 1 FUSE 9
PUR = PURPLE HEATER UNSW ITCHED 1210 E PROTECTED POWER
FRONT &
GRY = GRAY 30A 25A REAR SWITCH 25A 1910 F COMPUTER POWER
MARKER CONNECTS TO
FUSE 6 FUSE 2 LIGHT POWER FUSE 10 C407 9210 K SYSTEM Rx
LIGHT
TAILGATE/
FUEL PULL FR & MK LT ATTCHMNT ON THIS PAGE
2650 30A 25A
9110 H SYSTEM Tx
15A
2640
FUSE 7 FUSE 3 FUSE 11 C407 9300 A CLOCK/LATCH
WORK LIGHTS
2630 2600 REAR LT ALT & KITS 9310 B DATA
15A FUEL 25A
2620 STARTER 9330 J START
A
FUSE 8 FUSE 4 PULL FUSE 12
2610 9320 C BUZZER
HARNESS 6716419 COMPUTER
25A
ACC PLUGS
25A
RIGHT FUEL SENDER
6100
TAILLIGHT 2610 6320 20-270 ohm 9320 + BUZZER
BACKUP 2930 -
ALARM RIGHT PANEL
MAIN FRAME
LEFT 6100 8 8 6100
2640 6330 SWITCH
TAILLIGHT 11
9340 11 9340
9200 10 10 9200 9330 J START
A
B
RIGHT 9
C404 C406 9 B
WORK 2620 6200 HARNESS 6719383 9100 9100 9310 DATA
C408
LIGHT 6210 2900 4 4 2900 9300 A CLOCK/LATCH
B
A
A
B
1900 2 2 1900 9120 H SYSTEM Tx
LEFT WORK 1200 1 1 1200 9220 K SYSTEM Rx
2630 6210
LIGHT 12
9350 12 9350 1920 F COMPUTER POWER
7100
3100
3110
3900 5 5 3900 1220 E PROTECTED POWER
3920 7 7 3920 2920 G GROUND
7100
3910 6 6 3910 9350 D KEY/ENTER SWITCH
BACKUP
ALARM 2650 2740 3 3 2740 C OPEN
2600
7100
6200
6310
2910
C445 C444 C443

t 2900 2920
HYD TEMP SENDER
3300 A A 3300 2930
538-1824 ±30 ohm
3310 B B 3310
9340
2900
3900
B F G D E C H A
9350
9200
9100
1900
1200
3920
3910
C
3900
SEAT
B
C103 3920 BAR

+
A
3400 A A 3400 HYD CHARGE PRESS A
3910
C SENDER 0.5-7.5 V
B F G D E C H A 3420 C C 3420
B MAIN
D2
D1
D3
C3
C2
C1
E3
E2
A1
A2
A3
F2
B3
B2
B1
B B J2
F3
E1
F1
3410 3410 -
2000 CAB
FRAME
ENGINE
2600
6600
6500
6400
7100
6200
6310
HYD OIL FILTER
3430 A A 3430
PRESSURE SWITCH
HARNESS 6719160 J2
RIGHT HANDLE
D2
D1
D3
C3
C2
C1
B3
B2
B1
A1
A2
A3
E3
E2
F2
F3
E1
F1
J4 J4
6310 N E1 E1 4300 4300 B B WHT

J1 J2
+
A
6200 S E3 E3 4320 4320 D D WHT/
SEATBAR SENSOR
PWM
SEATBAR SENSOR
3500 RED
FUEL SENDER SPARE ANALOG
ENG COOLANT SPARE ANALOG
SPARE DIGITIAL
SENSOR SIGNAL
3020 WHT/
7100 R R C
GROUND
C 7100 E2 E2 C
SEATBAR
ENG OIL PRESSURE 4310 4310
SUPPLY
3920
3110
3900
3910
BLK
IN 1
IN 2
IN 1
3520
A1
A2
A3
A1
A2
A3
SENDER 0.5-7.5 V 6400 W 3310 3010
3510 K3 K3
-
B 6500 P TWO
TEMP SENDER
3410 J1
HYD TEMP
C409
SENDER
WHT/ SPEED
SIGNAL
A1 A1 F F
OPEN
OPEN
4910 4910
OPEN
3100
3200
3300
B1
B2
B3
B1
B2
B3
6600 V LGN
ENGINE COOLANT
t
3010 F2 G G
HYD CHARGE
HYD CHARGE
PRESSURE +
DIGITAL IN 2
3200
PRESSURE
SENDER DETENT
SIGNAL
SPARE
OPEN
OPEN
OPEN
E3 B1 B1 E E
3400
3420
3430 J3 J4 4920 4920
C1
C2
C3
C1
C2
C3
500-3000 ± 30 ohm DGN
3210 3020 H H 3020
3420 C2 K2 K2 K K
RH TWO SPEED
BATTERY IN (1)
BATTERY IN (2)
BATTERY IN (3)
LH AUX RIGHT
UNSWITCHED
UNSWITCHED
UNSWITCHED
BRAKE SW
C1 J
1110
1120
1130
4910
4810
4500
3400 C1 C1 4930 4930
BLACK
WHITE
A1
A2
A3
J
A1
A2
A3
IN
YEL
J1
J2
3610 SKI
SPEED SENSOR (VR) 3300 B3 D1 D1 4940 4940 H H LGN CONTROL
3600
LH AUX LEFT
ENG SPEED +
RH FRONT
PRESSURE +
BRAKE SW
SYSTEM Rx
E2
SYSTEM Tx
GROUND
GROUND
PRESSURE
DETENT
B3 A A
ENG OIL
ENG OIL
B3 RNG
OPEN
SIGNAL
1400 1490
4920
4820
1400
2100
OUT
OPEN
2110
(hall)
B1
B2
B3
9100
9200
3500
3520
B1
B2
B3
D1
D2
D3
D1
D2
D3
3100 B1
J J BRAKE SWITCH
RH SKI DOWN
LH SKI DOWN
FILTER SIGNAL
HYD CHARGE
EHC INPUT
FUEL HOLD
Dealer Copy -- Not for Resale
ENG SPEED
FEEDBACK
COMPUTER
KEY/ENTER
FUEL PULL
FUEL PULL
HEADLIGHT
SIGNAL (vr)
AIR FILTER
SWITCH
SWITCH
K D1 A3 A3
POWER
C405
A A
SIGNAL
RELAY
3700 3500 K 3500 3500 4500 1450
4930
4830
9400
8800
8110
8150
1900
9350
9340
C1
C2
C3
3600
3700
3430
C1
C2
C3
E1
E2
E3
E1
E2
E3
C403
AIR FILTER SWITCH
B B 3710 3520 L L 3520 3520 D2 K1 K1
STARTER RELAY
EHC OUTPUT
SIGNAL (hall)
PROTECTED
BRAKE PULL
C C B2
GLOW PLUG
H
ENG SPEED
3200 3200 3200
LH SKI UP
H
GROUNDS
RH SKI UP
GROUND
SENSOR
POWER
OPEN
RELAY
RELAY
OPEN
LEFT HANDLE
1200
2900
4940
4840
9410
3010
8210
4110
8510
D1
D2
D3
F1
F2
F3
F1
F2
F3
D1
D2
D3
3600 M M 3600 3600 E1 C3 C3 9400 J J
X X F3 D3 D3 9400 1480 A A RNG
PWM SIGNAL
GLOW PLUG
BRAKE PULL
FEEDBACK
FEEDBACK
FEEDBACK
STARTER
COLD START TEMP
PWM +
PWM -
4310
4320
4300
8250
4150
8550
E1
E2
E3
B B C3 D2 D2 4840 C C
E1
E2
E3
SWITCH 2300 2300 4840 WHT SKI
C410
3700 F F 3700 3700 A1 C2 C2 4830 4830 B B DBL CONTROL
YEL/
G
WHITE
G W 6400 A3 B2 B2 4820 4820 G
BLACK
J4
8600 LGN PADDLE
J3
YEL/ MOMENTARY
FUEL SHUTOFF
2800
P 6500 F1 A2 A2 4810 4810 F F RED
SOLENOID
TRACTION HOLD SPOOL LOCK
FRONT BASE
FRONT ROD
8100 V 6600 D3 G2 G2 K K
REAR WKLT
MARKER LT
4340
4330
4360
RELAY
RELAY
OPEN
F1
F2
F3
6210
6320
F1
F2
F3
T T 8800 A2 G1 G1 E
E
U 8250 900 SERIES J1 J1 4460 D D
REAR BASE
REAR ROD
RESERVED
RESERVED
RESERVED
(L TURN)
(R TURN)
(HORN)
4440
4430
4200
G1
G2
G3
G J2 J2 4450
G1
G2
G3
B BRN
8610 8620 D 8200 J3 J3 4480
C412 C411
COLD START SOLENOID TURN
D
RELAY OUTPUT
TWO SPEED
BICS LOCK
ATTACHMENT
YEL
POSITION
ACCESSORY
BUCKET
KEY INPUT
SIGNAL
CONTROL
8100 E S 6200 F2 F2 4330
TRAVEL
4410
4420
4350
H1
H2
H3
ACCESSORY
8000
9800
4730
H1
H2
H3
CONNECTOR
A DGN
1800 A N 6310 F1 F1 4340
C
SPARE OUTPUT 1
CAN SHIELD SPARE OUTPUT 2
REAR BLEED
HIGH FLOW
DIVERTER
8200 D E 8100 H1 H1 4410
RESERVED
(ATT ACC)
4460
4450
4470
E
J1
J2
J3
ALTERNATOR
J1
J2
J3
1020 8250 U A 1800 F3 F3 4360
S RNG/
(SERIAL RIGHT)
H2 H2 A
(SERIAL LEFT)
4420 ACCESSORY DBL
G
FUTURE
FUTURE
EXC
CAN HIGH
CAN LOW
OPEN
1020
K1
K2
K3
CONNECTOR RNG/
9500
9600
9700
1800 K1 H3 H3 4350 B HORN
K2
K3
1010 WHT
BAT G3 G3 4200
2010
STARTER 2600
G1
G2
G3
H3
C1
H1
C3
C2
D1
B3
D3
B1
B2
D2
K1
K2
K3
H2
A1
A2
A3
J3
E1
F3
F2
E3
E2
F1
J3
J1
J2
2300 CONNECTS TO
1010
M S
8200 2800 C407
ACCESSORY
ON THIS PAGE
R CONNECTOR
8250
C407 C427 120 ohm
G1
G2
G3
H3
C1
H1
C3
C2
D1
D3
D2
H2
J3
E1
F3
F2
B3
E3
B1
B2
E2
F1
A1
A2
A3
K1
K2
K3
J3
J1
J2
ACD & REMOTE START
H
A
G
C
D
E
B
A
F
CONNECTOR
2090
2090
LOCATED AT REAR OF
MACHINE
6400
6500
6600
6300
4730
4730
8800
8250
8000
8150
8110
6320
6210
8210
2100
2110
4650
9450
9450
1110
1120
1130
9500
9600
9700
9800
6000
GROUNDS DIVERTER
G
D
C
B
A
E
F
C426 4450 A A 7.5 ohm nominal
C416
4660 ACCESSORY ACCESSORY YELLOW TIE STRAP at 12 VDC
2480 CONNECTOR CONNECTOR 2450 B B
G
D
C
B
A
E
F
2450
2400 C401 C402 REAR AUX RELIEF
C417
2340 4480 A A 9.8 ohm nominal
D
B
A
at 12 VDC
B
A
GREEN TIE STRAP
2330 2480 B B
9800
9700
9600
9500
2710
1160
1710
FRONT ROD
4330 A A
C418
3.3 ohm nominal
2730
1140
1700
1150
2100
2720
1720
2330 B B at 10 VDC
2350
FRONT BASE
2420
4340 A A
C419
3.3 ohm nominal
2410
2340 B B at 10 VDC
2380 2390
HYD LOCK VALVE
2370
4410 A A
C420
9.8 ohm nominal
2200 at 12 VDC
2410 B B
2000
TILT SPOOL LOCK
1800 4370 A A
C421
2300 FUSE 11
2740 1720 7.7 ohm nominal
25A 2370 B B
2730 1700 1055
LIFT SPOOL LOCK
8000
2120
2720 FUSE 12
USED IN AHC
6310
6000
6300
4380 A A
8100
8150
8110
6320
6200
6210
8200
8210
25A
C422
EQUIPPED LOADERS AHC 7.7 ohm nominal
1140
2710
2110 ONLY POWER FRONT
2380 B B
1150
1160
SWITCHED REAR
FUSE 10 FUEL PULL AND STARTER
25A POWER LIGHT
ATTACHMENT MARKER BUCKET POSITION
C423
1710 87A 87 86 87A 87 86 87A 87 86 87A 87 86
4650
87A 87 86
1130
LIGHT
1110
1120
HEATER 4420 A A 6.7 ohm nominal

30 85 2420 B B at 12 VDC
30 85 30 85 30 85 30 85 UNSW
25A COOLING POWER
FUSE 1 FAN TWO SPEED
2020
2030
1330
1050
2000
2010
1350
2040
1320
2010
2020
1030
2030
2040
RELAY GROUNDS 2000-2060 25A
C436
ARE CONNECTED IN SERIES FUSE 9 4350 A A
COMPUTER 9.8 ohm nominal
2350 B B at 12 VDC
9.8 ohm nominal
30A 15A 15A
4660
1070
at 12 VDC 25A
BATTERY FUSE 6 FUSE 2 FUSE 3 TRACTION LOCK
1050 FUSE 4
+ - 1300
100A 1030 9.8 ohm nominal

4200 A A
C425
at 12 VDC
1010 2200 B B
1310
1040
Printed in U.S.A. V-0013 (4-10-01)
343 of 640
WIRES CONNECT BY LETTER
ACROSS CONNECTORS
GROUND 2000-2999 BLK
RED = RED
RNG = ORANGE CAB FRONT LIGHT
ACCESSORY
2750
963 WIRING SCHEMATIC BLK = BLACK 2740

A CONNECTORS 2760
B MONITORING 3000-3999 LBL LBL = LIGHT BLUE HARNESS 6718870 M M
B DBL = DARK BLUE
A HYDRAULIC 4000-4999 LGN LEFT FRONT WORKLIGHTS
WITH ADVANCED HAND CONTROL OPTION LGN = LIGHT GREEN
C435
ATTACHMENT CONTROLS 5000-5999 YEL DGN = DARK GREEN 2750 B B 2750
S/N 562215001-15356 SOME CONNECTOR
LIGHTS 6000-6999 PNK YEL = YELLOW 6110 A A 6110 2750
BODIES NOT SHOWN
S/N 516515001-15999 FOR DRAWING CLARITY ACCESSORIES 7000-7999 WHT
PNK = PINK
WHT = WHITE RIGHT
DGN
DGN
(PRINTED APRIL 2001)
RED
RED
RED
RED
BLK
BLK
BLK
BLK
ENGINE 8000-8999 TAN BRN = BROWN
C434
V-0014 TAN = TAN 6120 A A 6120 2760
COMMUNICATION 9000-9999 PUR PUR = PURPLE 2760 B B 2760
GRY = GRAY
LEFT PANEL
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
TILT ACTUATOR LIFT ACTUATOR
C428 C429
9340 D HEADLIGHTS
2910 G GROUND
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
HEATER UNSW ITCHED 1210 E PROTECTED POWER
FRONT & 25A
30A 25A REAR SWITCH 1910 F COMPUTER POWER
MARKER CONNECTS TO
LIGHT POWER FUSE 10
TAILGATE/
FUSE 6 FUSE 2 C407 9210 K SYSTEM Rx
LIGHT
30A 25A
9110 H SYSTEM Tx
2650 15A
C407 9300 A CLOCK/LATCH
WORK LIGHTS
2640 FUSE 7 FUSE 3 FUSE 11
REAR LT ALT & KITS 9310 B DATA
ADVANCED HAND CONTROL MODULE
2630 2600
15A FUEL 25A
STARTER 9330 J START
A
2620 FUSE 4 PULL FUSE 12
HARNESS 6716419 2610
FUSE 8
COMPUTER AHC
9320 C BUZZER
25A 25A
RIGHT
2610 6320 FUEL SENDER
TAILLIGHT
6100
20-270 ohm 9320 +
G
H
C
D
K
E
B
A
BUZZER
F
A
B
J
BACKUP 2930 -
LEFT
2640 6330 ALARM RIGHT PANEL C430 C431
MAIN FRAME
TAILLIGHT 6100 8 8 6100
A
B
SWITCH
G
H
C
D
K
E
B
A
F
J
9340 11 11 9340
9200 10 10 9200 9330 J START
A
B
RIGHT 6200
4580
9410
9400
4720
4700
4710
4620
4600
4610
2620 9
1740
2240
C404 C406 9 B
WORK LIGHT 6210 HARNESS 6725193 9100 9100 9310 DATA
C408
2900 4 4 2900 9300 A CLOCK/LATCH
B
A
A
B
1900 2 2 1900 9120 H SYSTEM Tx
LEFT WORK
LIGHT
2630 6210 1200 1 1 1200 9220 K SYSTEM Rx
9350 12 12 9350 1920 F COMPUTER POWER
7100
3100
3110
7100 3920 7 7 3920 2920 G GROUND
BACKUP
1730
ALARM 2650
4720
4700
4710
4620
4600
4610
2740 3 3 2740 C OPEN
2600
7100
6200
6310
POWER FROM
2910 FUSE 12
ON THIS SHEET
C445 C444 C443

t 2900 2920
C
A
B
A
B
HYD TEMP SENDER
3300 A A 3300 2930
538-1824 ±30 ohm R HANDLE L HANDLE
G
D
C
H
B
A
F
3310 B B 3310
9340
2900
3900
9350
9200
9100
1900
1200
3920
3910
C
3900 C432 C433
C103 A
+ 3920 B
SEAT
BAR
CONNECTS TO CONNECTS TO
C432
3400 A A 3400 HYD CHARGE PRESS A C433
3910 ON THIS PAGE ON THIS PAGE
C SENDER 0.5-7.5 V
3420 C C 3420
G
D
C
H
B
A
F
B MAIN
D2
D1
D3
C3
C2
C1
E3
E2
A1
A2
A3
F2
B3
B2
B1
B B J2
F3
E1
F1
3410 3410 -
2000 CAB
FRAME RIGHT HANDLE
ENGINE
2600
6600
6500
6400
7100
6200
6310
HYD OIL FILTER
3430 A A 3430
PRESSURE SWITCH
C432
HARNESS 6719160 J2 CONNECTS TO A
PNK/
RED
D2
D1
D3
C3
C2
C1
E3
E2
A1
A2
A3
F2
B3
B2
B1
F3
E1
F1
J4 J4 C432 PNK/ TILT
C DGN CONTROL
ON THIS PAGE PNK/
6310 N D3 D3 9410 B BLK
3020 J1 J2
6200 S C3 9400
C3
+
A
SEATBAR SENSOR
3110
SEATBAR SENSOR
3500
SPARE DIGITIAL
SENSOR SIGNAL
7100 R R E1 4300 4300 B B
GROUND
7100 3310 3010 E1 WHT
SEATBAR
ENG OIL PRESSURE
SUPPLY
3920
C
3900
3910
IN 1
IN 2
IN 1
3520
A1
A2
A3
A1
A2
A3
WHT/
SENDER 0.5-7.5 V 6400 W 3410 E3 E3 4320 4320 D D RED PWM
3510 WHT/
C
-
B P
6500 E2 4310 C
TEMP SENDER
J1 J1 E2 4310
HYD TEMP
BLK
SENDER
SIGNAL
OPEN
OPEN
OPEN
3100
3200
3300
B1
B2
B3
B1
B2
B3
6600 V K3
K3
ENGINE COOLANT t TWO
3010 F2 F2 LGN/
HYD CHARGE
HYD CHARGE
SPEED
PRESSURE +
DIGITAL IN 2
3200 A1 F F
PRESSURE
SENDER A1 4910 4910
SIGNAL
SPARE
WHT
OPEN
OPEN
OPEN
C409
E3 E3
3400
3420
3430 J3 J4
C1
C2
C3
C1
C2
C3
500-3000 ± 30 ohm
3210 3020 H H 3020
3420 C2 C2 G G
RH TWO SPEED
BATTERY IN (1)
BATTERY IN (2)
BATTERY IN (3)
LH AUX RIGHT
UNSWITCHE D
UNSWITCHE D
UNSWITCHE D
DETENT
BRAKE SW
C1 B1 4920 4920 E E DGN
1110
1120
1130
4910
4810
4500
3400 C1 B1
BLACK
WHITE
A1
A2
A3
A1
A2
A3
IN
J1
J2
3610
SPEED SENSOR (VR) 3300 B3 B3 K2 K2 K K
3600
LH AUX LEFT
C1 J
ENG SPEED +
BRAKE SW
RH FRONT
PRESSURE +
A1 E2 C1 4930 4930 J
SYSTEM Rx
GROUND
GROUND
PRESSURE
SYSTEM Tx
DETENT
YEL
ENG OIL
ENG OIL
OPEN
SIGNAL
4920
4820
1400
2100
OUT
OPEN
2110
SKI
(hall)
9100
9200
B1
B2
B3
3500
3520
B1
B2
B3
D1
D2
D3
D1
D2
D3
3100 B1 B1 D1 D1 4940 4940 H H LGN CONTROL
J J
FUEL PULL RELAY
A
RH SKI DOWN
LH SKI DOWN
FILTER SIGNAL
B3 A RNG
HYD CHARGE
1400 1490
EHC INPUT
FUEL HOLD
ENG SPEED
COMPUTER
KEY/ENTER
B3
HEADLIGHT
FEEDBACK
SIGNAL (vr)
AIR FILTER
FUEL PULL
K D1
SWITCH
SWITCH
D1
POWER
C405
SIGNAL
A A 3700 3500 K 3500 3500
4930
4830
9400
8800
8110
8150
1900
9350
9340
C1
C2
C3
3600
3700
3430
C1
C2
C3
E1
E2
E3
E1
E2
E3
AIR FILTER SWITCH
C403
B B 3710 3520 L L 3520 3520 D2 D2
STARTER RELAY
A3 H
EHC OUTPUT
4500 1450
SIGNAL (hall)
PROTECTED
C C B2 B2 H
GLOW PLUG
A3
ENG SPEED
BRAKE PULL
3200 3200 3200
GROUNDS
LH SKI UP
RH SKI UP
GROUND
SENSOR
POWER
LEFT HANDLE
OPEN
RELAY
RELAY
OPEN
1200
2900
4940
4840
9410
3010
8210
4110
8510
D1
D2
D3
F1
F2
F3
F1
F2
F3
D1
D2
D3
3600 M M 3600 3600 E1 E1 K1 K1 BRAKE SWITCH J J
X X F3 F3 1480 A A RNG
PWM SIGNAL
BRAKE PULL
COLD START
GLOW PLUG
FEEDBACK
FEEDBACK
FEEDBACK
STARTER
PWM +
PWM -
4310
4320
4300
D2 4840 4840 C C
8250
4150
8550
E1
E2
E3
B B C3 C3 D2 WHT
E1
E2
E3
TEMP SWITCH 2300 2300 SKI
C410
C2 4830 4830 B B DBL CONTROL
3700 F F 3700 3700 E2 A1 C2
YEL/
B2 4820 4820 G G
WHITE
G W 6400 A3 A3 B2
BLACK
LGN PADDLE
J4
8600
J3
YEL/ MOMENTARY
FUEL SHUTOFF P 6500 F1 F1 A2 A2 4810 4810 F F RED
2800
SOLENOID G2 K K
FRONT BASE
FRONT ROD
8100 V 6600 D3 D3 G2
REAR WKLT
MARKER LT
4340
4330
4360
RELAY
RELAY
OPEN
F1
F2
F3
6210
6320
F1
F2
F3
T T 8800 A2 A2 G1 G1 E E
U 8250 900 SERIES J1 J1 D D
REAR BASE
REAR ROD
RESERVED
RESERVED
RESERVED
(R TURN)
(L TURN)
(HORN)
4440
4430
4200
J2
G1
G2
G3
G J2 4450
G1
G2
G3
COLD START B BRN
SOLENOID 8610 8620 D 8200 J3 J3 4480 TURN
C433 C412 C411

D YEL
RELAY OUTPUT
TWO SPEED
BICS LOCK
ATTACHMENT
POSITION
ACCESSORY
SIGNAL
BUCKET
H3
KEY INPUT
CONTROL
8100 E S 6200 H3 4350
TRAVEL
4410
4420
4350
H1
H2
H3
ACCESSORY
8000
9800
4730
A
H1
H2
H3
DGN
1800 A N 6310 F2 F2 4330 CONNECTOR
C
SPARE OUTPUT 1
SPARE OUTPUT 2
REAR BLEED
F1
HIGH FLOW
4340
DIVERTER
8200 D E 8100 F1
RESERVED
(ATT ACC)
E
4460
4450
4470
ALTERNATOR
J1
J2
J3
J1
J2
J3
1020 8250 U A 1800 H1 H1 4410
S RNG/
F3 A
(SERIAL RIGHT)
F3
(SERIAL LEFT)
ACCESSORY DBL
G
CAN SHIELD
FUTURE
FUTURE
CAN HIGH
CAN LOW
EXC
OPEN
1020 RNG/
H2 B
K1
K2
K3
4420 CONNECTOR HORN
9500
9600
9700
1800 K1 H2
K2
K3
1010BAT WHT
G3 G3 4200
2010 BRN/
A RED
STARTER CONNECTS TO BRN/ LIFT
C
G1
G2
G3
H3
C1
H1
C3
C2
D1
D3
D2
H2
J3
E1
F3
F2
B3
E3
B1
B2
E2
F1
A1
A2
A3
K1
K2
K3
C433
J3
J1
J2
CONNECTS TO DGN CONTROL
1010
M S
8200 C407 ON THIS PAGE B
BRN/
BLK
ON THIS PAGE ACCESSORY
R CONNECTOR
8250
2600
C407 C427 120 ohm
G1
G2
G3
H3
C1
H1
C3
C2
D1
D3
D2
H2
J3
E1
F3
F2
B3
E3
B1
B2
E2
F1
A1
A2
A3
K1
K2
K3
J3
J1
J2
ACD & REMOTE START
H
A
G
C
D
E
B
A
F
2300 CONNECTOR
2090
2090
2800 LOCATED AT REAR OF
MACHINE
6400
6500
6600
6300
4730
4730
8800
8250
8000
8150
8110
6320
6210
8210
2100
2110
4650
9450
9450
1110
1120
1130
9500
9600
9700
9800
6000
GROUNDS DIVERTER
G
D
C
B
A
E
F
A A
C426
4450 7.5 ohm nominal
C416
ACCESSORY ACCESSORY at 12 VDC
2480 CONNECTOR CONNECTOR
YELLOW TIE STRAP 2450 B B
G
D
C
2450
B
A
E
F
C401 C402
REAR AUX RELIEF
4660 2400
C417
4480 A A 9.8 ohm nominal
2340
D
B
A
at 12 VDC
B
A
2330 GREEN TIE STRAP 2480 B B
9800
9700
9600
9500
2710
1160
1710
TWO SPEED
2730
1140
1700
1150
2100 4350 A A
2720
1720
9.8 ohm nominal
C436
at 12 VDC
2240 2350 B B
2350
2420 FRONT ROD
2410 2390 4330 A A
C418
3.3 ohm nominal
2200 2330 B B at 10 VDC
2000 FRONT BASE
4340 A A
C419
3.3 ohm nominal
2340 B B at 10 VDC
2300 1800
2740 1720 FUSE 11 HYD LOCK VALVE
25A
2730 1700 1055 4410 A A
C420
9.8 ohm nominal
8000
2120 at 12 VDC
2720 FUSE 12 2410 B B
GOES TO
6310
6000
6300
8100
8150
8110
6320
6200
6210
8200
8210
AHC POWER 25A
ADVANCED HAND
1140
2710 1730
2110 CONTROL MODULE FRONT
1150
1160
BUCKET POSITION
FUSE 10 SWITCHED
C423
FUEL PULL AND REAR STARTER
ATTACHMENT 25A POWER MARKER LIGHT 4420 A A 6.7 ohm nominal
1710 87A 87 86
4650
87A 87 86 87A 87 86 87A 87 86 87A 87 86

1130
LIGHT at 12 VDC
1110
1120
2420 B B
HEATER
30 85 30 85 30 85 30 85 30 85
25A UNSW TRACTION LOCK
COOLING POWER
FUSE 1 FAN
2020
2030
1330
1050
2000
2010
1350
2040
1320
2010
2020
1030
2030
2040
FUSE 9
ARE CONNECTED IN SERIES A
C425
COMPUTER
4200 A 9.8 ohm nominal
9.8 ohm nominal 2200 B B at 12 VDC
30A 15A 15A
4660
1070
at 12 VDC 25A
BATTERY FUSE 6 FUSE 2 FUSE 3
1050 FUSE 4
+ - 1300
100A 1030
1010
1310
1040
V-0014 (4-10-01)
Printed in U.S.A.
344 of 640
ACROSS CONNECTORS
RED = RED
RNG = ORANGE CAB FRONT LIGHT
ACCESSORY
2750
963 WIRING SCHEMATIC BLK = BLACK 2740

A CONNECTORS 2760
B MONITORING 3000-3999 LBL LBL = LIGHT BLUE HARNESS 6718870 M M
B DBL = DARK BLUE
A HYDRAULIC 4000-4999 LGN LEFT FRONT WORKLIGHTS
WITH ADVANCED HAND CONTROL OPTION LGN = LIGHT GREEN
C435
ATTACHMENT CONTROLS 5000-5999 YEL DGN = DARK GREEN 2750 B B 2750
S/N 562215357-15999 SOME CONNECTOR
LIGHTS 6000-6999 PNK YEL = YELLOW 6110 A A 6110 2750
BODIES NOT SHOWN PNK = PINK
(PRINTED APRIL 2001) FOR DRAWING CLARITY ACCESSORIES 7000-7999 WHT WHT = WHITE RIGHT
DGN
DGN
RED
RED
RED
RED
BLK
BLK
BLK
BLK
V-0085 ENGINE 8000-8999 TAN BRN = BROWN
C434
TAN = TAN 6120 A A 6120 2760
COMMUNICATION 9000-9999 PUR PUR = PURPLE 2760 B B 2760
GRY = GRAY
LEFT PANEL
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
C428 C429
9340 D HEADLIGHTS
2910 G GROUND
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
HEATER UNSW ITCHED 1210 E PROTECTED POWER
FRONT & 25A
30A 25A REAR SWITCH 1910 F COMPUTER POWER
MARKER CONNECTS TO
LIGHT POWER FUSE 10
TAILGATE/
FUSE 6 FUSE 2 C407 9210 K SYSTEM Rx
LIGHT
30A 25A
9110 H SYSTEM Tx
2650 15A
C407 9300 A CLOCK/LATCH
WORK LIGHTS
2640 FUSE 7 FUSE 3 FUSE 11
REAR LT ALT & KITS 9310 B DATA
ADVANCED HAND CONTROL MODULE
2630 2600
15A FUEL 25A
STARTER 9330 J START
A
2620 FUSE 4 PULL FUSE 12
HARNESS 6716419 2610
FUSE 8
COMPUTER AHC
9320 C BUZZER
25A 25A
RIGHT
2610 6320 FUEL SENDER
TAILLIGHT
6100
20-270 ohm 9320 +
G
H
C
D
-
E
B
A
BUZZER
F
A
B
J
BACKUP 2930
LEFT
2640 6330 ALARM RIGHT PANEL C430 C431
MAIN FRAME
TAILLIGHT 6100 8 8 6100
A
B
SWITCH
G
H
C
D
K
E
A
F
J
9340 11 11 9340
9200 10 10 9200 9330 J START
A
B
RIGHT 6200
4580
9410
9400
4640
4720
4700
4710
4620
4600
4610
2620 9
1740
2240
C404 C406 9 B
WORK LIGHT 6210 HARNESS 6808364 9100 9100 9310 DATA
C408
2900 4 4 2900 9300 A CLOCK/LATCH
B
A
A
B
1900 2 2 1900 9120 H SYSTEM Tx
LEFT WORK
LIGHT
2630 6210 1200 1 1 1200 9220 K SYSTEM Rx
9350 12 12 9350 1920 F COMPUTER POWER
7100
3100
3110
7100 3920 7 7 3920 2920 G GROUND
BACKUP
1730
ALARM 2650
2740 3 3 2740 C OPEN
2600
7100
6200
6310
POWER FROM
2910 FUSE 12
ON THIS SHEET
C445 C444 C443

t 2900 2920
B
C
C
A
A
B
HYD TEMP SENDER
3300 A A 3300 SEAT 2930
538-1824 ±30 ohm R HANDLE L HANDLE
G
D
C
H
B
A
F
3310 B B 3310 BAR
9340
2900
3900
9350
9200
9100
1900
1200
3920
3910
C
3900 C432 C433
C103 A
+ 3920 B
MAIN
FRAME 2000 CAB CONNECTS TO
C432
CONNECTS TO
3400 A A 3400 HYD CHARGE PRESS A C433
3910 ON THIS PAGE ON THIS PAGE
C SENDER 0.5-7.5 V
3420 C C 3420
G
D
C
H
B
A
F
D2
D1
D3
C3
C2
C1
E3
E2
A1
A2
A3
F2
B3
B2
B1
B B J2
F3
E1
F1
3410 3410 -
RIGHT HANDLE
ENGINE
2600
6600
6500
6400
7100
6200
6310
HYD OIL FILTER
3430 A A 3430
PRESSURE SWITCH
C432
HARNESS 6719160 J2
CONNECTS A
PNK/
RED
D2
D1
D3
C3
C2
C1
E3
E2
A1
A2
A3
F2
B3
B2
B1
F3
E1
F1
J4 J4 TO C432 PNK/ TILT
ON C DGN CONTROL
3020 THIS PAGE B PNK/
6310 N D3 D3 9410 BLK
3110 J1 J2
6200 S C3 9400
3310 3010 C3
+
A
SEATBAR SENSOR
SEATBAR SENSOR
3500
SPARE DIGITIAL
SENSOR SIGNAL
7100 R R E1 4300 4300 B B
GROUND
7100 3410 E1 WHT
SEATBAR
ENG OIL PRESSURE
SUPPLY
3920
C
3900
3910
IN 1
IN 2
IN 1
3520
A1
A2
A3
A1
A2
A3
WHT/
SENDER 0.5-7.5 V 6400 W E3 E3 4320 4320 D D RED PWM
3510 WHT/
C
-
B P
6500 E2 4310 C
TEMP SENDER
J1 J1 E2 4310
HYD TEMP
BLK
SENDER
SIGNAL
OPEN
OPEN
OPEN
3100
3200
3300
B1
B2
B3
B1
B2
B3
6600 V K3
K3
ENGINE COOLANT t TWO
3010 F2 F2 LGN/
HYD CHARGE
HYD CHARGE
SPEED
PRESSURE +
DIGITAL IN 2
3200 A1 F F
PRESSURE
SENDER A1 4910 4910
SIGNAL
SPARE
WHT
OPEN
OPEN
OPEN
C409
E3 E3
3400
3420
3430 J3 J4
C1
C2
C3
C1
C2
C3
500-3000 ± 30 ohm
3210 3020 H H 3020
3420 C2 C2 G G
RH TWO SPEED
BATTERY IN (1)
BATTERY IN (2)
BATTERY IN (3)
LH AUX RIGHT
UNSWITCHE D
UNSWITCHE D
UNSWITCHE D
DETENT
BRAKE SW
C1 B1 4920 4920 E E DGN
1110
1120
1130
4910
4810
4500
3400 C1 B1
BLACK
WHITE
A1
A2
A3
A1
A2
A3
IN
J1
J2
3610
SPEED SENSOR (VR) 3300 B3 B3 K2 K2 K K
3600
LH AUX LEFT
C1 J
ENG SPEED +
BRAKE SW
RH FRONT
PRESSURE +
A1 E2 C1 4930 4930 J
SYSTEM Rx
GROUND
GROUND
PRESSURE
SYSTEM Tx
DETENT
YEL
ENG OIL
ENG OIL
OPEN
SIGNAL
4920
4820
1400
2100
OUT
OPEN
2110
SKI
(hall)
9100
9200
B1
B2
B3
3500
3520
B1
B2
B3
D1
D2
D3
D1
D2
D3
3100 B1 B1 D1 D1 4940 4940 H H LGN CONTROL
J J
FUEL PULL RELAY
A
RH SKI DOWN
LH SKI DOWN
FILTER SIGNAL
B3 A RNG
HYD CHARGE
1400 1490
EHC INPUT
FUEL HOLD
ENG SPEED
COMPUTER
KEY/ENTER
B3
HEADLIGHT
FEEDBACK
SIGNAL (vr)
AIR FILTER
FUEL PULL
K D1
SWITCH
SWITCH
D1
POWER
C405
SIGNAL
A A 3700 3500 K 3500 3500
4930
4830
9400
8800
8110
8150
1900
9350
9340
C1
C2
C3
3600
3700
3430
C1
C2
C3
E1
E2
E3
E1
E2
E3
AIR FILTER SWITCH
C403
B B 3710 3520 L L 3520 3520 D2 D2
STARTER RELAY
A3 D
EHC OUTPUT
4500 1450
SIGNAL (hall)
PROTECTED
C C B2 B2 D
GLOW PLUG
A3
ENG SPEED
BRAKE PULL
3200 3200 3200 4640
GROUNDS
LH SKI UP
RH SKI UP
GROUND
SENSOR
POWER
LEFT HANDLE
OPEN
RELAY
RELAY
OPEN
1200
2900
4940
4840
9410
3010
8210
4110
8510
D1
D2
D3
F1
F2
F3
F1
F2
F3
D1
D2
D3
3600 M M 3600 3600 E1 E1 K1 K1 BRAKE SWITCH J J
X X F3 F3 1480 A A RNG
PWM SIGNAL
BRAKE PULL
COLD START
GLOW PLUG
FEEDBACK
FEEDBACK
FEEDBACK
STARTER
PWM +
PWM -
4310
4320
4300
D2 4840 4840 C C
8250
4150
8550
E1
E2
E3
B B C3 C3 D2 WHT
E1
E2
E3
TEMP SWITCH 2300 2300 SKI
C410
C2 4830 4830 B B DBL CONTROL
3700 F F 3700 3700 E2 A1 C2
YEL/
B2 4820 4820 G G
WHITE
G W 6400 A3 A3 B2
BLACK
LGN PADDLE
J4
8600
J3
YEL/ MOMENTARY
FUEL SHUTOFF P 6500 F1 F1 A2 A2 4810 4810 F F RED
2800
SOLENOID G2 K K
FRONT BASE
FRONT ROD
8100 V 6600 D3 D3 G2
REAR WKLT
MARKER LT
4340
4330
4360
RELAY
RELAY
OPEN
F1
F2
F3
6210
6320
F1
F2
F3
T T 8800 A2 A2 G1 G1 E E
U 8250 900 SERIES J1 J1 H H
REAR BASE
REAR ROD
RESERVED
RESERVED
RESERVED
(R TURN)
(L TURN)
(HORN)
4440
4430
4200
J2
G1
G2
G3
G J2 4450
G1
G2
G3
COLD START B BRN
SOLENOID 8610 8620 D 8200 J3 J3 4480 TURN
C433 C412 C411

D YEL
RELAY OUTPUT
TWO SPEED
BICS LOCK
ATTACHMENT
POSITION
ACCESSORY
SIGNAL
BUCKET
H3
KEY INPUT
CONTROL
8100 E S 6200 H3 4350
TRAVEL
4410
4420
4350
H1
H2
H3
ACCESSORY
8000
9800
4730
A
H1
H2
H3
DGN
1800 A N 6310 F2 F2 4330 CONNECTOR
C
SPARE OUTPUT 1
SPARE OUTPUT 2
REAR BLEED
F1
HIGH FLOW
4340
DIVERTER
8200 D E 8100 F1
RESERVED
(ATT ACC)
E
4460
4450
4470
ALTERNATOR
J1
J2
J3
J1
J2
J3
1020 8250 U A 1800 H1 H1 4410
S RNG/
F3 A
(SERIAL RIGHT)
F3
(SERIAL LEFT)
ACCESSORY DBL
G
CAN SHIELD
FUTURE
FUTURE
CAN HIGH
CAN LOW
EXC
OPEN
1020 RNG/
H2 B
K1
K2
K3
4420 CONNECTOR HORN
9500
9600
9700
1800 K1 H2
K2
K3
1010BAT WHT
G3 G3 4200
2010 BRN/
A RED
STARTER CONNECTS TO BRN/ LIFT
C
G1
G2
G3
H3
C1
H1
C3
C2
D1
D3
D2
H2
J3
E1
F3
F2
B3
E3
B1
B2
E2
F1
A1
A2
A3
K1
K2
K3
C433
J3
J1
J2
CONNECTS TO DGN CONTROL
1010
M S
8200 C407 ON THIS PAGE B
BRN/
BLK
ON THIS PAGE ACCESSORY
R CONNECTOR
8250
2600
C407 C427 120 ohm
G1
G2
G3
H3
C1
H1
C3
C2
D1
D3
D2
H2
J3
E1
F3
F2
B3
E3
B1
B2
E2
F1
A1
A2
A3
K1
K2
K3
J3
J1
J2
ACD & REMOTE START
H
A
G
C
D
E
B
A
F
2300 CONNECTOR
2090
2090
2800 LOCATED AT REAR OF
MACHINE
6400
6500
6600
6300
4730
4730
8800
8250
8000
8150
8110
6320
6210
8210
2100
2110
4650
9450
9450
1110
1120
1130
9500
9600
9700
9800
6000
GROUNDS DIVERTER
G
D
C
B
A
E
F
A A
C426
4450 7.5 ohm nominal
C416
ACCESSORY ACCESSORY at 12 VDC
2480 CONNECTOR CONNECTOR
YELLOW TIE STRAP 2450 B B
G
D
C
2450
B
A
E
F
C401 C402
REAR AUX RELIEF
4660 2400
C417
4480 A A 9.8 ohm nominal
2340
D
B
A
at 12 VDC
B
A
2330 GREEN TIE STRAP 2480 B B
9800
9700
9600
9500
2710
1160
1710
TWO SPEED
2730
1140
1700
1150
2100 4350 A A
2720
1720
9.8 ohm nominal
C436
at 12 VDC
2240 2350 B B
2350
2420 FRONT ROD
2410 2390 4330 A A
C418
3.3 ohm nominal
2200 2330 B B at 10 VDC
2000 FRONT BASE
4340 A A
C419
3.3 ohm nominal
2340 B B at 10 VDC
2300 1800
2740 1720 FUSE 11 HYD LOCK VALVE
25A
2730 1700 1055 4410 A A
C420
9.8 ohm nominal
8000
2120 at 12 VDC
2720 FUSE 12 2410 B B
GOES TO
6310
6000
6300
8100
8150
8110
6320
6200
6210
8200
8210
AHC POWER 25A
ADVANCED HAND
1140
2710 1730
2110 CONTROL MODULE FRONT
1150
1160
BUCKET POSITION
FUSE 10 SWITCHED
C423
FUEL PULL AND REAR STARTER
ATTACHMENT 25A POWER MARKER LIGHT 4420 A A 6.7 ohm nominal
1710 87A 87 86
4650
87A 87 86 87A 87 86 87A 87 86 87A 87 86

1130
LIGHT at 12 VDC
1110
1120
2420 B B
HEATER
30 85 30 85 30 85 30 85 30 85
25A UNSW TRACTION LOCK
COOLING POWER
FUSE 1 FAN
2020
2030
1330
1050
2000
2010
1350
2040
1320
2010
2020
1030
2030
2040
FUSE 9
ARE CONNECTED IN SERIES A
C425
COMPUTER
4200 A 9.8 ohm nominal
9.8 ohm nominal 2200 B B at 12 VDC
30A 15A 15A
4660
1070
at 12 VDC 25A
BATTERY FUSE 6 FUSE 2 FUSE 3
1050 FUSE 4
+ - 1300
100A 1030
1010
1310
1040
V-0085 (4-11-01)
345 of 640
LEFT RIGHT TILT SPOOL LOCK
LEFT PANEL
(NOT Used With AHC and ACS)
FRONT
C421
WORKLIGHTS 2910 G GROUND A A 4370
7.7 ohm
9340 D HEADLIGHTS PWM B B 2370
B A A B 1210 E PROTECTED POWER LIFT SPOOL LOCK
SEE FUSE/RELAY LIFT ARM
C434 C435 1910 F COMPUTER POWER (NOT Used With AHC and ACS)
CENTER SEE CONTROL B A A B SEE CAB CONNECTOR
C422
RELEASE
9110 H SYSTEM Tx 7.7 ohm A A 4380 H
(EUROPEAN FUSE/RELAY SEE THIS PAGE SWITCH THIS PAGE
PWM B B
NON AHC Machines ONLY
2380
2750
LIGHTING)
6110
6120
9210 K SYSTEM Rx
2760
CENTER THIS PAGE H 4030 H H 4030
WIRES CONNECT BY LETTER THIS PAGE
9300 A CLOCK/LATCH
ACROSS CONNECTORS J
C407
G 1340 J 1340 4010 1 FOR
9310 B DATA
S/N 562216000-16025
FUTURE
A B A 6100 A A 6100 2210 2
9330 J START FOR USE
B A 2900 M M 2900 A 4560
9320 C BUZZER FUTURE
(PRINTED APRIL 2001) SOME CONNECTOR
9340 C C 9340 USE
FRONT ROD
B 2560
9200 D D 9200
V-0090 BODIES NOT SHOWN
FOR DRAWING CLARITY 9100 E E 9100
9320 + BUZZER 4020 1 FOR
C420
A A
SEE CONTROL - 9.7 ohm
4410
FUTURE
C408
2930
RED = RED B 4500 F F 4500 1930 RIGHT PANEL 12V B B 2410 2220 2 USE
RNG = ORANGE
MODULE J4 BRAKE
BLK = BLACK THIS PAGE 2740 S S 2740 2770
SWITCH 9330 J START
LBL = LIGHT BLUE 1900 P P 1900
9310 B DATA 4405 A FOR
DBL = DARK BLUE BATTERY FEED 1000-1999 RED, RED/WHT, RNG
LGN = LIGHT GREEN
1200 R R 1200 FUTURE
GROUND 2000-2999 BLK 9300 A CLOCK/LATCH FOR A 4570 2450 B USE
DGN = DARK GREEN MONITORING 3000-3999 LBL 9350 B B 9350 FUTURE
YEL = YELLOW HYDRAULIC 4000-4999 LGN C
9220 K SYSTEM Rx
USE B 2570
3900 L L 3900
PNK = PINK ATTACHMENT CONTROLS 5000-5999 YEL 9120 H SYSTEM Tx
WHT = WHITE LIGHTS 6000-6999 PNK 3920 B SEAT BAR FRONT ROD
2530 GROUNDS G G 3920
SENSOR FOR
BRN = BROWN ACCESSORIES 7000-7999 WHT A
1920 F COMPUTER POWER 44125 A
C418
2480 TAN = TAN ENGINE 8000-8999 TAN 3910 K K 3910 3.3 ohm A A 4330 FUTURE
COMMUNICATION 9000-9999 PUR 1220 E PROTECTED POWER PWM 2415 B USE
2460 PUR = PURPLE N N B B 2330
GRY = GRAY 2910 9350 D RUN/ENTER SWITCH
2900 2920
2900
9340
9200
9100
1900
1200
9350
3900
3920
3910
2450 2930
MAIN 2920 G GROUND
2440 2400 2770 CAB 2000 FRONT BASE DIVERTER
2750 FRAME C OPEN
2740
C419
2430 2760 3.3 ohm A A 4340
CAB 6727178
C416
PWM 4450 A A 7.5 ohm
2340 B B 2340
B3
D3
D2
D1
A1
A2
A3
C3
C2
C1
B2
B1
F2
F3
E3
E1
F1
E2
YELLOW TIE STRAP 2450 B B 12V
2330
2520
J2 WHITE
C406
2100 FUEL SENDER A A 3100 3100 B1 PROTECTED COMPUTER
SYSTEM Tx OPEN OPEN
SEATBAR SENSOR F1 4340
POWER POWER SUPPLY
30-270 ohm REAR AUX RELIEF
2490 B B 3110 F1 F1 E1 D1 C1 B1 A1 F2 4330
C417
4480 A A 9.8 ohm
F3 1200 1900 9100 3900 H1 4410 GREEN TIE STRAP
K3
K2
K1
2420 KEY/ENTER SEATBAR 12V
OPEN
SWITCH
SYSTEM R x OPEN OPEN
SENSOR SIGNAL 2480 B B
2410 J2
K3 4570
F2 E2 D2 C2 B2 A2
900 LOAD SENSE
C405
WHITE
HIGH FLOW /
A A 3700 3700 E2 K2
REAR AUX
DIVERTER
2380 2390 AIR FILTER 9350 9200 3910 4560
RELIEF
4460
4470
4450
J3
J2
J1
HEADLIGHT SEATBAR SENSOR
SWITCH B B 3710 3010 F2 GROUND
SWITCH
OPEN OPEN OPEN
GROUND
F3 4360 TWO SPEED
2370
F3 E3 D3 C3 B3 A3
C441
G2 4350 A A
TWO SPEED
+
SOLENOID
HYD LOCK
2200 7.5 ohm
POSITION
BUCKET
A 2900 9340 3920
4350
4420
4410
H3
H2
H1
A A 3400 3400 C1 G1 2350 B B 12V
C105
2000 HYDRAULIC CHARGE
C
PRESSURE SENDER C C 3420 3420 C2 J2 4450
TRACTION HOLD
2240
- B
REAR BASE
0.5 - 7.5 V
REAR ROD
B B 3410 D3 J3
4200
4430
4440
4480 BUCKET POSITIONING
RESERVED
G3
G2
G1
GROUNDS
DIGITAL 2
SENSOR
3010
SPARE
(hall)
F3
F2
F1
CONTROL MODULE
C423
HYDRAULIC J1 4420 A A 9.8 ohm
2800 TEMPERATURE 12V
C108
SPOOL LOCK
FRONT BASE
FRONT ROD
A A 3300 3300 B3 H3 4350 2420 B B
FILTER SIGNAL
HYD CHARGE
J4 WHITE
4360
ENG SPEED
SENDER
4330
4340
AIR FILTER
3610
F3
F2
F1
3700
SIGNAL
3600
SIGNAL
3430
E3
E2
E1
2300 500-3000 ohm B B 3310 H2 4420
3510
D2 4840
PRESS SIGNAL
2600
PRESSURE +
WHITE
E3
ENG OIL
ENG OIL
3430 3430
3520
J4
C2 4830
OPEN
3500
D3
D2
D1
HYDRAULIC OIL FILTER
BLACK
2110 (DIFFERENTIAL) SWITCH SEE LEFT B2 4820
PWM SIGNAL
HANDLE C A3
PWM +
4640 A2
PWM -
4300
4810
4310
4320
E3
E2
E1
BLACK
2740 CONNECTOR
J1
+ THIS PAGE B3 1400
2730 A SEE CAB CONNECTOR
EHC OUTPUT
D1
PRESS SIGNAL
ENGINE OIL A A 3500 3500 A3
RH SKI UP
2120 4500 B
HYD CHARGE ENG COOLANT
HYD CHARGE
LH SKI UP
PRESSURE +
RESERVED
C107
(AC INPUT)
9410
4840
4940
3420
3400
D3
D2
D1
2720 PRESSURE C THIS PAGE
C3
C2
C1
C C 3520 3520 D2 D1 4940 SEE
J1
2710 SENDER -
0.5-7.5 V
B 3510 CONTROL
B B C1 4930
RH SKI DOWN
LH SKI DOWN
FUEL SENDER
EHC INPUT
MODULE
HYDRAULIC
2350 SPARE ACCESSORY STARTER UNSWITCHED
9400
3300
SIGNAL
4830
4930
3100
OPEN
3200
CAN HIGH OPEN STARTER RELAY FUEL HOLD
C3
C2
C1
TEMP
TEMP
OUTPUT 2 RELAY OUTPU T FEEDBACK BATTERY IN (1 )
B3
B2
B1
OPEN
B1 4920 J1 THIS
K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
C106
SPEED A A 3600 3600 E1
8800
A1 4910 PAGE
9500 8000 8250 8210 1110
LH AUX LEFT
BRAKE SW
RH FRONT
SENSOR
ANALOG 2
ANALOG 1
DETENT
B B
HANDLE
3610 C3
ATTACHMEN T REAR WKLT BRAKE PULL BRAKE PULL UNSWITCHED
E2
4640
SPARE
SPARE
4310
FLOAT
1400
4820
4920
OUT
B3
B2
B1
CAN LOW OPEN FUEL PULL RELAY GROUND
A3
A2
A1
KEY INPUT RELAY FEEDBACK RELAY BATTERY IN (2 )
C
ENGINE t K2 J2 H2 G2 F2 J3
BLACK E2 D2 C2 B2 A2 E3 4320
C104
COOLANT A A B2
RH TWO SPEED
3200 3200
LH AUX RIGHT
9600 9800 6210 4150 4110 8110 2110 1120
BRAKE SW
SENDER E1 4300
4500
TWO SPEED TRAVEL MARKER LT GLOW PLUG GLOW PLUG FUEL PULL UNSWITCHED
4810
4910
A3
A2
A1
CAN SELECT OPEN GROUND
IN
500-3000 ohm B B 3210 MAKE-U P CONTROL RELAY FEEDBACK RELAY FEEDBACK BATTERY IN (3 )
K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
K1
COLD START 9700 4730 6320 8550 8510 8150 2100 1130 C3 9400
TEMPERATURE
SWITCH
J3 BLACK Dealer Copy -- Not for Resale D3
2520
4240
4810
4820
4830
4840
4640
1480
4940
4300
4320
4310
4230
4910
4920
2530
1490
G3
4930
4200
8600
H3
H1
D3
D1
C1
C3
C2
B2
B3
D2
H2
K1
K2
K3
G1
G2
G3
B1
A3
A2
A1
F3
F2
E3
E1
E2
F1
J1
J2
J3
2800 E H J A F G B C K D
8100 B D C G F E K J H A
FUEL SHUTOFF SOLENOID
C409 C410
ALTERNATOR B D C G F E K J H A E H J A F G B C K D
4730
9450
8000
6320
4650
6210
8250
8210
8150
8110
2110
2100
9450
1130
1120
1110
9800
9500
9600
9700
COLD START SOLENOID
S
WHT/LGN
8610 8620
WHT/RED
YEL/RED
YEL/LGN
WHT/BLK
1020
G
DBL
1015 L
DGN
WHT
RNG
RNG
YEL
LGN
WHT
B 1800
STARTER
E
2015
M R
8250
BATTERY CABLE PWM
B S
8200
TWO SKI SIDE SKI
SPD CTRL SHIFT CTRL
C446
A 4650 DETENT
TAILGATE / WORKLIGHTS 6716419 B 4660
FLOW
LEFT HANDLE
F F RIGHT HANDLE
FAN CONNECTOR
2600 B B 2600 (Two Speed Hydraulic Coil)
RIGHT HORN
2620 6200 6200 H H 6200 TURN SIGNAL
WORKLIGHT
C103
6210 6310 A A 6310

LEFT TRACTION LOCK
WORKLIGHT
2630 6210 E E 6400
C425
D D 6500 4200 A A
RIGHT SEE CAB 2200 B B
2610 6320 G G 6600
RNG/WHT
TAILLIGHT
RNG/DBL
CONNECTOR
C404
BRN
DGN
A
YEL
BACKUP 7100 C C 7100 TO OPTIONS
THIS PAGE
LEFT ALARM B (BACKUP
TAILLIGHT
2640 6330 2650 ALARM SWITCH) C407
A
J 2730 E B A D D B A
2650
P 6600
2640
C411 C412
6000
2630 2600 M 6500
TO OPTIONS TO OPTIONS
2620 L 6400 (ACCESSORY (ACCESSORY
F 4730 CONNECTOR) CONNECTOR)
2610
D 4235
N 6300
C488
C 4275
E 4550
S 1700
A 1140
H 1150
R
B
G
K (ALTERNATOR
& KITS) SEE CAB TO OPTIONS
TO OPTIONS 1800 (ACS
FUSE 11 CONNECTOR
(ACCESSORY CONNECTOR) THIS PAGE CONNECTOR)
25A
8000
6300
6000
6310
6320
6200
6210
8200
8210
8100
8150
8110
1130
1120
1110
1700 1055 4220 M M
G
4275 L L
C489
B 2720 SWITCHED MARKER REAR FUEL

POWER LIGHT LIGHT STARTER PULL P P
(COMPUTER)
A 1720 1720
1340
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86
FUSE 4
N N
(ATTACHMENT)
25A
TO OPTIONS K
FUSE 10 4550 K
(ACCESSORY 30 85 30 85 30 85 30 85 30 85
CONNECTOR) 25A FUSE 7 9720 E E
1710 15A
1050
2000
2010
1330
2020
2030
1320
2010
2020
1350
2040
2050
D D
NON-AHC JUMPER
1030
2030
2040
9620 9620
C492
120
(HEATER) OHM R R 120
FUSE 1
25A
FUSE 2
15A
FUSE 3
15A
FUSE 6
30A RESISTOR S S OHM
RESISTOR
HARNESS - 6810192
MAINFRAME HARNESS - 6809286 1140 F J J
9520 C C 9520
1150 1160 G G
1070 2240 H H
RELAY GROUNDS 2000-2060 FUSE 9 1740 B B
ARE CONNECTED IN SERIES 25A
FUSE / RELAY CENTER
25A
(UNSWITCHED 1170 A A
POWER) (ACS) F F
FUSE 12
1040
HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
FUEL PULL FR & MK LT ATTCHM NT
30A 15A 25A

LIFT ARM REAR LT ALT & KITS
1160
1730
9800
9510
9610
9710
2710
15A 15A FUEL 25A
STARTER
COMPUTER ACS 1050
25A 25A - + 1300 F E D A B C G
TO OPTIONS
100A
1010 1030
C426 (ATTACHMENT
CONTROL)
1310 F E D A B C G
ACD & REMOTE
Printed in U.S.A.
1040 START CONNECTOR
V-0090 (4-10-01)
2090
346 of 640 BATTERY 120
OHM
RESISTOR
LEFT RIGHT LEFT PANEL
FRONT
WORKLIGHTS 2910 G GROUND
9340 D HEADLIGHTS
B A A B 1210 E PROTECTED POWER
LIFT ARM
C434 C435 1910 F COMPUTER POWER
RELEASE B A A B
S/N 562216000-16025 (AHC Machines ONLY) SWITCH
9110 H SYSTEM Tx
2750
TILT SPOOL LOCK
6110
6120
9210 K SYSTEM Rx
2760
WIRES CONNECT BY LETTER SEE CONTROL H H 4030 (NOT Used With AHC and ACS)
S/N 562216026 AND ABOVE SEE FUSE/RELAY FUSE/RELAY 9300 A CLOCK/LATCH DIVERTER

ACROSS CONNECTORS
C421
J
C407
CENTER G 1340 J 1340 A A 4370
CENTER THIS PAGE 9310 B DATA 7.7 ohm
C416
A B (EUROPEAN A 6100 A A 6100 PWM B B 2370 4450 A A 7.5 ohm
S/N 516516001 AND ABOVE LIGHTING) 9330 J START 12V

B A THIS PAGE
2900 M M 2900 YELLOW TIE STRAP 2450 B B
9320 C BUZZER LIFT SPOOL LOCK
9340 C C 9340 (NOT Used With AHC and ACS)
(PRINTED APRIL 2001) SOME CONNECTOR
D
C422
BODIES NOT SHOWN 9200 D 9200 7.7 ohm A A 4380
9320 +
E E PWM
V-0084 B B
FOR DRAWING CLARITY 9100 9100 BUZZER 2380
SEE CONTROL -
C408
2930
MODULE J4
B 4500 F F 4500 1930 RIGHT PANEL
BRAKE
RED = RED THIS PAGE 2740 S S 2740 2770
SWITCH
RNG = ORANGE
9330 J START BICS HYDRAULIC
1900 P P 1900 LOCK REAR AUX RELIEF
BLK = BLACK
9310 B DATA
C417
C420
LBL = LIGHT BLUE 1200 R R 1200 9.7 ohm A A 4410 4480 A A 9.8 ohm
GROUND 2000-2999 BLK 9300 A CLOCK/LATCH GREEN TIE STRAP
DBL = DARK BLUE MONITORING 3000-3999 LBL 9350 B B 9350 12V B B 2410 2480 B B 12V
LGN = LIGHT GREEN HYDRAULIC 4000-4999 LGN C
9220 K SYSTEM Rx
DGN = DARK GREEN 3900 L L 3900
ATTACHMENT CONTROLS 5000-5999 YEL 9120 H SYSTEM Tx
YEL = YELLOW LIGHTS 6000-6999 PNK 3920 B SEAT BAR FRONT ROD
2530 GROUNDS G G 3920
SENSOR
PNK = PINK ACCESSORIES 7000-7999 WHT A
1920 F COMPUTER POWER
C418
2480 WHT = WHITE ENGINE 8000-8999 TAN 3910 K K 3910 3.3 ohm A A 4330
BRN = BROWN COMMUNICATION 9000-9999 PUR 1220 E PROTECTED POWER PWM
2460 N N B B 2330
TAN = TAN 2910 9350 D RUN/ENTER SWITCH
2900 2920
2900
9340
9200
9100
1900
1200
9350
3900
3920
3910
2450 PUR = PURPLE 2930
GRY = GRAY MAIN 2920 G GROUND
2440 2400 2770 CAB 2000 FRONT BASE
2750 FRAME C OPEN
2740
C419
2430 2760 3.3 ohm A A 4340
2340 CAB 6727178 PWM

B B 2340
B3
D3
D2
D1
A1
A2
A3
C3
C2
C1
B2
B1
F2
F3
E3
E1
F1
E2
2330 TWO SPEED
C441
2520 4350 A A
J2 WHITE 7.5 ohm
C406
2100 FUEL SENDER A A 3100 3100 B1 PROTECTED COMPUTER
SYSTEM Tx OPEN OPEN
SEATBAR SENSOR F1 4340 2350 B B 12V
POWER POWER SUPPLY
30-270 ohm
2490 B B 3110 F1 F1 E1 D1 C1 B1 A1 F2 4330
F3 1200 1900 9100 3900 H1 4410 BUCKET POSITIONING
K3
K2
K1
2420 OPEN
KEY/ENTER
SYSTEM R x OPEN OPEN
SEATBAR
C423
SWITCH SENSOR SIGNAL
2410 J2
K3 4420 A A 9.8 ohm
F2 E2 D2 C2 B2 A2
900 LOAD SENSE
12V
C405
WHITE
HIGH FLOW /
A A 3700 3700 E2 K2 2420 B B
REAR AUX
DIVERTER
2380 2390 AIR FILTER 9350 9200 3910
RELIEF
4460
4470
4450
J3
J2
J1
HEADLIGHT SEATBAR SENSOR
SWITCH B B 3710 3010 F2 GROUND
SWITCH
OPEN OPEN OPEN
GROUND
F3 4360
2370
F3 E3 D3 C3 B3 A3
G2
TWO SPEED
+
SOLENOID
HYD LOCK
2200
POSITION
BUCKET
A 2900 9340 3920
4350
4420
4410
H3
H2
H1
A A 3400 3400 C1 G1
C105
2000 HYDRAULIC CHARGE
C
PRESSURE SENDER C C 3420 3420 C2 J2 4450
TRACTION HOLD
2240
- B
REAR BASE
0.5 - 7.5 V
REAR ROD
B B 3410 D3 J3
4200
4430
4440
4480
RESERVED
G3
G2
G1
GROUNDS
DIGITAL 2
SENSOR
3010
SPARE
(hall)
F3
F2
F1
2800
HYDRAULIC
TEMPERATURE CONTROL MODULE J1
C108
SPOOL LOCK
FRONT BASE
FRONT ROD
A A 3300 3300 B3 H3 4350
FILTER SIGNAL
HYD CHARGE
J4 WHITE
4360
ENG SPEED
SENDER
4330
4340
AIR FILTER
3610
F3
F2
F1
3700
SIGNAL
3600
SIGNAL
3430
E3
E2
E1
2300 500-3000 ohm B B 3310 H2 4420
3510
D2 4840
PRESS SIGNAL
2600
PRESSURE +
WHITE
E3
ENG OIL
ENG OIL
3430 3430
3520
J4
C2 4830
OPEN
3500
D3
D2
D1
HYDRAULIC OIL FILTER
BLACK
2110 (DIFFERENTIAL) SWITCH SEE LEFT B2 4820
PWM SIGNAL
HANDLE C A3
PWM +
4640 A2
PWM -
4300
4810
4310
4320
E3
E2
E1
BLACK
2740 CONNECTOR
J1
+ THIS PAGE B3 1400
2730 A SEE CAB CONNECTOR
EHC OUTPUT
D1
PRESS SIGNAL
ENGINE OIL A A 3500 3500 A3
RH SKI UP
2120 4500 B
HYD CHARGE ENG COOLANT
HYD CHARGE
LH SKI UP
PRESSURE +
RESERVED
C107
(AC INPUT)
9410
4840
4940
3420
3400
D3
D2
D1
2720 PRESSURE C THIS PAGE
C3
C2
C1
C C 3520 3520 D2 D1 4940 SEE
J1
2710 SENDER -
0.5-7.5 V
B 3510 CONTROL
B B C1 4930
RH SKI DOWN
LH SKI DOWN
FUEL SENDER
EHC INPUT
MODULE
HYDRAULIC
2350 SPARE ACCESSORY STARTER UNSWITCHED
9400
3300
SIGNAL
4830
4930
3100
OPEN
3200
CAN HIGH OPEN STARTER RELAY FUEL HOLD
C3
C2
C1
TEMP
TEMP
OUTPUT 2 RELAY OUTPU T FEEDBACK BATTERY IN (1 )
B3
B2
B1
OPEN
B1 4920 J1 THIS
K1 J1 H1 G1 F1 E1 D1 C1 B1 A1
C106
SPEED A A 3600 3600 E1
8800
A1 4910 PAGE
9500 8000 8250 8210 1110
LH AUX LEFT
BRAKE SW
RH FRONT
SENSOR
ANALOG 2
ANALOG 1
DETENT
B B
HANDLE
3610 C3
ATTACHMEN T REAR WKLT BRAKE PULL BRAKE PULL UNSWITCHED
E2
4640
SPARE
SPARE
4310
FLOAT
1400
4820
4920
OUT
B3
B2
B1
CAN LOW OPEN FUEL PULL RELAY GROUND
A3
A2
A1
KEY INPUT RELAY FEEDBACK RELAY BATTERY IN (2 )
C
ENGINE t K2 J2 H2 G2 F2 J3
BLACK E2 D2 C2 B2 A2 E3 4320
C104
COOLANT A A B2
RH TWO SPEED
3200 3200
LH AUX RIGHT
9600 9800 6210 4150 4110 8110 2110 1120
BRAKE SW
SENDER E1 4300
4500
TWO SPEED TRAVEL MARKER LT GLOW PLUG GLOW PLUG FUEL PULL UNSWITCHED
4810
4910
A3
A2
A1
CAN SELECT OPEN GROUND
IN
500-3000 ohm B B 3210 MAKE-U P CONTROL RELAY FEEDBACK RELAY FEEDBACK BATTERY IN (3 )
K3 J3 H3 G3 F3 E3 D3 C3 B3 A3
K1
COLD START 9700 4730 6320 8550 8510 8150 2100 1130 C3 9400
TEMPERATURE
D3 9410
SWITCH
J3 BLACK
2520
4240
4810
4820
4830
4840
4640
1480
4940
4300
4320
4310
4230
4910
4920
2530
G3
4930
4200
1490
8600
H3
H1
D3
D1
C1
C3
C2
B2
B3
D2
H2
K1
K2
K3
G1
G2
G3
B1
A3
A2
A1
F3
F2
E3
E1
E2
F1
J1
J2
J3
2800 E H J A F G B C K D
8100 B D C G F E K J H A
FUEL SHUTOFF SOLENOID
C409 C410
ALTERNATOR B D C G F E K J H A E H J A F G B C K D
4730
9450
8000
6320
4650
6210
8250
8210
8150
8110
2110
2100
9450
1130
1120
1110
9800
9500
9600
9700
COLD START SOLENOID
S
WHT/LGN
8610 8620
WHT/RED
YEL/RED
YEL/LGN
WHT/BLK
1020
G
DBL
1015 L
DGN
WHT
RNG
RNG
YEL
LGN
WHT
B 1800
STARTER
E
2015
M R
8250
BATTERY CABLE PWM
B S
8200 TWO SKI SIDE SKI
SPD CTRL SHIFT CTRL
C446
A 4650 DETENT
TAILGATE / WORKLIGHTS 6716419 B 4660
FLOW
LEFT HANDLE
F F RIGHT HANDLE
FAN CONNECTOR
2600 B B 2600 (Two Speed Hydraulic Coil)
RIGHT HORN
2620 6200 6200 H H 6200 TURN SIGNAL
WORKLIGHT
C103
6210 6310 A A 6310

TRACTION LOCK
9410
9400
LEFT
WORKLIGHT
2630 6210 E E 6400
C425
D D 6500 4200 A A
RIGHT SEE CAB 2200 B B
2610 6320 G G 6600
RNG/WHT
TAILLIGHT B A
RNG/DBL
CONNECTOR
C404
BRN
DGN
A
YEL
7100 C C 7100 TO OPTIONS
LEFT
BACKUP
ALARM B (BACKUP
THIS PAGE
C473
TAILLIGHT
2640 6330 2650 ALARM SWITCH) C407 B A
A
J 2730 ACS E B A D D B A
2650
9420
9420
P 6600 JUMPER
2640
C411 C412
6000
2630 2600 M 6500
2620 L 6400 (ACCESSORY (ACCESSORY
F 4730 CONNECTOR) CONNECTOR)
2610
D 4235
N 6300
C488
C 4275
E 4550
S 1700
A 1140
H 1150
R
B
G
K (ALTERNATOR
& KITS) SEE CAB TO OPTIONS
TO OPTIONS 1800 (ACS
FUSE 11 CONNECTOR
(ACCESSORY CONNECTOR) THIS PAGE CONNECTOR)
25A
8000
6300
6000
6310
6320
6200
6210
8200
8210
8100
8150
8110
1130
1120
1110
1700 1055 4220 M
G
4275 L
C489
B 2720 SWITCHED MARKER REAR FUEL

POWER LIGHT LIGHT STARTER PULL P
(COMPUTER)
A 1720 1720
1340
87A 87 86 87A 87 86 87A 87 86 87A 87 86 87A 87 86
FUSE 4
N
(ATTACHMENT)
25A
TO OPTIONS 4550 K
(ACCESSORY FUSE 10 30 85 30 85 30 85 30 85 30 85
CONNECTOR) 25A FUSE 7 9720 E
1710 15A
1050
2000
2010
1330
2020
2030
1320
2010
2020
1350
2040
2050
D
1030
2030
2040
9620
C492
(HEATER) 120 R
FUSE 2
FUSE 1 FUSE 3 FUSE 6 OHM S
25A 15A 15A 30A
RESISTOR
MAINFRAME HARNESS - 6729058 1140
9520
J
C
1150 1160 G
1070 2240 H
RELAY GROUNDS 2000-2060 FUSE 9 1740 B
ARE CONNECTED IN SERIES 25A
FUSE / RELAY CENTER
25A
(UNSWITCHED 1170 A
POWER) (ACS) F
FUSE 12
HEATER UNSWITCHED
FRONT &
30A 25A REAR SWITCH 25A
MARKER
FUSE 6 FUSE 2 LIGHT POWER FUSE 10
LIGHT
1040
FUEL PULL FR & MK LT ATTCHM NT
30A 15A 25A

LIFT ARM REAR LT ALT & KITS
1160
1730
9800
9510
9610
9710
2710
15A 15A FUEL 25A
STARTER
COMPUTER ACS 1050
25A 25A - + 1300 F E D A B C G
TO OPTIONS
100A
1010 1030
C426 (ATTACHMENT
ACD & REMOTE CONTROL)
1310 START CONNECTOR
Printed in U.S.A.
1040 V-0084 (4-11-01)
BATTERY
347 of 640
OPTIONS EUROPEAN ONLY TO ENGINE OR MAINFRAME
TO ENGINE OR MAINFRAME
S/N 562215001 AND ABOVE 7100 C
RNG C
S/N 516515001 AND ABOVE RNG/DGN F
2650 F
G
C103
(PRINTED APRIL 2001) 6600
DGN/YEL G
C103
V-0080 BACK-UP
6400 E
BACK-UP
YEL E
ALARM 6310 A
ALARM PNK A
6500 D
DGN D
6200 H
BLK/WHT H AIR CONDITIONER SWITCH
2600 B
BLK B THERMOSTAT
3100 A A
DGN/YEL
C630
DGN/YEL
C612
6340
OFF A 7010 B B
2620
PNK
BLK
2610
6610
6320
BLK
6620
6330
2640
PNK
PNK
BLK
BLK
LOW B 2310 2205 C C
2100
MEDIUM TO OPTIONS (AC)
2630 6210 HIGH
DBL/WHT E F C A B D F E D C B A
E F C A B D F E D C B A
C602 C603 C604 C605 REGISTRATION LEFT WORK RIGHT WORK
REGISTRATION LEFT WORK RIGHT WORK HERE OR TO OPTIONS
E F C A B D F E D C B A LAMP (HVAC JUMPER) HEATER VALVE
E F C A B D F E D C B A LAMP
DBL A A 3200 1300 A A RED 10
C613
WHT B B 7200 D D WHT 8 M
C614
7000
DELUXE EUROPEAN C
1110
BLK C C 2110 2130 C C BLK 7
REAR TAILLIGHT HARNESS - 6714546
POTENTIOMETER B B
LEFT TAILLIGHT RIGHT TAILLIGHT
TAILLIGHT HARNESS - 6718198 1000 B E E
LEFT TAILLIGHT RIGHT TAILLIGHT F F
L BLOWER MOTOR
5000 3 3 YEL
TO OPTIONS
TO MAINFRAME M
2 2
C617 OR C642
(HVAC OR HVAC/ACCESSORY) 1200 RED

C611
A 1140 1140 B H 1010 1 1 RNG M
D A 4 4
C401
1700 1740 2200 BLK

BLOWER SWITCH POWER RELAY
B 2730 2740 C 5 5 TO OPTIONS
(DELUXE ACCESSORY)
C 1120 FLASHER TO OPTIONS REAR WIPER 6 6 85 86
1740 2210
(POWER BOB-TACH) MOTOR 87 A
C617
1150
LIGHT SWITCH 30
POWER BOB-TACH B
BEACON SWITCH 2770 E V 87A 1190

2745
1
6420
SWITCH
2760 D M HVAC HARNESS - 6725933 2740 C
C601
6 5 2 1 REAR WIPER 1700
4 7000 A SWITCH
2
1130 6010 HAZARD SWITCH C
X L 6520 TRAVEL CONTROL
3 1 3 1720 LOCKOUT SWITCH
1180 6430 7010 B 2 1 FRONT WIPER
1 2 3
2 3 4 7220 SWITCH
5 1
4 TO OPTIONS (HVAC)
4 5 2
6530 3 1730 TO OPTIONS (HVAC) HEATER VALVE
TO OPTIONS 6 6
C631
C612
5 2750 2 1 B B 2310 2300 B
(EXTERIOR CAB) 6 TO MAINFRAME
5
4 1750 4700 A 1300 A A RED 10
C633
2725 3 A A 7030 A
E 6700 A 3 4
2715 D 7200 B B WHT 8 M
C614
D 2780 B 6
4 5 C 2130 C C BLK 7
C670
7310 DIODE
C 6300 6300 G 5 B AIR CONDITIONER
TO OPTIONS 6 CLUTCH SOLENOID
C427
F 6440 6400 E (DOME LIGHT)
6 E
A C HVAC JUMPER HARNESS -
C608
2710 B F
B 6540 6500 F
TO LEFT HANDLE CONNECTOR 6600 H 2
1110
1190
A
6725934 OR 6725936
7020
7010
6410 D TO EUR0. LIGHTS 4700 D 1 2700
CONNECTOR
6510 A C411 POWER 2790 TO OPTIONS (FRONT WIPER)
PLUG
6000 B C DOME LIGHT
C TO OPTIONS SWITCH B A
F
C608
E A RED C632
C667
7210 A
4710 D B BLK
B A
E
1160
2735 B
DOME LIGHT AIR CONDITIONER
DELUXE ACCESSORY HARNESS - 6715366 HARNESS -
6719630 EVAPORATOR (AC)
PRESSURE SWITCH
TO OPTIONS
TO MAINFRAME
C617 OR C642
(HVAC OR HVAC/ACCESSORY)
A 1140 1140 B
D 1700 A
C401
1740
B 2730 2740 C
C 1150 FLASHER TO OPTIONS REAR WIPER
(POWER BOB-TACH) MOTOR
LIGHT SWITCH POWER BOB-TACH TO ENGINE OR MAINFRAME
BEACON SWITCH 2770 E V
1
SWITCH
M
2745 6420 2760 D BACK-UP
RNG C
C601
6 5 2 1 REAR WIPER 1710
4 7000 A SWITCH
ALARM RNG/DGN F
2
HAZARD SWITCH
1130
C103
6010
6520 C TRAVEL CONTROL G TO ENGINE OR MAINFRAME
3 X L 1 3
1180 6430 7010 B 1720 LOCKOUT SWITCH E
1 2 3 2 1 FRONT WIPER
2 3 4 7220 RNG C
5 SWITCH PNK A
4 1
4 5 2 RNG/DGN F
6530 3
1730 D
TO OPTIONS 5 6 2 1 G
6 2750
C103
(EXTERIOR CAB) 6 TO MAINFRAME 4 1750
DBL/WHT H
5 4700 E
E 6700 2725 A 3 2715 BLK B BACK-UP
3 4
6
ALARM A
D 2780 B 4 5
BACK-UP ALARM
C670
5 7310 D
C 6300 6300 G
DBL/WHT
TO OPTIONS 6 H
C427
F 6440 6400 E (DOME LIGHT) 6

HARNESS - 6715659
PNK
BLK
PNK
BLK
BLK
BLK
B
A C
C608
2710 B
B 6540 6500 F 1110 A
TO LEFT HANDLE CONNECTOR 6600 H 2 1190
6410 D TO EUR0. LIGHTS 4700 D 1 2700
CONNECTOR LEFT RIGHT
6510 A POWER 2790 LEFT RIGHT
C411
TO OPTIONS (FRONT WIPER) WORK WORK

PLUG TAILLIGHT TAILLIGHT
6000 B C LIGHT LIGHT
C F TO ATTACHMENT
E REAR LIGHT HARNESS - 6714350 B
C667
7210 A
4710 D J
1760 E N
TO MAINFRAME
DELUXE ACCESSORY HARNESS - 6725273 2735 B P
C404
B
M TO OLDER
7100 A A MODEL ATTACHMENTS
C506
D WHT S
BACK-UP ALARM
TO MAINFRAME C BRN LT
SWITCHES
C623
TO OPTIONS
B 2730 (POWER BOB-TACH) 7110 E BLK TM
STROBE OR TO MAINFRAME
POWER BOB-TACH F DBL CENTER
C401
BEACON A 2770 E
SWITCH
C402
FLASHER 1720 1730 A G RED GD
C 2760 D
C601
1 2720 B H YEL RT
D 1700 7000 A
2 1
BEACON SWITCH
6
2
C BACK-UP ALARM L RNG
2745 ADDITIONAL POWER
LEFT
FLASHER
RIGHT
FLASHER
C609 4
5 HAZARD SWITCH 3
7010 B
SWITCHES HARNESS - CONNECTOR
K RNG
2 1
GRADER HARNESS -
C491
B
LIGHT LIGHT 2 1 TO
STROBE/BEACON 3
1180
1130
X L
6010
3
6430 5 4
6718820 OR 6807152 1740 A
(EXTERIOR CAB)
1 2
4
6530
6 6707303
6700 E 5 2750
6
C668 OR C670
E 6700
2775
TO OPTIONS A
TO OPTIONS A TO MAINFRAME
(EXTERIOR CAB)
2790
2795
(4 WAY FLASHER) C
C668
C G ADDITIONAL POWER CONNECTOR
6440 1 2 2785 2780 D
C669
C490
1740
C669
F 6440 6400 E
2785 2 1 6440 F
D 2780 D 2740 B
6540 3 3 6540 B FRONT WIPER
C427
B 6540 6500 F M BOTTLE AND TANK

4 WAY FLASHER EXTERIOR CAB HARNESS - A
FRONT WIPER
TO MAINFRAME
B (ACCESSORY CONNECTOR)
HARNESS - 6718873 6718872 C
MOTOR
1730 1720 A
STANDARD ACCESSORY HARNESS - 6715365
C402
V
H
M
2720 B
C622 ALARM
7200 or YEL
7150 or DGN
TO HANDLE CONNECT0R
2765 or BRN
HORN
L X
C412
2730 B
AIR CONDITIONER SWITCH
7200 A
OFF
7000
3100
FRONT HORN HARNESS -
TO OPTIONS
2745
LOW
MEDIUM TO OPTIONS (HVAC) 2205 C C THERMOSTAT
(HVAC) (DELUXE ACCESSORY)
(DELUXE ACCESSORY)
C 7310
6719151 or 6727498
2100
C639
HIGH C 2740 C
C636
C642
6 7010 B B B 2735 2755 B B
C610
B 1140 B
C667
5 3100 A A E 7160 C C
A 1740 A
C634
HEATER VALVE 4 2200 A 7210 A A

DBL A A 3200 1300 A A RED 10 3 5000 3 3 YEL BLOWER MOTOR
HVAC/ACCESSORY D
WIPER HARNESS - 6718295
C637
C635
WHT B B 7200 B B WHT 8 M 2 1200 2 2 RED

F
7000
HARNESS -
C638
M
C
1110
BLK
POTENTIOMETER
C C 2110 2130 C C BLK 7 1 1010 1 1 RNG
or 6729739
B
2210 4
5
4
5
BLK
6725390 OR 6807266
1000 RED = RED
TO OPTIONS 6 6 TO ATTACHMENT RNG = ORANGE WIRES CONNECT BY LETTER
TO
(HVAC ADAPTER) (BOOM BLK = BLACK ACROSS CONNECTORS
MAINFRAME
L CONNECTOR) LBL = LIGHT BLUE
5000 3 TO OPTIONS A B
A 9500 A DBL = DARK BLUE
M (HVAC HARNESS)
1200 2 LGN = LIGHT GREEN B A BATTERY FEED 1000-1999 RED, RED/WHT, RNG
B 9600 B
C634
C640
H DGN = DARK GREEN GROUND 2000-2999 BLK
1010 1 7020 A MONITORING 3000-3999 LBL
C 9700 C YEL = YELLOW
2200 4 SOME CONNECTOR HYDRAULIC 4000-4999 LGN
C666
C426
PNK = PINK
C640
BLOWER SWITCH POWER RELAY D 9800 D BODIES NOT SHOWN ATTACHMENT CONTROLS 5000-5999 YEL

C641
A 7010 6 TO OPTIONS 2320 B B AIR CONDITIONER WHT = WHITE

BRN = BROWN FOR DRAWING CLARITY LIGHTS 6000-6999 PNK
(HVAC/ACCESSORY) 7020 A A CLUTCH SOLENOID 1 1710 E ACCESSORIES 7000-7999 WHT
TO OPTIONS 5 1740
85 86
2210
TAN = TAN
(HVAC ADAPTER) A 2 1160 F PUR = PURPLE ENGINE 8000-8999 TAN
87 COMMUNICATION 9000-9999 PUR
C636
30 3 2710 G GRY = GRAY
87A 1190 B
HVAC HARNESSES - 6717877 OR 6725275 2740 C HVAC ADAPTER HARNESSES - 6726357 BOOM HARNESS - 6718426 V-0080 (4-11-01)
Printed in U.S.A.
348 of 640
OPTIONS SSL 7-PIN
C426 To Mainframe
Harness
CAN CONNECTOR D F C E A B G
S/N 562215001 AND ABOVE
(PRINTED APRIL 2001)
9800
1160
9700
1710
9500
9600
2710
V-0017
KEY "RUN" D 9800 C705 J1 - 8-PIN
UNSW POWER 2 1160 2720 H GROUND
CAN SHIELD C 9720 9710 F CAN SHIELD
RIGHT HANDLE SW POWER 1 1740 1730 B SW POWER
A 1 1 PNK/RED
CAN HIGH A 9503 9604 E CAN LOW
C432
C450
C 3 3 PNK/DGN
TILT CAN LOW B 9606 9501 D CAN HIGH
CONTROL
B 2 2 PNK/BLK
GROUND 3 2730 7-PIN / 14-PIN C OPEN
7-PIN SELECTOR SWITCH
C666 ATTACHMENT
CONNECTOR 9501 1
2
A OPEN
G OPEN
3 9500
J 9503
B WHT
4 BOOM-MOUNTED
N 9604 5
D WHT/RED PWM 6 9600 ACD CONNECTORS
SW POWER K 1750 9606
C WHT/BLK
GROUND B 2740 C703 J2 - 10-PIN BLACK
TWO E OUTPUT E 5100 5100 C E OUTPUT
C409
F WHT/LGN SPEED F OUTPUT F 5350 5350 H F OUTPUT

G G OUTPUT G 5400 5400 J G OUTPUT
DETENT H
E DGN H OUTPUT 5050 5050 B H OUTPUT
K C OUTPUT C 5300 5300 G C OUTPUT
D OUTPUT D 5150 5150 D D OUTPUT
J YEL
SKI A OUTPUT A 5250 5250 F A OUTPUT
H LGN CONTROL
M OUTPUT M 5200 5200 E B OUTPUT
A RNG
ID (K TO L) L 5910 5000 A J OUTPUT
ID (K TO P) P 5510 5450 K K OUTPUT
D PUR FLOAT
J SIGNAL C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
A RNG CONNECTOR
5900 J ID #1
C WHT SKI 5500 A ID #2
C410
B DBL CONTROL
B ID #3
G PNK PADDLE C ID #4
F TAN MOMENTARY
D ID #0
K E OPEN
E F OPEN
H G OPEN
H OPEN
B BRN DELUXE ATTACHMENT CONTROL HARNESS - 6719434
Dealer Copy -- Not for Resale K OPEN
C449 C412 C411
TURN
D YEL
SIGNAL
A DGN
C
E SSL 7-PIN
C426 To Mainframe
Harness
CAN CONNECTOR D F C E A B G
A BLK
B RED HORN
9800
1160
1710
9500
9600
2710
9700
A 1 1 RED/WHT
C705
C433
3
LIFT KEY "RUN" D 9800 J1 - 8-PIN
C 3 PUR/WHT
CONTROL
2 UNSW POWER 2 1160 2720 H GROUND
B 2 BLK/WHT
CAN SHIELD C 9710 9710 F CAN SHIELD
LEFT HANDLE
SW POWER 1 1730 1720 B SW POWER
CAN LOW B 9620 9610 E CAN LOW
ADVANCED HAND CONTROL CAN HIGH
GROUND
A
3
9520
2730
9510 D CAN HIGH
C OPEN
(WITH PUSH BUTTON FLOAT) - 7-PIN A OPEN
C666 ATTACHMENT
RIGHT STEERING LEVER - 6675742 and J
CONNECTOR G OPEN
LEFT STEERING LEVER 6675750 N
BOOM-MOUNTED
ACD CONNECTORS
SW POWER K 1740
GROUND B 2740 C703 J2 - 10-PIN BLACK
C433
C433
E OUTPUT E 5100 5100 C E OUTPUT

(TO "D" PIN)
(TO "B" PIN)
A RNG A
C410
C431
C LGN C 4640
F OUTPUT F 5350 5350 H F OUTPUT
B BLK B G OUTPUT G 5400 5400 J G OUTPUT
- + H OUTPUT H 5050 5050 B H OUTPUT
C OUTPUT C 5300 5300 G C OUTPUT
D OUTPUT D 5150 5150 D D OUTPUT
ADVANCED HAND CONTROL ADVANCED HAND CONTROL A OUTPUT

M OUTPUT
A
M
5250
5200
5250
5200
F A OUTPUT
E B OUTPUT
G SERIES JUMPER G SERIES FLOAT ID (K TO L) L 5910 5000 A J OUTPUT
HARNESS - 6728742 HARNESS - 6727328 ID (K TO P) P 5510 5450 K K OUTPUT
C506 14-PIN
ATTACHMENT C704 J3 - 10-PIN GRAY
CONNECTOR
RED = RED 5900 J ID #1
RNG = ORANGE WIRES CONNECT BY LETTER 5500 A ID #2
BLK = BLACK ACROSS CONNECTORS BATTERY FEED 1000-1999 RED, RED/WHT, RNG
LBL = LIGHT BLUE GROUND 2000-2999 BLK B ID #3
DBL = DARK BLUE A B MONITORING 3000-3999 LBL
C ID #4
LGN = LIGHT GREEN HYDRAULIC 4000-4999 LGN
B A
DGN = DARK GREEN ATTACHMENT CONTROLS 5000-5999 YEL D ID #0
YEL = YELLOW LIGHTS 6000-6999 PNK
SOME CONNECTOR ACCESSORIES 7000-7999 WHT E OPEN
PNK = PINK
WHT = WHITE BODIES NOT SHOWN ENGINE 8000-8999 TAN F OPEN
COMMUNICATION 9000-9999 PUR
BRN = BROWN FOR DRAWING CLARITY G OPEN
TAN = TAN
H OPEN
PUR = PURPLE
GRY = GRAY DELUXE ATTACHMENT CONTROL HARNESS - 6727177 or 6729380 K OPEN
Printed in U.S.A. V-0017 (4-11-01)
349 of 640
To
Mainframe C410
963 WIRING SCHEMATIC E H J A F G B C K D
OPTIONS
1480
4820
4840
4640
4810
4830
S/N 562216000-16107 MONITORING 3000-3999 LBL
HYDRAULIC 4000-4999 LGN
S/N 516516001-16011 ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK
4650
(PRINTED APRIL 2001) ACCESSORIES 7000-7999 WHT
ENGINE 8000-8999 TAN
V-0081 COMMUNICATION 9000-9999 PUR
E H J A F G B C K D
To
Mainframe C409 C410
B D C G F E K J H A E H J A F G B C K D
WHT/LGN
ACROSS CONNECTORS
WHT/RED
WHT/BLK
TAN
A B
DBL
DGN
PNK
WHT
RNG
PUR
RNG
YEL
LGN
WHT
B A
SOME CONNECTOR
BODIES NOT SHOWN PWM
FOR DRAWING CLARITY TWO SKI SIDE SKI
SPD FLOAT
CTRL SHIFT CTRL
DETENT
RED = RED FLOW
AHC LIFT
RNG = ORANGE
RIGHT HANDLE HALL
BLK = BLACK LEFT HANDLE
SENSOR
LBL = LIGHT BLUE
DBL = DARK BLUE AHC TILT HORN
TURN SIGNAL
LGN = LIGHT GREEN HALL
DGN = DARK GREEN SENSOR
YEL = YELLOW
PNK = PINK
C473
RED/WHT
PUR/WHT
PNK/DGN
PNK/RED
BLK/WHT
PNK/BLK
WHT = WHITE
BRN = BROWN To
TAN = TAN Mainframe
B A
BRN
DGN
YEL
PUR = PURPLE
RED
GRY = GRAY
BLK
9410
9400
AHC 1 3 2 1 3 2
JUMPER C450 C449
HARNESS - 1 3 2 1 3 2 E B A D D B A
6809952 B A
C411 C412
C460 A C B A C B TO OPTIONS TO OPTIONS
B A C494 C495 (ACCESSORY (ACCESSORY
A C B A C B CONNECTOR) CONNECTOR)
Extra Power
9410
9400
Connector
4600
4620
4610
4700
4720
4710
C496
A 1750
B 2750
To
Mainframe
C489
A 1740
B 2740
2720
1720
4620
4720
4600
4610
4580
4645
4700
4710
M M
B A K H J D C E G A F B
C474 C493
B A K H J D C E G A F B
DGN
DGN
RED
RED
RED
RED
BLK
BLK
BLK
BLK
ADVANCED
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
HAND C428 C429
CONTROL 8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
HIBBING
HARNESS -
6729054
HIBBING AHC CONTROLLER
Printed in U.S.A. V-0081 (4-11-01)
350 of 640
TO TO
MAINFRAME C409 MAINFRAME C410
963 WIRING SCHEMATIC B D C F E J H A G K E H J A F G B C K D
OPTIONS
WHT/LGN
RNG/BLK
RNG/BLK
YEL/RED
WHT/RED
WHT/BLK
YEL/RED
PNK
TAN
DBL
DGN
WHT
RNG
PUR
RNG
LGN
YEL
WHT
1 3 2 2 1 3
(PRINTED APRIL 2001) C466 C465
PWM
V-0082 TWO SKI 1 3 2 2 1 3
SPD SIDE SKI FLOAT
CTRL SHIFT CTRL
DETENT
FLOW
HANDLE HANDLE
RIGHT HANDLE LOCK LOCK LEFT HANDLE
WIRES CONNECT BY LETTER AHC TILT AHC LIFT TURN HORN

HALL SIGNAL
ACROSS CONNECTORS HALL
SENSOR SENSOR
A B
B A
PUR/WHT
PUR/WHT
RED/WHT
RED/WHT
BLK/WHT
BLK/WHT
SOME CONNECTOR
BODIES NOT SHOWN
BRN
DGN
YEL
FOR DRAWING CLARITY
RED
BLK
1 3 2 1 3 2
C450 C449
BATTERY FEED 1000-1999 RED, RED/WHT, RNG 1 3 2 1 3 2 E B A D D B A
MONITORING 3000-3999 LBL C411 C412
HYDRAULIC 4000-4999 LGN A C B A C B TO OPTIONS TO OPTIONS
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK C469 C472 (ACCESSORY (ACCESSORY
A C B CONNECTOR) CONNECTOR)
ACCESSORIES 7000-7999 W HT A C B
COMMUNICATION 9000-9999 PUR
1510
4650
2650
1610
4750
2750
RED = RED
RNG = ORANGE
BLK = BLACK
LBL = LIGHT BLUE TILT ACTUATOR LIFT ACTUATOR
DBL = DARK BLUE
LGN = LIGHT GREEN
DGN = DARK GREEN
M M
YEL = YELLOW
PNK = PINK
WHT = WHITE
BRN = BROWN
TAN = TAN
PUR = PURPLE 13 ohm 13 ohm
DGN
DGN
RED
RED
RED
RED
BLK
BLK
BLK
BLK
GRY = GRAY at 12V at 12V
FOOT PEDAL FOOT PEDAL
LOCK - TILT LOCK - LIFT
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
C428 C429
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1
A B A B
C467 C468
4790
4780
1630
4770
2770
4690
4680
1530
4670
2670
A B A B
4270
2500
4280
2510
M 4220
L 4275
A 1170
N
2270
2260
4260
4220
4780
4690
4680
1190
4790
1180
K
E
C B G E J K A H D F
C492
TO D
MAINFRAME R 4550 C GRAY
S 9720 F J3
J 9620 E
C 9520 D
G 2250 J1 ADVANCED HYDRAULIC CONTROL MODULE
G
H 2240 2280 H
B 1740 B
J2
F 1500 A
P
BLACK
A G B K C J D F H E
2760
2660
4760
1620
4660
1520
2 3 1 2 3 1
C470 C471
B C 1 B C 1
ADVANCED CONTROL
SYSTEM HARNESS -
6726925 TILT LIFT
PEDAL PEDAL
Printed in U.S.A. V-0082 (4-2-01)
351 of 640
OPTIONS
S/N 562216000 AND ABOVE TO OPTIONS
(POWER BOB-TACH)
S/N 516516001 AND ABOVE POWER BOB-TACH 2770 E
SWITCH
(PRINTED APRIL 2001) FLASHER
2760 D
C601
V-0083 2
1
7000 A
BEACON SWITCH
6
C
5 HAZARD SWITCH 7010 B
4 3
2 1
1130 6010 6430 4
L 5
3 X 3
1180
RED = RED TO OPTIONS 1 2
4 6
RNG = ORANGE WIRES CONNECT BY LETTER (EXTERIOR CAB) 6530
5 2750
BLK = BLACK ACROSS CONNECTORS 6 TO MAINFRAME
E 6700
LBL = LIGHT BLUE 2755 ACS SWITCH
DBL = DARK BLUE A B D 2780 1
E
C670
LGN = LIGHT GREEN 4550
B A B 6540 2
DGN = DARK GREEN 3 R
YEL = YELLOW F 6440 2745
SOME CONNECTOR 4
PNK = PINK A
2755 4235 D
BODIES NOT SHOWN 5
WHT = WHITE 4275 C
6
BRN = BROWN FOR DRAWING CLARITY C
K
TAN = TAN
C488
PUR = PURPLE G
GRY = GRAY B
2730 J
1700 S
6400 L
6500 M
BATTERY FEED 1000-1999 RED, RED/WHT, RNG 1150 H
MONITORING 3000-3999 LBL N
HYDRAULIC 4000-4999 LGN P
ATTACHMENT CONTROLS 5000-5999 YEL
LIGHTS 6000-6999 PNK F
ACCESSORIES 7000-7999 WHT A
COMMUNICATION 9000-9999 PUR STANDARD ACCESSORY HARNESS - 6727468
TO OPTIONS
C617 OR C642
(HVAC OR HVAC/ACCESSORY)
1140 B
1740 A
2740 C
FLASHER TO OPTIONS REAR WIPER
(POWER BOB-TACH) MOTOR
LIGHT SWITCH POWER BOB-TACH E
-- NotMV for Resale
BEACON SWITCH 2770
2745
1
6420
SWITCH
Dealer Copy
D
2760
C601
6 5 2 1 REAR WIPER 1710
4 7000 A SWITCH
2
1130 6010 HAZARD SWITCH C
L 6520 TRAVEL CONTROL
3 X 1 3 1720
1180 6430 7010 B LOCKOUT SWITCH
1 2 3 2 1 FRONT WIPER
2 3 4 7220
5 SWITCH
4 1
4 5 2
6530 3
TO OPTIONS 5 6 1730
6 2750 2 1
(EXTERIOR CAB) 6 4 1750
5 4730
E 6700 2725 3 2715
3 4
D 2780 6 5
4
C670
7310
B 6540 5
TO OPTIONS 6
F 6440 (DOME LIGHT) 6
A
C608
2710 B
C 6300 1110 A
TO LEFT HANDLE
CONNECTOR 2 1190
6410 D 1 2700
TO OPTIONS
6510 A POWER 2790
C411
(FRONT WIPER)
PLUG
6000 B C
C F
E
C667
7210 A
ACS SWITCH TO MAINFRAME 4710 D
1
1770 4550 E 1760 E
2 3 R 2735 B
4
2755 4235 D
5
6
4275 C
K
G
B
2730
C488
J
6400 L
6500 M
1150 H
6300 N
6600 P
TO EUR0. LIGHTS 4730 F
CONNECTOR 1140 A
1700 S
DELUXE ACCESSORY HARNESS - 6727190
V-0083 (3-29-01)
Printed in U.S.A.
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ELECTRICAL SYSTEM INFORMATION
963 WIRING SCHEMATICS 963 WIRING SCHEMATIC

S/N 562215001-15434 OPTIONS
S/N 516515001-15999 S/N 562215001 AND ABOVE
(Printed April 2001) S/N 516515001 AND ABOVE
V-0013 (Printed April 2001)
V-0017
963 WIRING SCHEMATIC 963 WIRING SCHEMATIC

WITH ADVANCED HAND CONTROL OPTION OPTIONS
S/N 562215001-15356 S/N 562216000-16107
S/N 516515001-15999 S/N 516516001-16011
(Printed April 2001) (Printed April 2001)
V-0014 V-0081

WITH ADVANCED HAND CONTROL OPTION OPTIONS
S/N 562215357-15999 S/N 562216108 AND ABOVE
V-0082

NON AHC Machines ONLY OPTIONS
S/N 562216000-16025 S/N 562216000 AND ABOVE
V-0083

S/N 562216000-16025 (AHC Machines ONLY)
(Printed April 2001)
V-0084

OPTIONS
(Printed April 2001)
V-0080
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ELECTRICAL SYSTEM INFORMATION (CONT’D)
WARNING
assistance in locating and correcting problems. Many of Instructions are necessary before operating or
the recommended procedures must be done by servicing machine. Read and understand the
authorized Bobcat Service Personnel only. Operation & Maintenance Manual, Handbook and
instructions in the manuals when making repairs,
injury or death.
W-2003-0199
PROBLEM SOLUTION#
Battery will not take a charge. 1, 2, 3, 4, 5
Alternator will not charge. 1, 2, 5
Starter will not turn the engine. 2, 3, 4, 6, 7, 8, 9
SOLUTION SUGGESTIONS
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.
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ELECTRICAL SYSTEM INFORMATION (CONT'D) Figure 60-10-3
Description
IMPORTANT
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397 1
Figure 1
N-21509
The fuse holder is located in the engine compartment,

below the engine harness connector (Item 1) [Figure 60-
10-2] & [Figure 60-10-3].
Figure 60-10-4
P-13848A
The loader has a 12 volt, negative ground alternator

charging system. The electrical system is protected by a
100 amp master fuse (Item 1) [Figure 1] to protect 1
against serious system overloads that could lead to
burned up harness or loader damage.
Figure 60-10-2 N-20754
The electrical system is also protected by fuses and

relays under the fuse panel cover (Item 1) [Figure 60-10-
4] located in the cab on the steering control panel.
N-21508
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Description (Cont'd)
IMPORTANT
Do Not use silicone base sprays and/or sealants on
harness connectors or components.
I-2123-0397
Figure 60-10-5
N-20754
The fuse panel cover (Item 1) [Figure 60-10-5] & [Figure

60-10-7] has a decal inside to show the location and amp
ratings.
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ELECTRICAL SYSTEM INFORMATION (CONT’D) The location and sizes are shown in [Figure 60-10-6] &
[Figure 60-10-7].
Fuse Location
Ref Description Amp.
Remove the cover to check or replace the fuses.
F1 Heater 25
Figure 60-10-6 F2 Front & Marker Lights 15
F3 Rear Lights 15
F4 Bobcat Controller 25
F5 Traction 30
F6 Fuel Shutoff 30
F7 Not Used --
F8 Not Used --
F9 Unswitched Attach. 25
F10 Switched Attach. 25
F11 Alternator & Kits 25
F12 AHC Power 25
N-19660
Relay Switch Location
F5 F1 E D C B F9 Remove the cover to check or replace the relays.
F6 F2 F10 The location is shown in [Figure 60-10-6] & [Figure 60-

10-7].
F7 F3 F G H J F11 Ref Description

B Switch Power
F8 F4 F12 C Rear Lights
D Front & Marker Lights
E Not Used
Fuses Relays Fuses
F Glow Plugs
N-18465A
G Fuel Shutoff
H Traction
Figure 60-10-7 J Starter
N-19661
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Solenoid Test
Figure 60-10-8
P9175
Use a test meter to measure coil resistance [Figure 60-

10-8]. Coil wires do not have polarity. Correct resistance
for the pressure relief (small) coil is 7-10 ohm and the
other coils 5-8 ohms.
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BATTERY Figure 60-20-2
1
WARNING 2
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
N-21749
minutes.
If electrolyte is taken internally drink large quantities Remove the positive battery cable (Item 1) [Figure 60-
of water or milk! DO NOT induce vomiting. Get 20-2].
prompt medical attention.
W-2065-1296
Remove the two nuts on the battery hold down (Item 2)
[Figure 60-20-2].
Open the rear door.
Remove the battery hold down from the loader.
Figure 60-20-1
Figure 60-20-3
N-21750
N-21382
Disconnect the negative battery cable (Item 1) [Figure

60-20-1]. Remove the wiring harness mount bolt (Item 1) [Figure
60-20-3]. Move the wiring harness mount to the side for
Always disconnect the negative cable first to prevent clearance when removing the battery.
sparks.
Remove the nut (Item 2) [Figure 60-20-3] from the
alternator mounting bolt.
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BATTERY (CONT’D) Figure 60-20-5
WARNING
rubber gloves to keep acid off body.

P-9589
minutes.
If electrolyte is taken internally drink large quantities Figure 60-20-6

of water or milk! DO NOT induce vomiting. Get
W-2065-1296
Figure 60-20-4
1 P-9590
Always clean the terminals and cable ends when

installing a new battery [Figure 60-20-5] and [Figure 60-
N-21748 20-6].
When installing the battery in the loader, do not touch any

Push the alternator mount bolt (Item 1) [Figure 60-20-4] metal parts with the battery terminal posts.
toward the alternator to allow clearance for the battery
removal. Connect and tighten the battery cables. Connect the
negative (-) cable last to prevent sparks.
Remove the battery from the loader.
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BATTERY (CONT’D)
Servicing The Electrical System
Figure 60-20-7
P-9588
The battery cables must be clean and the connections

tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution [Figure 60-20-7].
Clean the terminals and cable ends as shown in [Figure

60-20-5] and [Figure 60-20-6].
Check the electrolyte level in the battery. Add distilled

water as needed.
Put Battery Saver (P/N 6664458) or grease on the

battery terminals and cable ends to prevent corrosion.
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BATTERY (CONT’D) BATTERY (CONT’D)
Using A Booster Battery (Jump Starting) Figure 60-20-8
WARNING
4
rubber gloves to keep acid off body. 2

minutes.
If electrolyte is taken internally drink large quantities P-16026

of water or milk! DO NOT induce vomiting. Get
W-2065-1296
WARNING
Keep arcs, sparks flames and lighted tobacco away
1
from batteries. When jumping from booster battery 3
make final connection (negative) at engine frame.
Do not jump start or charge a frozen or damaged

battery. Warm battery to 60°F (16°C) before
N-16241
connecting to a charger. Unplug charger before
connecting or disconnecting cables to battery. Never
lean over battery while boosting, testing or charging. Connect the end of the first cable (Item 1) [Figure 60-20-
8] to the positive (+) terminal of the booster battery.
Battery gas can explode and cause serious injury. Connect the other end of the same cable (Item 2) [Figure
W-2066-1296
60-20-8] to the positive terminal on the starter.
If it is necessary to use a booster battery to start the Connect the end of the second cable (Item 3) [Figure 60-
engine, BE CAREFUL! There must be one person in the 20-8] to the negative (-) terminal of the booster battery.
operator's seat and one person to connect and Connect the other end of the same cable (Item 4) [Figure
disconnect the battery cables. 60-20-8] to the engine.
The ignition must be in the OFF position. The booster Keep cables away from moving parts. Start the engine
battery to be used must be 12 volt. (See Cold Temperature Starting Condition, Operation &
Maintenance Manual.)
After the engine has started, remove the ground (-) cable
(Item 4) [Figure 60-20-8] first.
Remove the cable from the starter.
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ALTERNATOR Connect the fuel stop solenoid, start the engine and run
at 2600 RPM.
Alternator Output Test
The ammeter reading should be between 45-55 amps. @
2600 RPM.
WARNING If the reading is low, remove the screws and pull the
regulator cover away from the alternator.
Rectifier (Diode) Test
Figure 60-30-2
W-2017-0286
Figure 60-30-1
Cover
2
P-6702
The alternator is removed from the loader for photo

N-16209 clarity purposes [Figure 60-30-2].
Disconnect the negative (-) cable from the battery.

Test the alternator in the following sequence:
Install the wires in their original location on the back of
Alternator Output Test the alternator.
Rectifier (Diode) Test
Alternator Regulator Test Remove the regulator cover from the back of the
alternator [Figure 60-30-2].
Disconnect the red wire from the alternator. Connect that

wire to the negative (-) side (Item 1) [Figure 60-30-1] of
the ammeter.
Connect the positive (+) side of the ammeter to the

output terminal on the alternator (Item 2) [Figure 60-30-
1].
Disconnect the fuel stop solenoid connector.
Connect the negative (-) cable to the battery.
Turn on the lights and crank the engine for 30 seconds to

discharge the battery.
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ALTERNATOR (CONT’D) Alternator Regulator Test
Rectifier (Diode) Test (Cont’d)
Figure 60-30-3
WARNING
Output When an engine is running in an enclosed area, fresh
Terminal air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
outside. Exhaust fumes contain odorless, invisible
gases which can kill without warning.
W-2050-1285
1
Figure 60-30-4
Regulator
Terminal
P-6703
Connect a jumper wire (Item 1) [Figure 60-30-3] to the

alternator output terminal and the regulator terminal.
Connect the battery negative (-) cable.
Start the engine and run at 2600 RPM.
If the reading is within 45-55 amps. at 2600 RPM replace

N-21507
the rectifier (diode) assembly or replace the alternator.
If the reading is low, do the Alternator Regulator Test. Connect the positive (+) voltmeter lead to the positive (+)
battery terminal [Figure 60-30-4].
Connect the negative (-) voltmeter lead to the negative (-)

battery terminal [Figure 60-30-4].
Start the engine and run at 1500-2000 RPM.
The voltmeter should read between 13.9-14.7 volts.
If the reading is low, stop the engine and disconnect the

battery negative (-) cable.
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ALTERNATOR (CONT’D) Removal And Installation
Alternator Regulator Test (Cont’d)
Figure 60-30-5
IMPORTANT
Damage to the alternator can occur if:
• Engine is operated with battery cables
disconnected.
• Battery cables are connected when using a fast
Ground charger or when welding on the loader. (Remove
Stud
both cables from the battery.)
• Extra battery cables (booster cables) are
connected wrong.
I-2023-1285
Brush
Terminal Figure 60-30-6
1
P-6705
The alternator is removed from the loader for clarity

purposes [Figure 60-30-5].
Remove the wires from the back of the alternator.
Remove the regulator cover from the back of the

1
alternator.
Install the wires on the back of the alternator.
Connect a jumper wire (Item 1) [Figure 60-30-5] from the

P-16028
brush terminal to the ground stud.
Connect the negative (-) battery cable and start the Open the rear door.
engine. Run at 1500 RPM.
Disconnect the negative (-) cable (Item 1) [Figure 60-30-
If the voltmeter reading is 14.5 or above, replace the 6] from the battery.
regulator.
If the voltmeter reading is below 14.5, repair or replace

the alternator.
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ALTERNATOR (CONT’D) Figure 60-30-9
Figure 60-30-7
2
1
N-21498
Remove the top bolt and washer (Item 1) [Figure 60-30-

N-21496 9], and the belt shield (Item 2) [Figure 60-30-9].
Figure 60-30-10
Disconnect the harness connector (Item 1) [Figure 60-
30-7] from the alternator connector.
Disconnect the red wire (Item 2) [Figure 60-30-7] from

the alternator. 1
Figure 60-30-8
2
N-21499
2 Remove the alternator belt (Item 1) [Figure 60-30-10]

from the pulley.

N-21497 lower mount bolt.
Loosen the top bolt (Item 1) [Figure 60-30-8] and

remove the bottom nut (Item 2) [Figure 60-30-8] from the
alternator belt shield.
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ALTERNATOR (CONT’D) Adjusting The Alternator Belt
Removal and Installation (Cont'd) Figure 60-30-12
Figure 60-30-11
3
1
1
N-21497
N-21500
Stop the engine.
Remove the mounting bolt (Item 1) [Figure 60-30-11]. Open the rear door.
Remove the alternator from the mounting bracket. Loosen the alternator mounting bolt (Item 1) [Figure 60-
30-12].
Loosen the adjustment bolt (Item 2) [Figure 60-30-12].
Move the alternator until the belt has 5/16 inch (8,0 mm)
movement at the middle of the belt span (Item 3) [Figure
60-30-12] with 15 lbs. (66 N) of force.
Tighten the adjustment bolt and mounting bolt.
Close the rear door.
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ALTERNATOR (CONT’D) Stator Continuity Test
Disassembly Use an ohmmeter to test the stator.
Figure 60-30-13 Figure 60-30-14

1. Nut 10. Case Half (Rear)
2. Pulley 11. Condenser Assy.
3. Fan 12. Strap
4. Bolt 13. Regulator
5. Case Half (Front) 14. Brush
6. Bearing 15. Cover
7. Rotor
8. Stator
9. Rectifier (Diode)
1 2 3
5 8
4 P-1369
6 7 Touch the probes to two of the bare stator wires [Figure

12 60-30-14].
Move one of the probes to the third wire.

13
The readings should be the same.
11 14
If there is no continuity, replace the stator.
9 10
Stator Ground Test
C-3312
15 Figure 60-30-15
Disassemble the alternator. (See Parts Identification

[Figure 60-30-13].)
Remove the regulator cover and regulator.
Remove the four bolts holding halves together.
Pry the halves apart.
Use a soft jaw vise to hold rotor while removing pulley

nut.
Remove front case half from the rotor using a plastic

hammer. P-1386
Un-solder the stator leads from the rectifier. Remove the

stator. Touch one probe to a bare stator lead and the other
probe to the bare metal surface of the stator [Figure 60-
30-15].
There should be no continuity.
Replace the stator if there is continuity.
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ALTERNATOR (CONT’D) Rectifier Continuity (Diode) Test
Rotor Continuity Test NOTE: In the diode tests there should be continuity
in one direction only. If the diode being tested
Use an ohmmeter to test the rotor. shows no continuity or continuity in both
directions, replace the rectifier assembly.
Figure 60-30-16
Figure 60-30-18
P-1365
P-1373
Touch the probes to the slip rings [Figure 60-30-16].

Touch the probes to the terminals of each diode and read
The ohmmeter should read between 3.0-33.0 ohms. the meter [Figure 60-30-18].
If there is no continuity replace the rotor. Reverse the probes to check the diode in the other
direction.
Rotor Ground Test
There should be continuity in one direction only.
Figure 60-30-17
Figure 60-30-19
P-1378
P-1370
Touch one probe to one of the slip rings and the other
probe to the rotor shaft [Figure 60-30-17]. Touch one probe to the diode and the other probe to the
connected heat sink and read the meter [Figure 60-30-
There should be no continuity. 19].
Replace the rotor if there is continuity. Reverse the probes to check the diode in the other
direction.

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ALTERNATOR (CONT’D) Assembly
Rectifier Continuity (Diode) Test (Cont'd) Reverse the order of disassembly.
Figure 60-30-20 Do not assemble the rear case half.
Figure 60-30-21
P-1390
P-1808
Touch one probe to the diode and the other probe to the
connected heat sink and read the meter [Figure 60-30-
20]. Place the rotor in soft jaws when tightening the shaft nut.
Reverse the probes to check the diode in the other Tighten to 50 ft.-lbs. (68 Nm) torque [Figure 60-30-21].
direction.
Install the rear case half and the remaining parts.
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STARTER Figure 60-40-3

1
Figure 60-40-1
1 1
N-21493
Remove the five bolts (Item 1) [Figure 60-40-3] from the

N-21491 belt shield.
Figure 60-40-4
Open the rear door.

1
Disconnect the positive (+) cable (Item 1) [Figure 60-40-
1] from the starter solenoid.
Figure 60-40-2
N-21494
1 Remove the belt shield (Item 1) [Figure 60-40-4].
1
N-21492
Disconnect the two wires (Item 1) [Figure 60-40-2] from

the starter solenoid terminal.
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STARTER (CONT’D)
Figure 60-40-5
N-21495
Remove the three nuts and bolts (Item 1) [Figure 60-40-

5] and remove the starter.
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STARTER (CONT’D)
Parts Identification
1. Felt Washer
2. Bearing
3. Armature
4. Bearing 8
5. Field Wingdings 9 10
6 7
Housing Assy.
6. Cover
7. Brush Holder 11. Brushes
5
8. Cover 12. Cover
9. Bolt 13. Gasket
10. Bolt 4 14. Screw
15. Pinion Shaft
3
16. Nut
17. Washer
18. Nut
1 19. Washer
20. Roller
2
11
17 13
16 12
14
15
20 19 11
21
22
18
25 16
24
17
23
35
34 21. Retainer
22. Pinion
33 23. Ball
24. Spring
31 25. Housing
26. Screw
28 27. Washer
27
30 32 28. O-ring
26 29. Housing
30. Gear
31. Spring
32. O-ring
33. Drive
34. Spring
29 35. Shaft
D-2297A
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STARTER (CONT'D) Figure 60-40-8
Figure 60-40-6
B-14442
Remove the field windings housing from the magnetic

B-14441 switch [Figure 60-40-8].
Figure 60-40-9
Disconnect the wire from the magnetic switch [Figure 60-
40-6].
Assembly: Tighten the nut to 52-86 in.-lbs. (5,9-9,7 Nm)

torque. Securely put the rubber boot over the terminal. 1
Figure 60-40-7
B-14468
Assembly: When installing the field windings housing to

the magnetic switch, engage the tab (Item 1) [Figure 60-
40-9] on the field windings housing with the notch in the
magnetic switch.
B-14474
Remove the through bolts from the drive end frame

[Figure 60-40-7].
Assembly: Tighten the through bolts to 60-104 in.-lbs.

(6,8-11,8 Nm) torque.
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STARTER (CONT’D) Figure 60-40-12
Figure 60-40-10
B-14448
Remove the steel ball from the overrunning clutch

B-14446 [Figure 60-40-12].
Figure 60-40-13
Remove the drive end frame from the magnetic switch
[Figure 60-40-10].
Figure 60-40-11
B-14449
Remove the pinion (Item 1) [Figure 60-40-13] from the

B-14447 drive end frame.
Remove the overrunning clutch from the drive end frame

[Figure 60-40-11].
NOTE: If the pinion is installed on the drive end frame

(externally attached to the overrunning clutch
shaft), it will be necessary to remove the
pinion prior to removing the over-running
clutch. (See External Pinion on Page 60-40-6.)
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STARTER (CONT’D) External Pinion
Disassembly And Assembly (Cont'd) If the pinion is installed on the drive end frame (externally
attached to overrunning clutch shaft), it will be necessary
Figure 60-40-14 to remove the pinion prior to removing the overrunning
clutch.
Figure 60-40-16
B-14450
Remove the retainer and rollers from the drive end frame
B-14452
[Figure 60-40-14].
Figure 60-40-15 Push down on the drive end frame [Figure 60-40-16].
Figure 60-40-17
Collar
B-14451
B-14453
Remove the return spring from the magnetic switch
[Figure 60-40-15].
While pressing down on the starter pinion, tap the collar
Assembly: Reverse the order of disassembly. Before using a pipe (Item 1) [Figure 60-40-17].
reassembling, put grease on the following parts:
Overrunning Clutch
Retainer and Rollers
Steel Ball
Return Spring
Armature Bearing
Felt Washer
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External Pinion (Cont’d)
Figure 60-40-18
B-14456
Armature Winding Ground Test: Use a circuit tester,

B-14454 touch one probe to a commutator segment and the other
probe to the armature core [Figure 60-40-20]. There
should be no continuity. If there is continuity, the armature
Remove the snap ring (Item 1) [Figure 60-40-18]. is grounded and must be replaced.
After the snap ring is removed, the pinion, overrunning Figure 60-40-21
clutch, shaft, washer, and spring can be removed.
Inspection And Repair
ARMATURE:
Figure 60-40-19
B-14457
Armature Winding Continuity Test: Use a circuit tester,

touch the probes to two commutator segments [Figure
60-40-21]. There should be continuity at any point. If
there is no continuity, the winding is open-circuited,
B-14455 replace the armature.
Armature Short-Circuit Test: Use a growler tester, put the

armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [Figure 60-40-19]. A short circuited armature
causes the blade to vibrate and be attracted to the core.
An armature which is short-circuited must be replaced.
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Inspection And Repair (Cont'd)
ARMATURE (Cont'd)
Figure 60-40-22 1
B-14460
Measure the segment mica depth (Item 1) [Figure 60-40-

24].
B-14458 Service Limit - 0.008 inches (0,2 mm)
If it is worn, undercut the segment mica.

Commutator Run-Out Test: Check the commutator run-
out as shown in [Figure 60-40-22]. Check the commutator surface for burned spots which
usually indicates an open-circuit, and correct it using
Service Limit - 0.02 inches (0,5 mm) #400 sand paper.
If the commutator exceeds the service limit, repair as Figure 60-40-25

needed.
Figure 60-40-23
B-14461
B-14459 Check the bearings for wear and damage [Figure 60-40-
25].
Measure the commutator outer diameter [Figure 60-40- If the bearings are worn or damaged, they should be
23]. replaced.
Service Limit - 1.38 inches (35 mm)
If it is worn, replace the armature.
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Inspection And Repair (Cont'd)
ARMATURE (Cont'd)
Figure 60-40-26
Press
Bearing B-14463
Armature Field Windings Continuity Test: Use a circuit tester, touch

one probe to the wire and the other probe to the brush
[Figure 60-40-28]. There should be continuity. If there is
B-14439 no continuity, the field windings are open-circuited.
Replace the field windings.

Use a press as shown in [Figure 60-40-26], replace the
worn or damaged bearing(s).
FIELD WINDINGS:
Check the field windings for wear and damage.
Check all the connections for clean and tight solder joints.
Figure 60-40-27
B-14462
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 field windings housing
[Figure 60-40-27]. There should be no continuity. If there
is continuity, the field windings are grounded.
Replace the field windings.
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STARTER (CONT’D) OVERRUNNING CLUTCH:
Inspection And Repair (Cont'd) Figure 60-40-30
Figure 60-40-29
B-14465
B-14464
Inspect the pinion, it must rotate freely in the direction of
the starter rotation and locked in the opposite rotation
BRUSH AND BRUSH HOLDER: [Figure 60-40-30].
Measure the brush length. Magnetic Switch Test
Service Limit - 0.512 inches (13 mm) Figure 60-40-31
If it exceeds the limit, replace the brush holder or field

windings assembly. 50
Check brush springs, for damage or rust. Replace as C

needed.
Brush Holder Insulation Test: Use a circuit tester, touch

one probe to the positive brush holder plate and the other
probe to the holder plate [Figure 60-40-29]. There
should be no continuity. If there is continuity, replace or
repair.
M.T.
B-14471
The following tests should be done without the armature

assembly.
NOTE: Each test should be performed a short time (3

to 5 seconds) to prevent the magnetic switch
winding from burning. Each test should be
performed with 12 volts.
Pull-In Test: Connect the wires as shown in [Figure 60-

40-31]. When connecting Terminal C and M.T. are
closed, the pinion should engage.
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STARTER (CONT’D) No Load Test
Magnetic Switch Test (Cont’d) Figure 60-40-34
Figure 60-40-32 Ammeter
50 50
C M.T.
M.T.
B-14440
B-14470
The following test should be done after reassembling the
starter:
Hold-In Test: With the same conditions as in the pull-in
test, open the connecting Terminal C [Figure 60-40-32]. Clamp the starter in a vise. Use a 12 volt battery and
The pinion should remain in the engaged position. ammeter, connect the positive wire of the battery, and the
ammeter to the 50 Terminal [Figure 60-40-34]. Connect
Figure 60-40-33 the negative wire to the starter body.
50 The starter should show smooth and steady rotation

immediately after the pinion is engaged, it should draw
less than the specified current.
C
Service Limit - 220 Amp. Maximum Draw
M.T.
B-14469
Return Test: With the same conditions as in the hold-in

test, open the connecting Terminal 50 [Figure 60-40-33].
The pinion should return immediately.
M.T. Main Terminal to which the main cable from
the battery is connected.
C C-Terminal to which the wire from the field
windings is connected.
50 50-Terminal to which the wire from the starting
switch or stator relay is connected
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963 Bobcat Loader
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INSTRUMENT PANEL The left instrument panel is the same for both Standard
and the Deluxe Instrument Panels [Figure 60-50-1].
Left Panel
The table below shows the DESCRIPTION and
Figure 60-50-1 FUNCTION / OPERATION for each of the components of
the left panel.
2
1 3 Press and hold LIGHTS Button (Item 4) [Figure 60-50-1]

for two seconds to view SERVICE CODES in the
4 5 6 7 8 HOURMETER/CODE DISPLAY (Item 2) [Figure 60-50-
1]. If more than one SERVICE CODE is present, the
codes will scroll on the HOURMETER/CODE DISPLAY.
13
9 10 11 12
14 B-15551
Ref
Description Function / Operation
No
1 TEMPERATURE GAUGE Shows the engine coolant temperature.
2 HOURMETER / CODE DIS- HOURMRETER - Records operating hours of loader. CODE DISPLAY - Displays numeric SERVICE
PLAY / GLOW PLUG COUNT- CODES* relating to the loader monitoring system. COUNTDOWN - Glow Plug time remaining.
DOWN
3 FUEL GAUGE Shows the amount of fuel in the tank.
4 LIGHTS / HOLD FOR CODES LIGHTS - Press once for FRONT LIGHTS. Press a second time for FRONT AND REAR lights. Press a third
time to turn all lights off. HOLD FOR CODES - Press and hold two seconds for display of SERVICE
CODES* (Item 2). (CODES* show only when there is an error found by loader monitoring system).
5 BUCKET POSITIONING Press to engage the BUCKET POSITIONING function. Press again to disengage. Press and hold 2 sec-
(OPTION) onds to view BASE or SHTDN (¤SHUTDOWN) feature in HOURMETER/CODE DISPLAY
ATTACHMENT AUXILIARY HYDRAULICS
6 HIGH FLOW Press to engage the HIGH FLOW auxiliary hydraulics. Press again to disengage.
7 MAXIMUM FLOW / VARI- Press once to engage the VARIABLE FLOW auxiliary hydraulics. Press a second time to engage MAXI-
ABLE FLOW MUM FLOW. Press a third time to disengage all auxiliary hydraulics. [VARIABLE FLOW allows for slow -
to-fast movement of auxiliary functions (The farther you move the switch, the faster the movement of aux-
iliary functions.) MAXIMUM FLOW allows for only fast movement.]
8 AUXILIARY PRESSURE Press and hold for two seconds. The engine will stop. Hydraulic pressure will be released in the auxiliary
RELEASE circuit.
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
(See Troubleshooting Guide on Page 60-90-4 for trouble shooting.)
9 PRESS TO OPERATE Press to activate BICS® System when the Seat Bar is down and operator is seated in operating position.
LOADER
10 SEAT BAR The light comes ON when the seat bar is down.
11 LIFT & TILT VALVE The light comes ON when the seat bar is down and the PRESS TO OPERATE Button is pressed. The lift
and tilt functions can be operated when the light is ON.
12 TRACTION The light comes ON when the seat bar is down, engine is running, and parking brake is released. The
loader can be moved forward or backward when the light is ON.
13 TRACTION LOCK OVER- (Functions Only When Seat Bar Is Raised And The Engine Is Running) Press to unlock the brakes.
RIDE Allows you to use the steering levers to move the loader forward or backward when using the backhoe
attachment or for loader service. (See TRACTION LOCK on Page 60-110-1.) Press a second time to lock
the brakes.
14 ALARM The ALARM beeps when there is an Error, WARNING or ¤SHUTDOWN condition.
* See ELECTRICAL SYSTEM SERVICE MANUAL for further description of SERVICE CODES.
¤ SHUTDOWN feature only in Deluxe Right Panel or Factory Option with Standard Panel.
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INSTRUMENT PANEL IDENTIFICATION (CONT’D) The right instrument panel shown [Figure 60-50-2] is the
Standard Panel.
Right Panel - Standard Instrument Panel (With Key
Switch) The table below shows the Icons and other components
of the Right Standard Panel.
Figure 60-50-2
● ACD Icon will also be ON when the 7 pin/14 pin
15 17 19 21 23 25 27
Connector Harness (Opt./Acc.) is installed and the
selector switch is in the 14 pin position.
◆ SHUTDOWN feature only in Deluxe Right Panel or

16 18 20 22 24 26 28 Factory Option with Standard Panel. (Engine can be
restarted to move or relocate loader.)
* These functions are monitored and have SERVICE

CODES associated with them. (See DIAGNOSTICS
SERVICE CODES on Page 60-80-1.).
29
B-15552
OPT. OR ICON/
REF. FUNCTION ALARM CODE CONDITION DESCRIPTION
STD. LIGHT
Advanced Hand Opt. ON 3 Beeps * Error Error with Advanced Hand Controls (AHC)
15 Controls (AHC)
Attachment Std. ON --- - --- Electrical controlled attachment is present.●
16 Control Std. FLASHING 3 Beeps * Error Error with Attachment Control Device (ACD)
Device (ACD)
General Std. ON 3 Beeps * Error Error with one or more engine or hydraulic functions.
17 Warning Std. ON 3 Beeps * WARNING Engine speed high or in shutdown.
^Opt. FLASHING Continuous * SHUTDOWN Engine speed very high. Engine will stop in 10 seconds.
HIGH RANGE Std. ON --- - --- Light is ON when High Range is activated.
18 Std. ON 3 Beeps * Error Solenoid error.
Fuel Std. ON 3 Beeps * Error Fuel level sender system fault.

19 Level Std. ON 3 Beeps * WARNING Fuel level low.
Glow Std. ON --- - --- Glow plugs are energized.

20 Plugs Std. FLASHING 3 Beeps * Error Error with glow plugs
System Voltage Std. ON 3 Beeps * WARNING Voltage low, high or very high.
21
Seat Belt Std. ON --- - --- Light stays on for 45 seconds to remind operator to fasten seat belt.
22
Engine Std. ON 3 Beeps * Error Engine Oil Pressure sender out of range.
23 Oil Pressure Std. ON 3 Beeps * WARNING Engine oil level low.
◆Opt. FLASHING Continuous * SHUTDOWN Engine oil pressure very low. Engine will shutdown in 10 seconds.
Hydrostatic Std. ON 3 Beeps * Error Hydraulic oil pressure sender out of range.
24 Charge Std. ON 3 Beeps * WARNING Hydraulic oil pressure low.
Pressure ◆Opt. FLASHING Continuous * SHUTDOWN Hydraulic charge pressure very low. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Engine coolant sender out of range
25 Coolant Std. ON 3 Beeps * WARNING Engine coolant temperature high.
Temperature ◆Opt. FLASHING Continuous * SHUTDOWN Engine coolant temperature very high. Engine will stop in 10 seconds.
Hydraulic Std. ON 3 Beeps * Error Hydraulic oil temperature out of range.
26 Oil Std. ON 3 Beeps * WARNING Hydraulic oil temperature high.
Temperature ◆Opt. FLASHING Continuous * SHUTDOWN Hydraulic oil temperature very high. Engine will stop in 10 seconds.
Engine Std. ON 3 Beeps * Error Air filter with high restriction.
27 Air Filter Std. FLASHING 3 Beeps * WARNING Air filter switch not connected.
Hydraulic Std. ON 3 Beeps * Error Hydraulic filter with high restriction.

Filter Std. FLASHING 3 Beeps * WARNING Hydraulic filter switch not connected.
28
29 Key Switch - - - - -> Used to start and stop the engine.
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INSTRUMENT PANEL (CONT’D) Figure 60-50-4
Right Panel - (Deluxe) (With Keyless Start)
1. Display Panel: The Display Panel is where all system

setup, monitoring, troubleshooting, and error
conditions are displayed.
2. Function Icons: The lower left area of the Deluxe

Panel has the same Icons as the Standard Panel
(See Right Panel - Standard Instrument Panel (With
Key Switch) on Page 60-50-2.). These Icons are
only visible when the monitoring system has
detected an error.
3. Selection Buttons: The four Selection Buttons allow B-16656

you to select items from the Display Panel and scroll
through screens.
The first screen you will see on your new loader will be as
Figure 60-50-3 shown in [Figure 60-50-4].
When this screen is on the display you can enter the

password and start the engine or change the Display
1 3 Panel setup features.
2 NOTE: Your new loader (with Deluxe Instrument

Panel) will have a Owner Password. Your
dealer will provide you with this password.
Change the password to one that you will
4 easily remember to prevent unauthorized use
of your loader. (See ELECTRICAL SYSTEM
SERVICE MANUAL.) Keep your password in a
safe place for future needs.
6 5 Start Engine: Use the Keypad to enter the numbers

B-15553
(letters) of your password and press the RUN / ENTER
key (Item 5) [Figure 60-50-3].
4. Keypad: The numeric keypad (Item 4) [Figure 60-
50-3] has two functions: Press and hold the START Button (Item 6) [Figure 60-
50-3] until the engine starts.
To enter a number code (password) to allow starting
the engine (Keyless Start). Change Language: Press the Selection Button at the end
of the arrow [Figure 60-50-4] to go to the next screen.
To enter a number as directed for further use of the
Display Panel.
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INSTRUMENT PANEL (CONT’D)
Right Panel - (Deluxe) (With Keyless Start) [Figure 60-

50-3]. (Cont’d)
Figure 60-50-5
B-16655
Use the Keypad to select the number of the language

[Figure 60-50-5].
Press EXIT. The screen will return to [Figure 60-50-4].

You can then enter the password and start the engine.
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INSTRUMENTATION PANEL (CONT’D
Icon Description
Right Panel Set Up Display Options (Deluxe)
YES/
Icon Identification Answer yes/no to current setup question.
NO
Make selection by pressing SELECTION BUTTON CLEAR Removes previously installed password.
opposite the Icon. SET Set accepts current installed password.
Deluxe Panel Setup

Display Options
Press
TOOL/SETUP
Icon Description
LOCK / UNLOCK: Allows machine to be
locked/ unlocked. You must lock machine
to activate security system. Press
When system is unlocked, the user can LOADER FEATURES
press RUN / ENTER then press START to
begin operation.
A valid password will need to be entered
at startup to run a locked machine.
TOOL / SETUP: Access system options.
Press
DISPLAY OPTIONS
Use to set clock, check system warnings,
select language, set passwords, etc.
HELP: Access help on current menu
? item.
EXIT EXIT returns you to previous level menu.
11:23 CLOCK / JOB CLOCK: Press to clear or
0.0 lock job clock; TOOL /SETUP to set time.
UP ARROW: Goes backward one screen.
DOWN ARROW: Goes forward one Press
screen. ADJUST CONTRAST
OUTLINE ARROWS: No screen available
(backward / forward).
SELECTION ARROW: Use to select

menu item.
Goes to the NEXT screen series. Press
NEXT EXAMPLE: The next Active Warning UP or Down
screen. Arrow to
change contrast.
INFO Goes to more information about an
attachment.
Press EXIT to
return to
previous level
menu.
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INSTRUMENTATION PANEL (CONT’D
Right Panel Setup Display Options (Deluxe) (Cont'd) Changing the Password (Cont’d)
All new machines with Deluxe Instrumentation arrive at

Bobcat Dealerships with the panel in locked mode. This
means that a password must be used to start the engine.
Passwords
For security purposes, your dealer may change the

password and also set it in the locked mode. Your
dealer will provide you with the password.
Enter Password on
Keypad
Owner Password: Allows for full use of the loader and
to setup the Deluxe Panel. Owner can select a
password to allow starting & operating the loader and Press Enter to
modify the setup of the Deluxe Panel. Owner should Continue
change the password as soon as possible for security
of the loader.
Re-enter new
User Password: Allows starting and operating the password. Press
loader; cannot change password or any of the other Enter to Continue
setup features. (See left)
Changing the Password Right Instrument Panel

Display Screen
Press Enter to
Press
Continue
TOOL / SETUP
(See left)
Press PASSWORD More EXAMPLES:

UTILITIES Clocks
TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
CLOCKS
SET CLOCK
Use the keypad to set time.
Press RUN / ENTER to set clock.
Press EXIT to return to previous level menu.
Press RESET JOB CLOCK (Password required).
Press CLEAR to reset job clock to zero.
MODIFY OWNER
Press LOCK / UNLOCK to unlock.
or
MODIFY USER Enter Passworf and press RUN / ENTER.
Languages
TOOL / SETUP
LOADER FEATURES
DISPLAY OPTIONS
LANGUAGES
Select the language, press RUN / ENTER
Press EXIT to return to previous level menu.
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INSTRUMENT PANEL (CONT'D)
Changing the Password (Cont’d)
Vitals (Monitor engine, hydraulic / hydrostatic,

electrical functions when engine is running.)
TOOL / SETUP
LOADER FEATURES
VITALS
Press SELECTION ARROW to select METRIC
or ENGLISH (M/E) readouts
You can monitor real-time readouts of:

Engine Oil Pressure
Engine Coolant Temperature
Hydraulic Charge Pressure
Hydraulic Oil Temperature
System Voltage
Engine Speed
The Display Panel is easy to use. Continue to set

your own preferences for running / monitoring your
Bobcat Loader.
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INSTRUMENT PANEL (CONT'D) Figure 60-50-6
Option And Field Accessory Panels
1 2 3 4 5 6
POWER
FRONT
WIPER
WIPER
REAR
PLUG
USED
USED
USED
NOT
NOT
NOT
SIDE
CONSOLE
7 8 9 10 11
POWER TURN SIGNAL HAZARD ROTATING
BOB-TACH NOT USED INDICATORS LIGHTS BEACON
FRONT
CENTER
PANEL
B-16642A
B-16641A
Side Console [Figure 60-50-6]

Ref.
No.
1 POWER PLUG Provides a 12V receptacle for accessories.
2 NOT USED –––
3 FRONT WIPER Press the top of the switch to start the front wiper (press and hold for washer fluid).
Press the bottom of the switch to stop the wiper.
4 REAR WIPER Press the bottom of the switch to start the rear wiper. Press the top of the switch to pro-
vide washer fluid to clean the rear window.
Front Center Panel [Figure 60-50-6]

Ref.
No.
7 POWER BOB- Press and hold the left side to disengage the Bob-Tach wedges. Press and hold the
TACH right side to engage the wedges into the mounting frame.
9 TURN SIGNAL Indicates left or right TURN SIGNALS are ON.
INDICATORS
10 HAZARD LIGHTS Press the left side to turn the HAZARD LIGHTS ON; right side to turn OFF.
11 ROTATING BEA- Press the left side to turn the ROTATING BEACON ON; right side to turn OFF.
CON
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INSTRUMENT PANEL (CONT’D) Ignition Switch Removal and Installation (Standard
Panel)
Standard Panel Removal And Installation (Right Side)
Figure 60-50-9
Figure 60-50-7
N-20140
P-21769B
Disconnect the key switch wiring harness (Item 1)

Remove the three mounting bolts (Item 1) [Figure 60-50- [Figure 60-50-9] from the back of the control panel.
7].
Figure 60-50-10
Installation: Be careful to not overtighten the instrument
panel mounting bolts to prevent stripping of the threaded
holes in the panels.
Figure 60-50-8
N-18410
Remove the ignition key (Item 1) [Figure 60-50-10] from

the switch. Remove the ignition switch retaining nut (Item
N-20158 2) [Figure 60-50-10] from the switch.
Pull the right instrument panel down and disconnect the

wire harness connector (Item 1) [Figure 60-50-8] from
the panel.
Remove the panel from the loader cab.
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INSTRUMENT PANEL (CONT’D) Figure 60-50-13
Standard Panel Removal And Installation (Right Side)

(Cont'd)
Ignition Switch Removal And Installation Standard Panel

(Cont'd)
Figure 60-50-11
1
1
N-20163
Pull the right instrument panel down and disconnect the

the panel.
Remove the panel from the loader cab.

N-20141
Figure 60-50-14
Remove the ignition switch (Item 1) [Figure 60-50-11]

from the control panel.
Deluxe Panel Removal And Installation (Right Side)
Figure 60-50-12 1
N-20142
1
NOTE: The instrument panel (Item 1) [Figure 60-50-
14] must be replaced as a complete unit.
N-20103

12].

panel mounting bolts to prevent stripping of the threaded
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INSTRUMENT PANEL (CONT’D) Alarm Removal and Installation
Standard And Deluxe Panel Removal And Installation Remove the left side instrument panel.
(Left Side)
Figure 60-50-17
Figure 60-50-15
1
1
N-20144
N-18409
Remove the retaining nut (Item 1) [Figure 60-50-17]

Remove the three mounting bolts (Item 1) [Figure 60-50- from the loader alarm.
15].
Remove the alarm from the loader instrument panel.
panel mounting bolts to prevent stripping of the threaded Bulb Removal And Installation
Remove the left side instrument panel. (See Standard
Figure 60-50-16 And Deluxe Panel Removal And Installation (Left Side)
on Page 60-50-11.)
Figure 60-50-18
2 1 1
N-20165
Pull the left instrument panel down and disconnect the

N-20145
the loader alarm.
Remove the two light bulb covers (Item 1) [Figure 60-50-
Disconnect the wire harness connector (Item 2) [Figure 18] from the back of the instrument panel.
60-50-16] from the loader instrument panel.
NOTE: The wiring harness (Item 3) [Figure 60-50-16]

is an optional accessory harness.
Remove the instrument panel from the loader.
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INSTRUMENT PANEL (CONT’D)
Standard And Deluxe Panel Removal And Installation

(Left Side) (Cont'd)
Bulb Removal And Installation (Cont’d)
Figure 60-50-19
N-20146
With a flat blade screw driver, turn the light bulb

counterclockwise [Figure 60-50-19] and remove from
the panel.
Figure 60-50-20
N-20147
To install the bulbs, place them in the sockets and turn

clockwise [Figure 60-50-20].
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LIGHTS Figure 60-60-3
Front Removal And Installation
Open the rear door.
Disconnect the negative(-) cable from the battery. (See

Removal And Installation on Page 60-20-1.).
Figure 60-60-1 1
N-19351
1
Remove the bulb (Item 1) [Figure 60-60-3] from the

socket.
Reverse the above procedure to install the bulb.
N-19348
Remove the light housing (Item 1) [Figure 60-60-1] from

the operator cab.
Figure 60-60-2
N-19349
Remove the bulb assembly (Item 1) [Figure 60-60-2]

from the light housing by turning bulb assembly a 1/4
turn.
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LIGHTS (CONT’D) Figure 60-60-6
Rear Removal And Installation
Open the loader tail gate.
Figure 60-60-4
N-21484
1
Using care press the rear light and housing from the door
[Figure 60-60-6].
N-21514 Reverse this procedure for installation.
Disconnect the wiring harness connector (Item 1) [Figure

60-60-4].
Figure 60-60-5
1
2
N-21483
Remove the bulb assembly (Items 1 & 2) [Figure 60-60-

5] from the light housing by turning bulb assembly a 1/4
turn.
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BOBCAT CONTROLLER
Identification Chart
J1 J2 J3 J4
Black 18 Pin Connector White 18 Pin Connector Black 30 Pin Connector White 30 Pin Connector
(All Blue Wires) (Mostly Blue And Purple Wires) (Multi Color Wires) (Mostly Green Wires)
Viewed From Mating End Viewed From Mating End

X = No Connection X = No Connection
Viewed From Mating End Viewed From Mating End

X = No Connection X = No Connection
MC-2577
TS-1941
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BOBCAT CONTROLLER (CONT’D) Figure 60-70-3
Figure 60-70-1
N-21487

N-21485 the left front panel.
Remove the panel.

Remove the bolt (Item 1) [Figure 60-70-1] and nut from
the lift linkage foot pedal. Figure 60-70-4
Figure 60-70-2
1
1
1
N-21488
N-21486
Remove the four harness connector bolts (Item 1)
[Figure 60-70-4] from the Bobcat controller.
Remove the bolt (Item 1) [Figure 60-70-2] and nut from
the lift linkage bar. Installation: Tighten the connector bolts to 30-35 in.-lbs.
(3,39-3,96 Nm) torque.
Reposition the linkage bar towards the rear of the loader.
Unplug the individual harness connectors from the
controller.
NOTE: The connectors are keyed and will only plug

in one way.
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BOBCAT CONTROLLER (CONT’D)
Figure 60-70-5
N-21489
Remove the two mount nuts (Item 1) [Figure 60-70-5]

and bolts.
Figure 60-70-6
N-21490
Remove the three bolts (Item 1) [Figure 60-70-6].
Remove the mount from the controller.
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963 Bobcat Loader
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DIAGNOSTICS SERVICE CODES CODE The controller is asking for a password. (Deluxe
instrument panel only).
Display
ERROR The wrong password was entered. (Deluxe
The left instrument panel is the same for both the instrument panel only.)
Standard and Deluxe Instrumentation [Figure 60-80-1].
The following number errors may be displayed.
NOTE: Corroded or loose grounds can cause
multiple service codes and/or abnormal The Prefix, in the left two columns, followed by one or
symptoms. All dash lights flashing, buzzer more Suffix, in the right two columns, will indicate a
going off, headlights and taillights flashing, Function and the type of error or errors that have
could indicate a bad ground. The same occurred.
symptoms could apply if the voltage is low,
such as loose or corroded battery cables. If Figure 60-80-1
you observe these symptoms, check grounds
and positive leads first. 2
Press and hold LIGHTS Button (Item 1) [Figure 60-80-1]

for two seconds to view SERVICE CODES in the
HOURMETER/CODE DISPLAY (Item 2) [Figure 60-80-
1]. If more than one SERVICE CODE is present, the
codes will scroll on the HOURMETER/CODE DISPLAY. 1
The following word errors may be displayed.
REPLY One or both instrument panel(s) not

communicating with the controller.
INPUT The controller not communicating with the left B-15551B

instrument panel.
EXAMPLE: 01-17 PLUGGED AIR FILTER
SERVICE CODES
PREFIX FUNCTION SUFFIX ERROR DESCRIPTION
01 Air Filter 02 Error ON (Detects ON when should be OFF)
02 Hydraulic Charge Filter 03 Error OFF (Detects OFF when should be ON)
03 Battery Voltage 04 In Error
04 Engine Oil Pressure 05 Short To Battery (Detects 12V & should not be)
05 Hydraulic Charge Pressure 06 Short To Ground
06 Engine Speed 07 Open Circuit (Not grounded)
07 Hydraulic Oil Temperature 09 Low
08 Engine Coolant Temperature 10 High
09 Fuel Level 11 Extremely High
11 Seat Bar Sensor 13 No Signal
12 Front Auxiliary PWM Switch (Proportional 14 Extremely Low
Control)
13 Fuel Shutoff Solenoid-Secondary 15 In Shutdown
14 Fuel Shufoff Solenoid-Primary 16 Not Connected
15 Traction Lock Solenoid-Primary 17 Plugged
16 Traction Lock Solenoid-Secondary 18 Out Of Range
17 Hydraulic Lock Valve Solenoid 21 Out Of Range High (Above detectable range of
sensor)
18 Spool Lock Solenoid 22 Out Of Range Low (Below detectable range of
sensor)
19 Bucket Positioning Solenoid
20 Two Speed Output
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DIAGNOSTIC SERVICE CODES (CONT’D)
Display (Cont’d)
SERVICE CODES
PREFIX FUNCTION SUFFIX ERROR DESCRIPTION
21 Glow Plugs 23 Not Calibrated
22 Starter Output 28 Failure
23 Solenoid for Rear Female Coupler 31 Tilt Actuator Fault
24 Solenoid for Rear Male Coupler 32 Tilt Actuator Wiring Fault
25 Rear Auxiliary Relief Solenoid 33 Tilt Handle Wiring Fault
26 Solenoid for Front Female Coupler 34 Tilt Actuator Not Calibrated
27 Solenoid for Front Male Coupler 35 Tilt Handle Not Calibrated
28 Diverter Valve Solenoid 36 Lift Actuator Fault
29 High Flow Auxiliary Solenoid 37 Lift Actuator Wiring Fault
30 Watchdog Failure (Internal System Failure) 38 Lift Handle Wiring Fault
31 Recovery Mode Failure (Loss of Power) 39 Lift Actuator Not Calibrated
32 Advanced Hand Controls 40 Lift Handle Not Calibrated
33 Constant Data (Stored Loader Information) 41 Invalid Frequency From Advanced Hand Controls
(AHC)
34 Deluxe Not Downgrades 48 Multiple Controllers Present - Error
35 Two Speed Fan
36 Attachment Control Device (ACD) Controller
80 ACD Output A
81 ACD Output B
82 ACD Output C
83 ACD Output D
84 ACD Output E
85 ACD Output F
86 ACD Output G
87 ACD Output H
90 Service Tool Output C
91 Service Tool Output D
92 Service Tool Output E
93 Service Tool Output F
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BICS™ SYSTEM 2. Raise the Seat Bar fully. All four BICS lights (Items 1,
2, 3, & 4) [Figure 60-90-1] [PRESS TO OPERATE
Inspecting The BICS™ Controller (Engine STOPPED - LOADER, SEAT BAR, LIFT & TILT VALVE and
Key ON) TRACTION*] on left instrument panel should be OFF
[Figure 60-90-1].
NOTE: Record what lights are blinking (if any) and

WARNING number of light flashes. (See Troubleshooting
Guide on Page 60-90-4.)
Inspecting Deactivation Of The Auxiliary Hydraulics
The Bobcat Interlock Control System (BICS™) must
System (Engine STOPPED - Key ON)
deactivate the lift, tilt and traction drive functions. If it
does not, contact your dealer for service. DO NOT
3. Sit in the operator's seat, lower the Seat Bar, and
modify the system.
W-2151-0394
press the PRESS TO OPERATE LOADER Button.
Press the auxiliary hydraulics FLOW Button. The
auxiliary FLOW Button light will come ON. Raise the
Figure 60-90-1 Seat Bar. The light should be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING)
4. Sit in the operator's seat, lower the seat bar, engage

the parking brake pedal and fasten the seat belt.
5. Start the engine and operate at low idle. Press the

PRESS TO OPERATE LOADER Button. While
raising the lift arms, raise the Seat Bar fully. The lift
arms should stop. Repeat using the tilt function.
Inspecting The Traction Lock (Engine RUNNING)
6. Fasten the seat belt, disengage the parking brake

pedal, press the PRESS TO OPERATE LOADER
N-18409
Button and raise the Seat Bar fully. Move the steering
levers slowly forward and backward. The TRACTION
lock should be engaged. Lower the Seat Bar. Press
7. Engage the parking brake pedal and move the

steering levers slowly forward and backward. The
TRACTION lock should be engaged.
NOTE: * The TRACTION light on the left instrument

panel will remain OFF until the engine is
started, the PRESS TO OPERATE LOADER
1 2 3 4 Button is pressed and the parking brake is
disengaged.
B-15551G
Inspecting The Lift Arm By-Pass Control
1. Sit in the operator's seat. Turn key ON (Standard 8. Raise the lift arms 6 feet (2 meters) off the ground.
Panel), press RUN / ENTER Button (Deluxe Panel, Stop the engine.
lower the Seat Bar and disengage the parking brake
pedal. Press the PRESS TO OPERATE LOADER Turn the lift arm by-pass control knob clockwise 1/4
Button. Three BICS lights (Items 1, 2, & 3) [Figure 60- turn. Pull up and hold the lift arm by-pass control knob
90-1] [PRESS TO OPERATE LOADER, SEAT BAR, until the lift arms slowly lower.
and LIFT & TILT VALVE] on left instrument panel
should be ON [Figure 60-90-1].
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BICS™ SYSTEM (CONT’D)
Additional Inspection For Loaders With Advanced

Hand Controls (AHC)
9. Sit in the operator's seat and fasten the Seat Belt.

Lower the Seat Bar, start the engine and press the
PRESS TO OPERATE LOADER Button.
10. Raise the lift arms about 6 feet (2 meters) off the
ground.
11. Turn key OFF (Standard Panel), press the STOP

Button (Deluxe Panel, and wait for the engine to come
to a complete stop.
12. Turn key ON (Standard Panel), press RUN /ENTER

Button (Deluxe Panel. Press the PRESS TO
OPERATE LOADER Button, move the left hand
control toward the operator. The lift arms should not
lower.
13. Move the right hand control away from the operator.
The bucket (or attachment) should not tilt forward.
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WARNING
The following troubleshooting guide is provided for
assistance in locating and correcting BICS™ system Check for correct function after adjustments, repairs
problems. It is recommended that these procedures be or service. Failure to make correct repairs or
done by authorized Bobcat Service Personnel only. adjustments can cause injury or death.
W-2004-1285
PROBLEM SOLUTION#
All indicator lights flashing. 5
One of the indicator lights flashing. 1
Intermittent indicator lights. 2, 3, 4
1. Refer to BICS™ troubleshooting guide. (See Troubleshooting Guide on Page 60-90-4.)
2. Check wire connections on Bobcat controller to make sure connectors are locked into place.
3. Check pins in connectors for pins pushed back or bent.
4. Use seatbar sensor tester MEL1428 to isolate problem between sensor and controller and wiring.
5. Possible low or high voltage.
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Troubleshooting Guide
The following list shows the effects which can happen to the loader, and the probable causes when the BICS™ System
lights are off or flashing and associated service code. (See DIAGNOSTICS SERVICE CODES on Page 60-80-1.) for
service codes.
Effect on Flashing Indicator Means System Problem (See Your
Operation of Bobcat Dealer for Service.)
Indicator Light ON Light OFF Loader when Number of Cause
Light Light is OFF Flashes/ Ser-
vice Codes
PRESS TO PRESS TO Lift, tilt and Continuous System voltage low.
OPERATE OPERATE traction func- 03-09
button is button not tions will not Continuous System voltage high.
activated activated operate. 03-10
Seat Bar Seat Bar Seat Bar Up Lift, tilt and 2 Seat bar sensor circuit shorted to
Down traction func- 11-05 battery voltage*.
tions will not 3 Seat bar sensor circuit shorted to
operate. 11-06 ground.
Valve Control Valve Control Valve Lift and tilt 1 Valve output circuit is open.
Can Be Used Cannot Be functions will 17-07
Used not operate. 2 Valve output circuit shorted to bat-
17-05 tery voltage*.
3 Valve output circuit shorted to
LIFT & TILT
17-06 ground.
3 Controller is not grounded or inter-
17-06 mittent ground.
Traction Loader can Loader can- Loader can- 1 Traction lock hold coil circuit is open.
be moved not be moved not be 16-07
forward and forward and moved 2 Traction lock hold coil circuit shorted
backward. backward. forward and 16-05 to battery voltage*.
backward. 3 Traction lock hold coil circuit shorted
16-06 to ground.
5 Traction lock pull coil circuit.
15-02 Error On•
6 Traction lock pull coil circuit.
15-03 Error Off °
* Normal BICS™ operating voltage is less than the electrical system voltage. If voltage is more, the circuit is
shorted to system voltage.
Notes:
(1) If the System Activated and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If
one of the lights stay OFF, check the circuit for continuity.
(2) Flashing patterns will repeat every 3.25 seconds.
• Error On - Shorted to battery stuck relay, faulty wiring.
° Error Off -Shorted to ground or blown fuse, faulty wiring, faulty open relay, no voltage from relay to controller.
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SEAT BAR SENSOR
WARNING
W-2004-1285
PROBLEM SOLUTION#
Indicator light does not come ON when seat bar is lowered. 1, 2, 3, 4, 5
1. Check sensor wire connection.
2. Use the BICS™ sensor tester MEL1428 with seat bar adapter MEL1567 to check sensor and controller.
3. Check for loose hardware.
4. Check keyed bushing to make sure magnet collar rotates with seat bar.
5. Check magnet collar magnets for contamination such as metal particles.
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SEAT BAR SENSOR (CONT’D) Figure 60-100-3
Test
Figure 60-100-1
1
P-4698
The toggle switch (Item 2) [Figure 60-100-3] can be in

N-18463 either the Absent or Present position.
If there is no power light (Item 1) [Figure 60-100-3] on

Use Sensor Tester (MEL1428) and seat bar sensor tester the sensor tester, check the tester or wiring harness.
adapter (MEL1567) for the following procedure:
Figure 60-100-4
Connect the seat bar adapter sensor leads (MEL1567) to
the sensor tester.
Disconnect the seat bar sensor connector (Item 1)

[Figure 60-100-1].
1
Figure 60-100-2
P-4699
N-19557
Lower the seat bar. The Sensor Test light (Item 1)

[Figure 60-100-4] should illuminate.
Raise the seat bar. The Sensor Test light (Item 1) [Figure
N-19558 60-100-4] should go off.
If the above test fails, there is a problem with the seat bar
Connect the Sensor Tester (Item 1) [Figure 60-100-2] sensor.
inline, to the seat bar sensor connectors. See inset
[Figure 60-100-2]. Disconnect the Sensor Tester.
Turn the key to the ON position. DO NOT START THE Replace the Seat Bar Sensor. (See Removal And
ENGINE. Installation on Page 60-100-3.)
If the above test passes, run the seat bar sensor BICS™
circuit test. (See BICS™ Circuit Test on Page 60-100-4.)
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IMPORTANT 3
Be careful to not overtighten the sensor mounting
bolt and nut to prevent breakage of the sensor.
I-2088-1095
Figure 60-100-5 1
2
1
N-19224
N-19219
Remove the seat bar (Item 1) [Figure 60-100-5] from the

loader. (See Removal And Installation on Page 50-10-1.) Remove the mounting bolt (Item 1) [Figure 60-100-6]
from the seat bar mount (Item 2) [Figure 60-100-6].
Installation: Tighten the mounting bolt to 50-70 in.-lbs.

(5,6-7,9 Nm) torque.
Remove the sensor mounting bolt (Item 3) [Figure 60-

100-6] and nut.
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SEAT BAR SENSOR (CONT’D) BICS™ Circuit Test
Removal And Installation (Cont’d) Use Sensor Testers (MEL1428) and seat bar sensor
tester adapter (MEL1567) for the following procedure:
Figure 60-100-7
Connect the seat bar sensor tester adapter MEL1567 to
the sensor tester.
2
Figure 60-100-8
1 3
N-19383
1
Remove the keyed plastic bushing (Item 1) [Figure 60-

100-7], magnetic bushing assembly (Item 2) [Figure 60-
N-18463
100-7] and sensor bracket (Item 3) [Figure 60-100-7].
Installation: Be sure the tabs on the pivot bushing are Disconnect the seat bar sensor connector (Item 1)
positioned in the slotted hole (Item 3) [Figure 60-100-7] [Figure 60-100-8].
of the seat bar
Inspect all parts for damage and wear and replace if

necessary.
Reverse the removal procedure to install the seat bar

sensor.
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BICS™ Circuit Test (Cont’d)
Figure 60-100-9
2
1
N-18409
1
The BICS™ seat bar indicator light (Item 1) [Figure 60-
P-4703 100-10] should illuminate.
Figure 60-100-11
Connect Sensor Tester (Item 1) [Figure 60-100-9] inline
to the seat bar sensor connectors.
Turn the key to the ON position. DO NOT START THE

ENGINE.
If there is no power light on the sensor tester, check the

tester or wiring harness.
1
When the power light is illuminated, move the toggle
switch (Item 2) [Figure 60-100-9] on the sensor tester to
the Present position.
NOTE: The sensor test light (Item 3) [Figure 60-100-9]

is only activated by the seat bar. It will be off P-4699
with the seat bar up or on with the seat bar
down.
Move the toggle switch (Item 1) [Figure 60-100-11] on
the sensor tester to the Absent position.
The Seat Bar light (Item 1) [Figure 60-100-10] should go

off.
If the above test fails, there is a problem with the Bobcat

controller or the wiring harness.
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TRACTION LOCK
WARNING
W-2004-1285
PROBLEM SOLUTION #
Traction lock stays engaged. 1, 2, 3, 4, 5, 6, 7
Traction lock will not engage. 6, 8
Intermittent activation of traction lock. 9, 10
1. Check that the controller power light is ON.
2. Make sure that the brake pedal is not engaged.
3. Measure charge pump pressure, should be above 280 PSI (1930 kPa).
4. Test traction lock solenoid, the coil resistance should be 9 or 11 ohms.
5. Check all hydraulic connections for the brake.
6. Traction lock solenoid valve is defective.
7. Brake discs are locked on pinion.
8. Red by-pass knob on the traction lock solenoid is not in the engaged position.
9. Check wire connections for loose connector body.
10. Check for loose or bent pins in connectors.
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ADVANCED HAND CONTROL (A.H.C.) SYSTEM Figure 60-120-3
Components Identification
Figure 60-120-1
1
1
2
P-13797
A.H.C. Controller (Item 1) [Figure 60-120-3].

N-17774 N-17783
Figure 60-120-4
Steering Lever/Handle Control (Item1) [Figure 60-120-

1].
Handle Control Unit (Item 2) [Figure 60-120-1].

1
Figure 60-120-2
P-21769B
A.H.C. error indicator (Item 1) [Figure 60-120-4].
NOTE: The A.H.C. icon will illuminate when an error

1 occurs. The error is stored as a service code.
N-19112 (See DIAGNOSTICS SERVICE CODES on
Page 60-80-1.)
Control Valve Actuators (Item 1) [Figure 60-120-2].
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ADVANCED HAND CONTROL (A.H.C.) SYSTEM
(CONT'D)
Troubleshooting Guide
The Advance Hand Control System (A.H.C.) has a built-in diagnostic function which uses an icon on the right instrument
panel to indicate the condition of the A.H.C. System. The system also records the alarm condition as a service code.
The control module continually checks the system in the order listed. The checks start with the lift handle controller and
then the lift actuator. If no problems are present, it will then check the tilt handle controller and the tilt actuator. The system
will stop its check at the first problem and then luminate the icon.
The system starts its diagnostics and calibration when the ignition key is turned ON.
The following list shows the probable causes when the icon is luminated.
Advanced General Fuel Level System Engine Oil Engine Air Filter
Hand Warning Voltage Pressure Coolant
Control Temp.
Attachment Two Speed Glow Plugs Seatbelt Hydraulic Hydraulic Hydraulic

Control Charge Oil Filter
Device Pressure Temp.
Advanced Hand Controls
Errors - Lights solid with 3 beeps

32–31 - Tilt actuator fault
32–32 - Tilt actuator wiring fault
32–33 - Tilt handle wiring fault
32–34 - Tilt actuator not calibrated
32–35 - Tilt handle not calibrated
32–36 - Lift actuator fault
32–37 - Lift actuator wiring fault
32–38 - Lift handle wiring fault
32–39 - Lift actuator not calibrated
32–40 - Lift handle not calibrated
32–41 - Invalid frequency
To see what error occurred. Check the service code on the left instrument panel. (See DIAGNOSTICS SERVICE CODES
on Page 60-80-1.)
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(CONT'D)
Parts Identification
C-428
C-430
C-431
C-429
P/N PIN DESCRIPTION P/N PIN DESCRIPTION

C-430 Connector, Metri-Pack C-428 Connector, 8-Way Plug
Orange/White A Switched Battery Power Dk. Blue/White 1 Low Reference To Resistive
Black B Ground Inputs
C-431 Male, 10-Way Lt. Green/White 2 Signal From Lift Actuator
Brown/Green A Signal From Lift Control Dk. Blue 3 High Reference To Resistive
Handle Input Inputs
Purple/Yellow B Float Switch On/Off 4 Open
Pink/Green C Signal From Tilt Control Handle Brown/White 5 Lift Spool Actuator Motor (-)
Input 6 Open
Dk. Blue D Tilt High Reference To Resis- 7 Open
tive Inputs Brown/Yellow 8 Lift Spool Actuator Motor (+)
Dk. Blue/White E Tilt Low Reference To Resistive C-429 Connector, 8-Way Plug
Inputs Dk. Blue/White 1 Low Reference To Resistive
Dk. Blue/White F Lift Low Reference To Resistive Inputs
Inputs Lt. Blue/White 2 Signal From Tilt Actuator
Dk. Blue G Lift High Reference To Resis- Dk. Blue 3 High Reference To Resistive
tive Inputs Inputs
Purple/White H BICS Input Status 4 Open
Purple/Red J AHC Status Output Pink/White 5 Tilt Spool Actuator Motor (-)
K Open
6 Open
7 Open
Pink/Yellow 8 Tilt Spool Actuator Motor (+)
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(CONT'D)
A.H.C. Controller Removal And Installation
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(CONT'D)
Handle Control Unit Connector
Figure 60-120-5
3
1
2
1
P-13733
1 With a pointed tool, lift the tab (Item 1) [Figure 60-120-7]

and pull the wire from the connector.
N-17392
Assembly: Install the wires into the connector as listed
below [Figure 60-120-7]:
The wire connector (Item 1) [Figure 60-120-5] can be
removed from the handle control unit wires, use the 1-Terminal - Red
following procedure.
2-Terminal - Black
Figure 60-120-6
3-Terminal - Green
1
1
P-13725 P-13732
Remove the wedge (Item 1) [Figure 60-120-6] from the

connector.
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(CONT'D)
Switch Handle Removal and Installation
Figure 60-120-8
P-13725 P-13732
Remove the wedge (Item 1) [Figure 60-120-9] from the

connector.
Figure 60-120-10
1
1
3
2
1
N-17786
P-13735
Remove the handle control unit from the steering lever.
(See Disassembly And Assembly on Page 30-30-1.)
Using a pointed tool, press down on the tab (Item 1)
To remove the switch handle the connector (Item 1) [Figure 60-120-10] and pull the wire from the connector.
[Figure 60-120-8] must be removed from the wires, use
the following procedure: Installation: Install the wires into the connector as listed
below [Figure 60-120-10]:
Right Steering Lever Switch Handle

1-Terminal - Pink/Red
2-Terminal - Pink/Black
3-Terminal - Pink/Green
Left Steering Lever Switch Handle

1-Terminal - Brown/Red
2-Terminal - Brown/Black
3-Terminal - Brown/Green
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ADVANCED HAND CONTROL (A.H.C.) SYSTEM Installation: The wire colors of the steering lever
(CONT'D) harness are as follows:
Switch Handle Removal and Installation (Cont'd) Right Switch Handle
Figure 60-120-11 Ten-Pin Connector

A-Terminal - Orange
B-Terminal - White
C-Terminal - White/Black
1 D-Terminal - White/Red
E-Terminal - Green
F-Terminal - White/Green
G-Terminal - Blank
H-Terminal - Lt. Green
J-Terminal - Yellow
K-Terminal - Blank
Three-Pin Connector
2 A-Terminal - Pink/Red
B-Terminal - Pink/Black
N-21872 C-Terminal - Pink/Lt. Green
Left Switch Handle

Disconnect the right switch handle connectors (Items 1 &
2) [Figure 60-120-11] from the loader wiring harness
Ten-Pin Connector
connectors.
A-Terminal - Orange
B-Terminal - Dk. Blue
Figure 60-120-12
C-Terminal - White
D-Terminal - Blank
3 E-Terminal - Blank
F-Terminal - Yellow/Red
G-Terminal - Yellow/Green
H-Terminal - Blank
J-Terminal - Blank
2 4 K-Terminal - Blank
1 Three-Pin Connector
A-Terminal - Brown/Red
B-Terminal - Brown/Black
C-Terminal - Brown/Lt. Green
Two-Pin Connector
N-21873
A-Terminal - Orange/Blue
B-Terminal - Orange/White
Disconnect the left switch handle connectors (Items 1, 2,
3 & 4) [Figure 60-120-12] from loader wiring harness Five-Pin Connector
connectors. A-Terminal - Green
B- Terminal - Brown
Remove the connector locks and connectors from the C-Terminal - Blank
wires to remove the switch handle from the steering D-Terminal - Yellow
handle. E-Terminal - Blank
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(CONT'D)
Switch Handle Removal and Installation (Cont'd)
Figure 60-120-13
2 2
N-17382
Roll the pistol grip handle cover (Item 1) [Figure 60-120-

13] down.
Using a small screwdriver, lift the handle tabs (Item 2)

[Figure 60-120-13] and slightly rotate the switch handle.
N-17383
Pull the switch handle and wiring harness assembly (Item

1) [Figure 60-120-14] from the steering lever.
Figure 60-120-15
N-17471
Installation: When installing the switch handle and

wiring harness assembly into the steering handle, route
the harness (Item 1) [Figure 60-120-15] to assure proper
return of the control handle to neutral position.
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(CONT'D)
Actuators Disassembly and Assembly
Figure 60-120-16
3
2
1
N-18941
1
Remove the rubber strap (Item 1) [Figure 60-120-18]

from the mounting shaft collar (Item 2) [Figure 60-120-
N-18912 18].
Remove the mounting bracket (Item 3) [Figure 60-120-

Remove the actuator (Item 1) [Figure 60-120-16] from 18].
the hydraulic control valve.
Check the rubber strap, mounting shaft collar, and
Installation: Tighten the mount bolts to 90-100 in.-lbs. mounting bracket for wear and replace as needed.
(130,2-11,3 Nm) torque.
NOTE: There must be a small amount of free play

between the actuators and the mount block
when properly installed.
Figure 60-120-17
N-18940
Check the mounting block (Item 1) [Figure 60-120-17]

and bolts for wear and replace as needed.
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(CONT'D)
Actuators Disassembly and Assembly (Cont’d)
Figure 60-120-19
1
N-17742 N-17741
Check the actuator wiring harness connector (Item 1)

[Figure 60-120-19] and replace if broken.
Installation: Install the wires into the connector as listed

below. The terminal numbers are written on the back of
the connector (Item 2) [Figure 60-120-19].
Lift and Tilt Actuator

1 - Terminal-Black-Larger diameter wire (16 gauge)
2 - Terminal-Green-Larger diameter wire (16 gauge)
3 - Terminal-Red/Green-Larger diameter wire (16
gauge)
4 - Terminal-Open
5 - Terminal-Red-Smaller diameter wire (18 gauge)
6 - Terminal-Open
7 - Terminal-Open
8 - Terminal-Black-Smaller diameter wire (18 gauge)
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PROPORTIONAL CONTROL (PWM) Figure 60-130-1
The PWM module sends a diagnostic code to the

Auxiliary Hydraulic Switch lights when the conditions
listed in the chart below occur.
• When the lights are flashing, the key needs to be

turned OFF and then ON. If the problem still exists
they will continue to flash.
1
• Proportional flow cannot be engaged if the lights are
blinking.
2
• Continuous flow (detent) can be engaged if alternate P-3272
blinking lights are off after the key switch is turned
OFF and then ON (during a proportional flow switch
failure).
MOMENTARY
DETENT LED
LED
(ITEM 2) PROBLEM AREA PROBLEM CAUSE
(ITEM 1)
[Figure 60-130-1]
[Figure 60-130-1]
Light Blinking Light OFF Base End Solenoid or Wiring Wires Disconnected
Wires Shorted
Wires Cut
Solenoid failed. Perform solenoid coil
test.
PWM module failed.
Light OFF Light Blinking Rod End Solenoid or Wiring Wires Disconnected
Wires Shorted
Wires Cut
test.
PWM module failed.
Light Blinking Light Blinking Diverter Solenoid or Wiring Wires Disconnected
Wires Shorted
Wires Cut
test.
PWM module failed.
*Blinking/OFF *OFF/Blinking Proportional Flow Switch Wires Disconnected
(Right Handle) Wires Shorted
Wires Cut
Proportional flow switch failed.
Check voltage to switch.
Perform handle test.
PWM module failed.
*Alternate Blinking Lights
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PROPORTIONAL CONTROL (PWM) (CONT’D) Electric Solenoid Coil Testing
Control Handle Testing Figure 60-130-3
Figure 60-130-2
1
1
N-15704
P-2129
The front auxiliary solenoid valves (Item 1) [Figure 60-
130-3] are located in the hydraulic control valve. Test the
The right side steering lever handle switch (Item 1) solenoid coils with a Ohm test meter.
[Figure 60-130-2] controls the proportional flow to front
auxiliary. Test the switch with a Ohm test meter. Disconnect the coil from the controls harness. The
correct reading is 1-5 Ohms.
Disconnect the handle switch harness from the controls
harness. Use the chart below to test the handle switch.
Handle Switch Position
Test between Full
Full Left Center
handle wires Right
White/Black 4.5-5.5 4.5-5.5 4.5-5.5
& White K-Ohms K-Ohms K-Ohms
White/Red 0.5-1.5 2.3-2.7 3.5-4.5
& White K-Ohms K-Ohms K-Ohms
White/Red & 3.5-4.5 2.3-2-7 0.5-1.5
White/Black K-Ohms K-Ohms K-Ohms
NOTE: Push the switch gradually from center to

either left or right. The Ohm reading must
change gradually. Replace the handle switch
assembly if required.
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ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
Attachment
xxxxxxxxx Harness
Switch Solenoid Number Attachment Harness
Terminal
Number Activated Connector
Left Side Activated Right Side
Control Handle Control Handle
Switches RH HFH Fourteen Pin Switches
Connector Viewed
1 1 1 1, 8 K from front
2 2 2 2 K (pin side of
connector)
*3 1 1 1, 8 K of loader.
4 2 2, 3 6, 7 K, A, D
5 1 1, 3 5, 7 K, A, C
6 1 1, 3 5, 7 K, E
7 1 1, 3 5, 7 K, F
8 1 1, 3 5, 7 K, G
9 1 1, 3 5, 7 K, H
B-16449
B-16447 10, 11, 12, - -- -- K
B-16448
13, 14 Early
Version
2 1
Current
Version
1
NOTE: All diagnostics must be done at the fourteen pin connector (Item 1).
On earlier versions, the switch (Item 2) must be in the fourteen pin position. The current version ACD
(Attachment Control Device) without switch, automatically recognizes the use of the seven or fourteen pin
connector when connected.
The ACD (Attachment Control Device) Icon, located in the right instrument panel on the loader cab, must
be illuminated continuously.
If the ACD light flashes, check for diagnostic service codes. See the Electrical System Service Manual for
the proper procedure.
RH - Loaders with Rear Hydraulics Option.
HFH - Loaders with High Flow Hydraulics Option.
* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 1 & 2.
* Terminal K is activated with Key switch ON.
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ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
(CONT’D)
Controls Identification Chart (Cont’d)
Figure 60-140-1
SOLENOID HYDRAULIC WIRING

NUMBER COUPLER NUMBER
4
2 9 1 Front Female 4330
3 6 (Rod)
3 2 Front Male 4340
1 (Base)
3 (Top) Diverter 4450
4 (Bottom) Bleed-Rear 4480
Male & Female
MC-2314
Note: Pushing the Hydraulic Pressure release button ON activates solenoids number 1, 4 and 9. The high flow
button in the left side instrument panel must be pushed ON to activate solenoid number 8.
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ENGINE SERVICE
AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-40-1

Housing Removal And Installation . . . . . . . . . . . . . . . . . . . 70-40-1
SAFETY &
COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-60-1 MAINTENANCE
Blower Housing Removal And Installation (Cont'd) . . . . . . 70-60-7
ENGINE AND ENGINE MOUNTS. . . . . . . . . . . . . . . . . . . . . . 70-80-1

Mounting Brackets Removal And Installation . . . . . . . . . . 70-80-6
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 70-80-1 DRIVE
SYSTEM
ENGINE COMPONENTS AND TESTING. . . . . . . . . . . . . . . . 70-70-1
Checking The Fuel Lift Pump. . . . . . . . . . . . . . . . . . . . . . . 70-70-6
Fuel Injection Pump Removal And Installation . . . . . . . . . 70-70-1
Fuel Injector Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-70-6
Fuel Injector Removal and Installation. . . . . . . . . . . . . . . . 70-70-3
ENGINE SPEED CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . 70-20-1

FLYWHEEL AND HOUSING. . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-1 ENGINE

Flywheel Removal And Installation . . . . . . . . . . . . . . . . . . 70-90-1 SERVICE
Ring Gear Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-2
Ring Gear Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-90-2
MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-1
Exhaust Extension Pipe. . . . . . . . . . . . . . . . . . . . . . . . . . . 70-30-3
Spark Arrestor Cleaning Procedure . . . . . . . . . . . . . . . . . . 70-30-1
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-50-1
Coolant Recovery Tank Removal And Installation . . . . . . . 70-50-1
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ENGINE SERVICE (CONT’D)
RECONDITIONING THE ENGINE . . . . . . . . . . . . . . . . . . . . 70-100-1

Camshaft And Tappets Installation. . . . . . . . . . . . . . . . . 70-100-19
Camshaft And Tappets Removal . . . . . . . . . . . . . . . . . . 70-100-19
Changing Valve Springs (With Cylinder Head Installed) 70-100-13
Checking Crankshaft End Play . . . . . . . . . . . . . . . . . . . 70-100-31
Checking Piston Height . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-26
Cooling System Description. . . . . . . . . . . . . . . . . . . . . . 70-100-32
Connecting Rod Bushing Replacement . . . . . . . . . . . . . 70-100-24
Connecting Rod Inspection . . . . . . . . . . . . . . . . . . . . . . 70-100-24
Crankshaft And Bearings Description . . . . . . . . . . . . . . 70-100-26
Crankshaft And Bearings Installation . . . . . . . . . . . . . . . 70-100-29
Crankshaft And Bearings Removal . . . . . . . . . . . . . . . . 70-100-26
Cutting A Valve Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-12
Cylinder Head Disassembly. . . . . . . . . . . . . . . . . . . . . . . 70-100-2
Cylinder Liner Inspection . . . . . . . . . . . . . . . . . . . . . . . . 70-100-45
Cylinder Head Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-5
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-4
Cylinder Liner Inspection . . . . . . . . . . . . . . . . . . . . . . . . 70-100-45
Cylinder Liner Installation. . . . . . . . . . . . . . . . . . . . . . . . 70-100-47
Cylinder Liner Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-46
Engine Block Description . . . . . . . . . . . . . . . . . . . . . . . . 70-100-43
Engine Block Disassembly And Assembly. . . . . . . . . . . 70-100-44
Engine Lubrication System Description . . . . . . . . . . . . . 70-100-38
Engine Oil Cooler Disassembly And Assembly . . . . . . . 70-100-37
Engine Oil Cooler Removal And Installation . . . . . . . . . 70-100-35
Exhaust Manifold Removal and Installation . . . . . . . . . . . 70-100-2
Front Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-16
Front Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-16
Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-45
Inspection Of Crankshaft And Bearings . . . . . . . . . . . . . 70-100-28
Intake Manifold Removal and Installation . . . . . . . . . . . . 70-100-1
Oil Filter Adapter Installation . . . . . . . . . . . . . . . . . . . . . 70-100-39
Oil Filter Adapter Removal. . . . . . . . . . . . . . . . . . . . . . . 70-100-39
Oil Pan Removal And Installation . . . . . . . . . . . . . . . . . 70-100-40
Oil Pressure Relief Valve Disassembly And Assembly . 70-100-43
Oil Pump Disassembly And Assembly. . . . . . . . . . . . . . 70-100-42
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-41
Oil Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-40
Oil Screen And Pick-up Tube. . . . . . . . . . . . . . . . . . . . . 70-100-40
Piston Ring End Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-23
Piston Ring Groove Clearance . . . . . . . . . . . . . . . . . . . 70-100-24
Piston Ring Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-23
Piston And Connecting Rod Assembly . . . . . . . . . . . . . 70-100-24
Pistons And Connecting Rods Description . . . . . . . . . . 70-100-21
Pistons And Connecting Rods Disassembly . . . . . . . . . 70-100-22
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ENGINE SERVICE (CONT’D)
Piston And Connecting Rod Installation. . . . . . . . . . . . . 70-100-25

Pistons And Connecting Rods Removal . . . . . . . . . . . . 70-100-21
Piston Cooling Jet Alignment . . . . . . . . . . . . . . . . . . . . . 70-100-45
Piston Cooling Jet Installation . . . . . . . . . . . . . . . . . . . . 70-100-44
Piston Cooling Jet Removal. . . . . . . . . . . . . . . . . . . . . . 70-100-44
Rear Oil Seal Housing Positioning. . . . . . . . . . . . . . . . . 70-100-30
Rear Oil Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-31
Rear Oil Seal Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-30
Rocker Shaft Disassembly And Assembly. . . . . . . . . . . . 70-100-8
Thermostat Removal and Installation . . . . . . . . . . . . . . 70-100-33
Thermostat Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-34
Timing Case And Drive Assembly Description . . . . . . . 70-100-15
Timing Case And Gear Installation . . . . . . . . . . . . . . . . 70-100-18
Timing Case And Gear Removal . . . . . . . . . . . . . . . . . . 70-100-17
Timing Cover Installation . . . . . . . . . . . . . . . . . . . . . . . . 70-100-15
Timing Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-15
Turbo Charger Description. . . . . . . . . . . . . . . . . . . . . . . 70-100-49
Turbo Charger Removal and Installation . . . . . . . . . . . . 70-100-49
Turbo Charger Troubleshooting . . . . . . . . . . . . . . . . . . . 70-100-48
Valves Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-12
Valve Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . 70-100-14
Valve Depth Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-10
Valve Guides Checking . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-10
Valve Guide Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-11
Valve Guide Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-11
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-9
Valve Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-12
Valve Springs Checking . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-9
Water Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-35
Water Pump Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 70-100-34
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-1
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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
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
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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.
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ENGINE SPEED CONTROL Figure 70-20-3
Figure 70-20-1
N-20746
Tilt the speed control lever and remove the throttle

N-15442 linkage (Item 1) [Figure 70-20-3].

support device. (See Engaging The Lift Arm Support Figure 70-20-4

on Page 10-70-1.)
1
Mark the front side of the stop bracket (Item 1) [Figure
70-20-1] and remove the stop bracket.
Installation: It is important for the front and rear side of

the stop bracket to be located correctly.
Figure 70-20-2
N-20747

remove the speed control lever from the mount.
N-20745
Remove the bolts (Item 1) [Figure 70-20-2].
Installation: Tighten the bolts evenly until the speed

control lever moves backward and forward at a
comfortable tension.
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ENGINE SPEED CONTROL (CONT’D) Figure 70-20-7
Disassembly And Assembly (Cont’d)
Figure 70-20-5
1
N-20750
Remove the washers (Item 1) [Figure 70-20-7] from the

N-20748 lever.
Figure 70-20-8
Remove the washer (Item 1) [Figure 70-20-5].
Figure 70-20-6
1
1
N-20751
N-20749 Turn the lever over and remove the two nuts (Item 1)
[Figure 70-20-8].
Remove the mount plate (Item 1) [Figure 70-20-6] from NOTE: Do not lubricate the speed control parts when
the lever. assembling.
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MUFFLER
Spark Arrestor Cleaning Procedure

WARNING
Never use machine in atmosphere with explosive
IMPORTANT dust or gases or where exhaust can contact

flammable material. Failure to obey warnings can
cause injury or death.
This loader is factory equipped with a U.S.D.A. W-2068-1285
Forestry Service approved spark arrestor muffler. It
is necessary to do maintenance on this spark
Figure 1
arrestor muffler to keep it in working condition. The
spark arrestor muffler must be serviced by dumping
the spark chamber every 100 hours of operation.
If this machine is operated on flammable forest,

brush or grass covered land, it must be equipped
with a spark arrestor attached to the exhaust system
and maintained in working order. Failure to do so will
be in violation of California State Law, Section 4442
PRC.
Make reference to local laws and regulations for

1
spark arrestor requirements.
I-2022-0595
N-20297
WARNING (See SERVICE SCHEDULE on Page 10-100-1.), for

service interval for cleaning the spark arrestor muffler.
When the engine is running during service, the
steering levers must be in neutral and the parking
Do not operate the loader with a defective exhaust
brake engaged. Failure to do so can cause injury or
system.
death.
W-2006-0284
Stop the engine. Open the rear door.
Remove the plug (Item 1) [Figure 1] from the bottom of

the muffler.
WARNING Start the engine and run for about 10 seconds while a
second person, wearing safety glasses, holds a piece of
When an engine is running in an enclosed area, fresh
wood over the outlet of the muffler.
air must be added to avoid concentration of exhaust
fumes. If the engine is stationary, vent the exhaust
This will force contaminants out through the clean out
outside. Exhaust fumes contain odorless, invisible
hole.
gases which can kill without warning.
W-2050-1285
Stop the engine. Install and tighten the plug. Close the
rear door.
WARNING
Stop engine and allow the muffler to cool before
cleaning the spark chamber. Wear safety goggles.
Failure to obey can cause serious injury.
W-2011-1285
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MUFFLER (CONT’D) Figure 70-30-4
Figure 70-30-2
1
1
2 P-10510

N-21504 and remove the coolant tube mounting bracket (Item 2)
[Figure 70-30-4].
Open the rear door. Figure 70-30-5
Lift the rear grill.
Drain the cooling system (See Replacing The Coolant on 2

Page 10-140-2.)
3
Remove the air cleaner from the loader. (See Housing 1
Remove the hose clamp (Item 1) [Figure 70-30-2].

1
Remove the U-clamp (Item 2) [Figure 70-30-2].
Figure 70-30-3
P-10508
1
from the thermostat housing (Item 2) [Figure 70-30-5].
2 Remove the hose clamp (Item 3) [Figure 70-30-5].
Remove the thermostat housing.
N-21505
Move the coolant tube (Item 2) [Figure 70-30-3] to allow

clearance for the removal of the mounting bracket.
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MUFFLER (CONT’D) Figure 70-30-7
Figure 70-30-6
1
1
N-21506

7] that hold the muffler to the engine block.
1
Remove the muffler.
2
Exhaust Extension Pipe.
Figure 70-30-8
N-16048
1
2
from the muffler and exhaust extension pipe.
Remove the muffler mounting bracket bolts (Item 2)

[Figure 70-30-6]. N-21550

from the muffler and extension pipe.

8] from the turbo end of the extension pipe.
Remove the exhaust extension pipe from the

turbocharger.
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AIR CLEANER Figure 70-40-3
Housing Removal And Installation
Figure 70-40-1
1 1
N-21503
Remove the bolt and nut from the mounting straps (Item
N-21501 1) [Figure 70-40-3].
Remove the air cleaner housing from the mounting

Open the rear door. straps.
Raise the rear grill. Figure 70-40-4
Disconnect the electrical connector (Item 1) [Figure 70-

40-1] from the air cleaner.
1
Figure 70-40-2
1
2
1
N-21504
Remove the four bolts and nuts from the mounting strap
(Item 1) [Figure 70-40-4].
N-21502
Remove the mounting strap from the loader.
Loosen the intake hose clamp (Item 1) [Figure 70-40-2]

from the air cleaner housing.
Cut and remove the sta-strap (Item 2) [Figure 70-40-2].
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RADIATOR Removal And Installation
Coolant Recovery Tank Removal And Installation Figure 70-50-3
Figure 70-50-1
1
2
P-16023
N-21519
Raise the rear grill.
Remove the mounting bolt (Item 1) [Figure 70-50-1] and Remove the oil cooler. (See Removal And Installation on
remove the overflow tank mounting bracket (Item 2) Page 30-80-1.)
[Figure 70-50-1] from the loader.
Remove the coolant recovery tank. (See Coolant
Figure 70-50-2 Recovery Tank Removal And Installation on Page 70-50-
1.)
Connect a hose to the drain valve (Item 1) [Figure 70-50-

3] on the engine block.
Figure 70-50-4
N-21520
Tilt the overflow tank and remove the hose (Item 1)

[Figure 70-50-2].
Remove the overflow tank from the loader.

N-16162
Open the drain valve and drain the coolant into a

container [Figure 70-50-4].
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RADIATOR (CONT’D) Figure 70-50-6
WARNING
Failure to use care around combustibles can cause 1
W-2103-1285
Figure 70-50-5 N-15791
Remove the hose clamp (Item 1) [Figure 70-50-6] from

the right side radiator hose.
Remove the radiator hose.

1
N-15789
Installation: One gallon and one pint (4,3 L.) of

propylene glycol mixed with one gallon (3,8 L.) of water is
the correct mixture of coolant to provide a -34× F. (-37×
C.) freeze protection. Mix the coolant in a separate
container.(See Capacities on Page SPEC-10-4.) for
correct capacity.
Installation: Fill the radiator with the premixed coolant

until full. Open the vent plug (Item 1) [Figure 70-50-4] to
remove the air from the engine block. Tighten the vent
plug. Continue to fill the radiator until full. Install the
radiator cap.
Remove the air cleaner and air cleaner mount brackets.

(See Housing Removal And Installation on Page 70-40-
1.)
Remove the hose clamp (Item 1) [Figure 70-50-5] from

the right side radiator hose.
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RADIATOR (CONT’D) Figure 70-50-9
Figure 70-50-7
1
3
1 1
2
N-15801
Remove the radiator mounting bolts (Item 1) [Figure 70-

N-15792 50-9] from the bottom of the radiator.
Remove the radiator.

Remove the left side radiator hose clamp (Item 1)
[Figure 70-50-7].
Remove the radiator hose from the radiator.
Remove the U-clamp (Item 2) [Figure 70-50-7] and move

the coolant tube (Item 3) [Figure 70-50-7] to the side for
clearance.
Figure 70-50-8
2
1
N-15790

from the radiator mounting bracket (Item 2) [Figure 70-
50-8].
Remove the radiator mounting bracket.
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COOLING FAN Figure 70-60-3
Figure 70-60-1 3
1
1
1
2
N-21342
Remove the two suction hoses (Item 1) [Figure 70-60-3]

N-21340 and fittings (Item 2) [Figure 70-60-3] from the top of the
hydrostatic pumps to allow clearance for the fan to be
removed.
Disconnect wire harness (Item 1) [Figure 70-60-1] from
the fan motor solenoid. Remove the two mount nuts (Item 3) [Figure 70-60-3]
from the rear of the fan housing.
Figure 70-60-2
Figure 70-60-4
1
1
N-21341
N-21343

70-60-2]. Remove the two front bolts (Item 1) [Figure 70-60-4] and
nuts from the fan mount.
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COOLING FAN (CONT’D) Figure 70-60-7
Figure 70-60-5
N-21346
Install a puller on the fan and remove the fan from the
N-21344 motor [Figure 70-60-7].
Figure 70-60-8
Lower the fan mount and remove the mount and fan (Item
1) [Figure 70-60-5] from the loader.
Figure 70-60-6
1
1
N-21347
Remove the key (Item 1) [Figure 70-60-8] from the motor

shaft.
N-21345
Remove the nut and washer (Item 1) [Figure 70-60-6]

from the motor shaft.
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Figure 70-60-9
1
1
N-21797
1
Remove the solenoid stem (Item 1) [Figure 70-60-11]

N-21348 from the from the fan motor.
Installation: Tighten the solenoid stem to 15-20 ft.-lbs.

Turn the mount over and remove the mount bolts and (20-27 Nm) torque.
nuts (Item 1) [Figure 70-60-9].
Figure 70-60-12
Remove the fan motor from the mount.
Figure 70-60-10
1
1 1
1
N-21819
Inspect the O-rings and back-up washers (Item 1)

[Figure 70-60-12] and replace as needed.
N-21818
Check the orifice (Item 2) [Figure 70-60-12] and replace
as needed.
Remove the nut (Item 1) [Figure 70-60-10] from the
solenoid.

torque.
Remove the solenoid (Item 2) [Figure 70-60-10] from the

solenoid stem.
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Figure 70-60-13 2
3
2 1
4
1 N-21801

N-21799 15] from the rear of the fan motor.
Installation: Tighten the four mounting bolts to 19-23 ft.-

Remove the plug (Item 1) [Figure 70-60-13] from the fan lbs. (26-31 Nm) torque.
motor. Replace the O-ring (Item 2) [Figure 70-60-13] and
check the spring (Item 3) [Figure 70-60-13] and ball Remove the end cover assembly (Item 2) [Figure 70-60-
(Item 4) [Figure 70-60-13] and replace. 15] from the motor body (Item 3) [Figure 70-60-15].
Installation: Tighten the plug (Item 1) [Figure 70-60-13] Figure 70-60-16

to 144-180 in.-lbs. (16-20 Nm) torque.
Figure 70-60-14
1
3
1 2
N-21802
N-21800 Remove the O-ring (Item 1) [Figure 70-60-16] and the

holder seal (Item 2) [Figure 70-60-16] and replace with
new from the seal kit.
Remove the cap (Item 1) [Figure 70-60-14] from the
adjustment screw (Item 3) [Figure 70-60-14], replace the
O-ring (Item 2) [Figure 70-60-14] before replacing the
cap.
NOTE: The adjustment screw (Item 3) [Figure 70-60-

14] is pre-set from the factory and is not
recommended to be adjusted.
Installation: Tighten the cap (Item 1) [Figure 70-60-14]

to 144-180 in.-lbs. (16-20 Nm) torque.
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Figure 70-60-17
1
N-21805
Remove the front gear holder (Item 1) [Figure 70-60-19]

N-21803 from the motor housing.
Remove the seal from the front side of the gear holder
Remove the gear holder (Item 1) [Figure 70-60-17] from and replace it with a new seal from the kit.
the motor housing.
Figure 70-60-20
Figure 70-60-18
1
2
N-21806
N-21804
Remove the motor housing (Item 1) [Figure 70-60-20]

Remove the two gears (Item 1) [Figure 70-60-18] from from the front cover (Item 2) [Figure 70-60-20] of the
the motor housing. motor.
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Figure 70-60-21
N-21809
With a snap ring pliers, remove the snap ring (Item 1)

N-21807 [Figure 70-60-23].
Figure 70-60-24
motor housing and replace with a new one from the kit.
NOTE: If the motor housing, gears, or gear holders

are worn the complete motor must be replace,
as these are non-serviceable parts.
1
Figure 70-60-22
1
N-21810
Remove the seal (Item 1) [Figure 70-60-24] from the

front cover, and replace with a new seal from the kit.
N-21808
Remove the seal (Item 1) [Figure 70-60-22] from the

front motor cover and replace with a new seal from the
kit.
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Blower Housing Removal And Installation (Cont'd)
Figure 70-60-25
1
1
N-15756A
Remove the nuts (Item 1) [Figure 70-60-26] and

N-15754 mounting bolts (Item 1) [Figure 70-60-27] from the
blower housing.
Disconnect the fuel tank vent hose (Item 1) [Figure 70- Early Model Loaders: Remove the mounting bolts (Item
60-25]. 1) [Figure 70-60-27] (the bolts have blind nuts under the
oil cooler) from the blower housing.
Later Model Loaders: Remove the oil cooler from the
loader. (See Removal And Installation on Page 30-80-1.) Figure 70-60-28
Figure 70-60-26
1
1
N-15755
N-15755A
Remove the blower housing from the loader frame
[Figure 70-60-28].
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ENGINE COMPONENTS AND TESTING Remove the water pump from the engine.
Fuel Injection Pump Removal And Installation Figure 70-70-3
Figure 70-70-1
2
1
1
P-10544
P-10543
Turn the crankshaft over slowly until the hole (Item 1)
[Figure 70-70-3] in the fuel injection pump gear, timing
The tool listed will be needed to do the following plate and the hole in the hub, align with a hole in the body
procedure: of the fuel injection pump.
MEL1540 - Timing Tool NOTE: Do not loosen the nut (Item 2) [Figure 70-70-3]
from the fuel injection pump. The timing of the
Disconnect the negative (-) cable from the battery. (See fuel injection pump comes set from the
Removal And Installation on Page 60-20-1.) factory.
Remove the nuts (Item 1) [Figure 70-70-1] from the Figure 70-70-4
water pump mounting bolts.
Installation: Tighten the nuts to 16 ft.-lbs. (22 Nm)

torque.
Figure 70-70-2
P-10547
Insert a timing pin (Item 1) [Figure 70-70-4] into the

aligned holes.
P-10545 NOTE: The dimensions of the timing pin are 8 mm

O.D. x 127 mm long.

from the front side of the water pump.
Installation: Tighten the bolts to 16 ft.-lbs. (22 Nm)

torque.
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ENGINE COMPONENTS AND TESTING (CONT’D) Figure 70-70-7
Fuel Injection Pump Removal And Installation 1

1
(Cont'd)
2
Figure 70-70-5
6
6
5 3
1 P-10550
2 Disconnect the injector tubelines (Item 1) [Figure 70-70-

7] from the injectors.
P-10546
Installation: Tighten the tubeline fittings to 16 ft.-lbs. (22
Nm) torque.
the top of the fuel injector pump. Disconnect the fuel tubeline (Item 2) [Figure 70-70-7]
Disconnect the tubeline (Item 2) [Figure 70-70-5] from and remove the tubeline.
the injector pump.
Remove the injector tubelines from the engine.
Disconnect the tubeline (Items 3, 4 & 5) [Figure 70-70-5]
from the top side of the fuel filter. Figure 70-70-8
from the fuel filter mounting bracket.
1
Remove the fuel filter mounting bracket and fuel filter
from the engine.
Figure 70-70-6
2
1
P-10548
1
1 Disconnect the electrical connections (Item 1) [Figure

70-70-8] from the temperature sender.
Remove the mounting nuts (Item 2) [Figure 70-70-8]

P-10549
from the injection pump.
Disconnect the injector tubelines (Item 1) [Figure 70-70- Installation: Tighten the nuts to 16 ft.-lbs. (22 Nm)
6] from the injector pump. torque.

Nm) torque.
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Fuel Injection Pump Removal And Installation

(Cont'd) 4
Figure 70-70-9
1
1
5 3
1
1 1
P-10546

the top of the fuel injection pump.
P-10547
the injector pump.
from the fuel injection pump gear. Disconnect the tubelines (Items 3, 4, & 5) [Figure 70-70-
10] from the fuel filter housing.
Installation: Tighten the bolts to 20 ft.-lbs. (28 Nm)
torque. Figure 70-70-11
Remove the fuel pump and timing pin from the engine.
Fuel Injector Removal and Installation

1
WARNING
penetrate skin or eyes, causing serious injury or 1
P-10549
enters skin or eyes, get immediate medical attention
from a physician familiar with this injury.
W-2072-0496
Disconnect the injector tubelines (Item 1) [Figure 70-70-
11] from the injector pump.

Nm) torque.
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Fuel Injector Removal and Installation (Cont’d)
IMPORTANT
Do not bend the high pressure fuel injection tubes
when removing or installing them.
I-2029-0289
Figure 70-70-12 1 1
1 1 N-16412
2
Disconnect the fuel return tubeline (Item 1) [Figure 70-
70-13] at the fuel injectors.
Remove the fuel return tubeline from the engine.
Figure 70-70-14
P-10550
1 1
Disconnect the injector tubelines (Item 1) [Figure 70-70-
12] from the fuel injectors.
Disconnect the fuel return tubeline (Item 2) [Figure 70-

70-12] and remove the tubeline.
Remove the high pressure injector tubelines from the

engine. N-16411
Installation: Always replace the copper gaskets (Item 1)

[Figure 70-70-14] at the fuel return tubeline.
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Fuel Injector Removal and Installation (Cont'd)
Figure 70-70-15
2
1
N-16408 N-16409
Installation: Make sure the ball (Item 1) [Figure 70-70-

N-16410 17], in the injector body, is aligned with the notch (Item 2)
[Figure 70-70-17] in the cylinder head when the fuel
injector is installed.
Loosen the nut (Item 1) [Figure 70-70-15] at the fuel
injector and remove it from the cylinder head.
Installation: Tighten the nut to 23 ft.-lbs. (30 Nm) torque.
Figure 70-70-16
N-16407
Installation: Always replace the copper washer (Item 1)

[Figure 70-70-16] at the nozzle.
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ENGINE COMPONENTS AND TESTING (CONT’D)
Fuel Injector Checking

WARNING
IMPORTANT penetrate skin or eyes, causing serious injury or

Do not disassemble or test the fuel injector nozzles not use your bare hand. Wear safety goggles. If fluid
unless you have the correct service and testing enters skin or eyes, get immediate medical attention
tools. from a physician familiar with this injury.
I-2027-0284 W-2072-0496
The tools listed will be needed to do the following Figure 70-70-19

procedure;
OEM1064 - Injection Nozzle Tester

OEM1065 - Accessory Set WRONG CORRECT
Figure 70-70-18
B-13330
Check the nozzle spray pattern [Figure 70-70-19]:
The spray pattern must be uniform from the nozzle.

B-8971
The nozzles are dirty or defective:
If the spray pattern is not uniform.
Connect the nozzle to the test pump, in a down position If the fuel drips from the end of the nozzle.
[Figure 70-70-18]. If the spray is solid stream instead of a mist.
Operate the test pump until the nozzle valve opens: Checking The Fuel Lift Pump
Injection Working Pressure Install a gauge to the outlet side of the lift pump. Turn the
4263 PSI (29393 kPa) engine for 10 seconds.
Standard Pressure 6-10 PSI (41-70 kPa)
Minimum Pressure 3.75 PSI (25 kPa)
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Remove the hydrostatic pump/engine assembly. (See 2

Figure 70-70-20 1
1
N-15844 N-15858
Disconnect the fuel in-let hose (Item 1) [Figure 70-70-21]

from the lift pump.
Disconnect the fuel tubeline (Item 2) [Figure 70-70-21]

N-15857 going to the fuel filter.
Remove the four mounting bolts (Inset) [Figure 70-70-

Remove the hose clamp (Item 1) [Figure 70-70-20] from 21].
the turbocharger air inlet hose (Item 2) [Figure 70-70-
20]. Installation: Tighten the bolts to 16 ft.-lbs. (22 Nm)
torque.
Remove the air inlet hose from the turbocharger.
Remove the fuel lift pump.
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ENGINE AND ENGINE MOUNTS Figure 70-80-2
WARNING
1
W-2059-0598
N-21508
Figure 70-80-1
Remove the ground wire mounting bolt (Item 1) [Figure

70-80-2] and remove the battery ground wire.
Remove the electrical mount bracket mounting bolt (Item

2) [Figure 70-80-2].
2
Move the electrical wires and bracket into the upright for
1 clearance when removing the engine.
Figure 70-80-3
N-21502
Raise the lift arms and install the lift arm support device.
(See Engaging The Lift Arm Support Device on Page 10-
50-1.)
1
on Page 10-70-1.)
Drain the hydraulic reservoir. (See Replacing The

Hydraulic Fluid on Page 10-150-2.) N-21894
Remove the battery. (See Removal And Installation on

Page 60-20-1.) Remove and plug the fuel line (Item 1) [Figure 70-80-3]
from the upper fuel filter.
Remove the engine coolant. (See Replacing The Coolant
on Page 10-140-2.)
Move the hose clamp (Item 1) [Figure 70-80-1] and

remove the fuel fill hose from the fill bracket.
Remove the two mount bolts (Item 2) [Figure 70-80-1],

and remove the fuel fill bracket from the loader.
Remove the air cleaner housing, and air cleaner mount.

(See Housing Removal And Installation on Page 70-40-
1.)
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ENGINE AND ENGINE MOUNTS (CONT’D) Figure 70-80-6
Figure 70-80-4
1
1 1
N-21558
2 Loosen the hose clamp (Item 1) [Figure 70-80-6] and

N-21896 remove the radiator hose (Item 2) [Figure 70-80-6].
Figure 70-80-7
Remove the fuel lines (Item 1) [Figure 70-80-4] from the
lower fuel filter.
Remove the fuel filter mount bracket bolts (Item 2)

[Figure 70-80-4] and remove the fuel filter and bracket
from the loader. 2
1
Figure 70-80-5
3
2
1
N-21561

that goes from the auxiliary pump to the hydraulic fan
motor.

N-21493 that goes from the auxiliary pump to the hydraulic filter.

Disconnect the engine wiring harness (Item 1) [Figure that goes from the auxiliary pump to the hydraulic
70-80-5] from the tailgate wiring harness. reservoir.
Disconnect the engine throttle linkage (Item 2) [Figure

70-80-5].
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Figure 70-80-8
3 1
1
2
N-21565
Disconnect the two left side drive motor hoses (Item 1)

N-21562 [Figure 70-80-10] from the hydrostatic pump.
Installation: Tighten the eight mounting bolts to 25 ft.-

Disconnect the hydraulic hose (Item 1) [Figure 70-80-8] lbs. (34 Nm) torque.
that goes from the auxiliary pump to the loader control
valve. Disconnect the hydraulic hose (Item 2) [Figure 70-80-10]
that goes from the hydrostatic pump to the hydrostatic
Figure 70-80-9 motor.

that goes from the hydrostatic pump to the fan motor.
2 Mark the hydraulic hoses for proper installation.
Figure 70-80-11
1 2
N-21563

that goes from the hydrostatic pump to the filter.

from the hydraulic fan motor.
N-21537
Disconnect the hydraulic hoses (Items 1 & 2) [Figure 70-

80-11] from the hydrostatic pumps.
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Figure 70-80-12
1 1
N-21547
At the back side of the hydrostatic pumps, disconnect the

N-21538 two charge pressure hoses (Item 1) [Figure 70-80-14].
Figure 70-80-15
Disconnect the two right side drive motor hoses (Item 1)
[Figure 70-80-12] from the hydrostatic pump.
Installation: Tighten the eight mounting bolts to 25 ft.-

Figure 70-80-13
1
1
N-15812
Remove the left side front engine mounting bolt (Item 1)

[Figure 70-80-15].
2
N-21539

that goes from the hydrostatic pump to the brake/two
speed controller.

that goes from the hydrostatic pump to the right side
hydrostatic motor.
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Figure 70-80-16
1
1
N-15813
Remove the left side rear engine mounting bolt (Item 1)

[Figure 70-80-16].
1
N-15814
Remove the right side engine mounting bolts (Item 1)

[Figure 70-80-17].
Installation: Tighten the engine mounting bolts to 200-

250 ft.-lbs. (271-339 Nm) torque.
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ENGINE AND ENGINE MOUNTS (CONT’D) Mounting Brackets Removal And Installation
Removal And Installation (Cont'd) Remove the drive belt. (See DRIVE BELT on Page 30-
70-1.)
Figure 70-80-18
Remove the hydrostatic pump. (See Removal And
Remove the belt tension assembly. (See Tensioner Pulley

Remove the idler pulley assembly. (See Idler Pulley

1
Remove the starter. (See Removal And Installation on
1 Page 60-40-1.)
Figure 70-80-19
N-15817
1 1 1
Connect a chain into the engine eye hooks (Item 1)

[Figure 70-80-18]. 1
Install a chain hoist.

1 1
Lift the engine a small amount. Slide the engine and
hydrostatic pump assembly to the rear to give the engine
clearance at the loader frame.
Lift and remove the engine and hydrostatic pump

assembly from the loader.
N-15831
Remove the flywheel housing mounting bolts (Item 1)

[Figure 70-80-19].
Remove the flywheel housing from the engine.
Installation: Tighten the flywheel housing bolts to 52 ft.-

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FLYWHEEL AND HOUSING Figure 70-90-3
Flywheel Removal And Installation
Figure 70-90-1
N-15830
Remove the flywheel by sliding outward over the guide

N-15828 pins figure [Figure 70-90-3].
Check the flywheel and ring gear for wear or damage.

Remove the drive belt. (See DRIVE BELT on Page 30-
70-1.) Replace as needed.
Remove the two opposite bolts (Item 1) [Figure 70-90-1]

from the flywheel.
Figure 70-90-2
N-15829
Install two guide studs (Item 1) [Figure 70-90-2] in the

flywheel to prevent the flywheel from falling.
Remove the remainder of the bolts from the flywheel.
Installation: Tighten the flywheel bolts to 77 ft.-lbs. (105

Nm) of torque.
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FLYWHEEL AND HOUSING (CONT’D) Ring Gear Removal
Flywheel Removal And Installation (Cont'd) Before the ring gear is removed note the position of the
chamfer on the teeth.
Figure 70-90-4
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.
Ring Gear Installation
The ring gear is a heat expansion fit on the flywheel.
Do not heat the ring gear to a temperature greater than

480° F (250° C) make sure the ring gear chamfer is in the
correct position.
B-5559
Install a dial indicator to check the flywheel run out

[Figure 70-90-4].
Flywheel run out must be less than 0.012 inch (0,30 mm).
Figure 70-90-5
8” (203 mm)
B-5560
Check the alignment of the flywheel face [Figure 70-90-

5].
The misalignment must not be more than 0.001 inch

(0,03 mm) total indicator reading for every 1.0 inch (25
mm) of the flywheel radius from the crankshaft axis to the
dial gauge plunger.
Example: The misalignment must not be greater than

0.008 inch (0,203 mm) at 8 inches. (203 mm) from the
centerline of the crankshaft towards the outside of the
flywheel.
During this check keep the crankshaft pressed toward the

front so crankshaft end play will not affect the reading.
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RECONDITIONING THE ENGINE Figure 70-100-3
Intake Manifold Removal and Installation
Figure 70-100-1
1
1
2
N-16424
Remove the mounting bolt (Item 1) [Figure 70-100-3]

N-16422 from the inside of the intake manifold.
Remove all the mounting bolts from the intake manifold

Remove the turbocharger. (See Turbo Charger Removal (Item 2) [Figure 70-100-3].
and Installation on Page 70-100-49.)
Disconnect the tubeline (Item 1) [Figure 70-100-1] from Nm) torque.
the intake manifold.
Figure 70-100-4
Figure 70-100-2
1 1
N-16425
N-16423
Remove the intake manifold from the cylinder [Figure 70-

Remove the four mounting bolts (Item 1) [Figure 70-100- 100-4].
2] from the intake manifold housing.
Installation: Always replace the intake manifold gasket.
Nm) torque.
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RECONDITIONING THE ENGINE (CONT’D) Cylinder Head Disassembly
Exhaust Manifold Removal and Installation Figure 70-100-6
Figure 70-100-5 6
6
4
1 5 3
1
P-10546
N-16421
Remove the turbocharger. (See Turbo Charger Removal
and Installation on Page 70-100-49.) Remove the oil cooler. (See Removal And Installation on
Page 30-80-1.)
Remove the intake manifold. (See Intake Manifold
Removal and Installation on Page 70-100-1.) Remove the intake manifold. (See Intake Manifold
Removal and Installation on Page 70-100-1.)
Remove all the nuts from the exhaust manifold (Item 1)
[Figure 70-100-5]. Remove the exhaust manifold. (See Exhaust Manifold
Removal and Installation on Page 70-100-2.)
Installation: Tighten the nuts to 24 ft.-lbs. (33 Nm)
torque. Disconnect the tubeline (Item 1) [Figure 70-100-6] from
the top of the fuel injector pump.

the injector pump.
Disconnect the tubeline (Items 3, 4 & 5) [Figure 70-100-

6] from the top side of the fuel filter.

from the fuel filter mounting bracket.
Remove the fuel filter mounting bracket and fuel filter

from the engine.
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RECONDITIONING THE ENGINE (CONT’D) Figure 70-100-8
Cylinder Head Disassembly (Cont’d) 1

1
Figure 70-100-7
2
1
P-10550
Disconnect the injector tubelines (Item 1) [Figure 70-

P-10549 100-8] from the injectors.
Disconnect the fuel tubeline (Item 2) [Figure 70-100-8]

Disconnect the injector tubelines (Item 1) [Figure 70- and remove the tubeline.
100-7] from the injector pump.
Remove the injector tube lines from the engine.
IMPORTANT
I-2029-0289
Remove the fuel injectors. (See Fuel Injector Removal

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Cylinder Head Removal
Figure 70-100-9
1
1
P-8718
Remove the push rods [Figure 70-100-11].

P-8716
Figure 70-100-12
Remove the three rocker cover retaining nuts (Item 1)

[Figure 70-100-9].
Figure 70-100-10
M 18 M 8 M 2 M 13
L 19 M 9 M 1 M 3 14 L
1 1
M 20 M 10 M 7 M 4 15 M
S 21 S 22 S 11 S 12 S 6 S 5 S 17 S 16
B-5561
Starting with bolt (number 22) [Figure 70-100-12] and

working down, remove the head bolts.
P-8717
NOTE: There are three different length head bolts.
Figure [Figure 70-100-12] shows the three
Remove the four nuts (Item 1) [Figure 70-100-10] and different bolt lengths: S short; M medium & L
remove the rocker shaft assembly [Figure 70-100-10]. long bolts.
(See Rocker Shaft Disassembly And Assembly on Page
70-100-8.) for disassembly and assembly of the rocker Check the head bolts for distortion and damage. Replace
shaft assembly.) as needed.
Lift off the cylinder head and clean the bottom face.
Remove the valves from the cylinder head. (See Valve

Removal on Page 70-100-9.)
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Cylinder Head Inspection

2 1
Figure 70-100-13
FRONT TOP
1 1 1 1 1 3
2
B-5562
3
NOTE: The locating pins (Item 1) [Figure 70-100-14]
B-5564 are pressed in the engine block so the head
gasket (Item 2) [Figure 70-100-14] can be
positioned correctly.
Put a straight edge on the cylinder head as shown in
[Figure 70-100-13]. The head gasket is installed with no sealer.
Using a feeler gauge between the straight edge and Place the head gasket in position with the Front Top (Item
head, check for warpage. 2) [Figure 70-100-13] marks in the correct position.
Maximum allowed (Item 1) [Figure 70-100-13] is 0.003 Lower the cylinder head in position.
inches (0,08 mm), (Item 2) [Figure 70-100-13] is 0.006
inches (0,15 mm) and (Item 3) [Figure 70-100-13] is Figure 70-100-15
0.006 inches (0,15 mm).
The head may be machined removing only a minimum

amount. Head thickness must not be less than 4.035
inches (102,5 mm).
M 18 M 8 M 2 M 13
Completely clean the rest of the head. M 9 M 3 14 L
19 M 1
Check for cracks or other damage.

M 20 M 10 M 7 M 4 15 M
Cylinder Head Installation
S 21 S 22 S 11 S 12 S 6 S 5 S 17 S 16
Make sure the mating surfaces of the head and block are
clean.
B-5561
Clean the engine block bolt bores with the correct size
tap to ensure correct torque for the cylinder head bolts.
[Figure 70-100-15] shows the three different bolt
Clean any debris out of the cylinder bores. lengths: S-short; M-medium and L-long.
Install all the cylinder head bolts in the correct location

[Figure 70-100-15].
Following the bolt tightening sequence shown in [Figure

70-100-15]. Tighten all cylinder head bolts to 80 ft.-lbs.
(108 Nm) torque.
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Cylinder Head Installation (Cont'd)
Figure 70-100-16
M 18 M 8 M 2 M 13
19 M 9 M 1 M 3 14 L
1
M 20 M 10 M 7 M 4 15 M
S 21 S 22 S 11 S 12 S 6 S 5 S 17 S 16
B-5561
Tighten short bolts 2.5 flats, medium bolts 3 flats, and

P-8839 long bolts 3.5 flats in the same sequence as shown in
[Figure 70-100-18].
Additional tightening of the head bolts requires the use of Figure 70-100-19
a torque angle gauge (Item 1) [Figure 70-100-16].
Tighten the short bolts 150°, medium bolts 180° and long
bolts 210°, in the same sequence as shown in [Figure
70-100-16].
Figure 70-100-17
S M
150° 180° 210° L
P-8718
Install the push rods [Figure 70-100-19].
Make sure the push rods seat in the tappet sockets.

B-5563
If no angle gauge is available make a suitable mark on

the head bolt corner. Make another mark on the cylinder
head the correct number of flats away [Figure 70-100-
17]. Turn the head bolt until the lines match.
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Cylinder Head Installation (Cont'd) 2

2
IMPORTANT
I-2029-0289
Figure 70-100-20
P-10550
P10550
1 1
2 Connect the fuel tubeline (Item 1) [Figure 70-100-21].
Tighten tubeline fittings to 16 ft.-lbs. (22 Nm) torque.
Connect the injector tubelines (Item 2) [Figure 70-100-

21].
Figure 70-100-22
P-8718
1
Install the rocker arm shaft. Tighten the rocker arm nuts
(Item 1) [Figure 70-100-20] to 55 ft.-lbs. (75 Nm) torque.
NOTE: Make sure the oil feed line seal (Item 2) [Figure
70-100-20] is correctly positioned in the 1
cylinder head.
The valve lash adjustment must be checked after the

cylinder head is installed. (See Valve Clearance
Adjustment on Page 70-100-14.) P-10549
Install the fuel injectors. (See Fuel Injector Removal and

Installation on Page 70-70-3.) Connect the injector tubelines (Item 1) [Figure 70-100-
22] to the injection pump.
Install the injector tubelines on the engine.
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RECONDITIONING THE ENGINE (CONT’D) Rocker Shaft Disassembly And Assembly
Cylinder Head Installation (Cont'd) Figure 70-100-24
Figure 70-100-23
1 4
1 1
3
6 4 2 2
3 5
5
P-8719
P-10546
Remove the clips (Item 1) [Figure 70-100-24] from both
ends of the shaft.
Install the fuel filter mounting bracket and fuel filter using
the mounting bolts (Item 1) [Figure 70-100-23]. Remove the location screw (Item 2) [Figure 70-100-24]
for the oil supply connection.
Connect the tubelines (Items 2, 3, & 4) [Figure 70-100-
23] to the filter housing. Remove the rocker arm (Item 3) [Figure 70-100-24],
mount bracket (Item 4) [Figure 70-100-24], rocker arm
Connect the tubeline (Item 5) [Figure 70-100-23] to the (Item 3) [Figure 70-100-24] and spring (Item 5) [Figure
injection pump. 70-100-24].
Connect the tubeline (Item 6) [Figure 70-100-23] to the Continue to disassemble the rocker shaft.
top of the injection pump.
Clean and inspect all components for damage and wear.
Install the exhaust manifold. (See Exhaust Manifold
Removal and Installation on Page 70-100-2.) Check the clearance between the rocker arms and shaft.
Install the intake manifold. (See Intake Manifold Removal Using a press and adapter, remove the old bushing and
and Installation on Page 70-100-1.) press in the new one making sure the oil holes line up.
Install the oil cooler. (See Removal And Installation on Shaft O.D. 0.7485-0.7495 inch
Page 30-80-1.) (19,01-19,04 mm)
Rocker Arm Bushing 0.8751-0.8763 inch
Install the turbocharger. (See Turbo Charger Removal Bore Dia. (22,23-22,26 mm)
and Installation on Page 70-100-49.) O.D. of Bushing 0.8771-0.8783 inch
(22,28-22,31 mm)
Rocker Arm Bushing 0.0008-0.0035 inch
Clearance (0,020-0,089 mm)
I.D. of Reamed Rocker 0.7503-0.7520 inch
Bushing (19,06-19,10 mm)
Clearance Between 0.001-0.0035 inch
Rocker Arm Bushing & (0,03-0,09 mm)
Shaft
If the clearance is more than 0.005 inch (0.13 mm)

replace the bushing(s).
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RECONDITIONING THE ENGINE (CONT’D) Valve Springs Checking
Valve Removal Figure 70-100-26
Figure 70-100-25
Outer Spring
1 3 7
5
inch
4 (mm) Inner Spring
1 2 6 B-5552
P-8720
Use the following chart [Figure 70-100-26]:
Valve Springs (Outer):
NOTE: Mark all components so they can be returned
to the same position. Compressed Height 1.41 inch
(35,8 mm)
Using a valve spring compressor compress the springs
and remove the retainers (Item 1) [Figure 70-100-25]. Installed Pressure 39.5-43.7 lbs.
(176-195 N)
Release the compressor and remove the valve spring
cap (Item 2) [Figure 70-100-25], outer spring (Item 3) Valve Springs (Inner):
[Figure 70-100-25] inner spring (Item 4) [Figure 70-100- Compressed Height 1.34 inch
25], valve seal (Item 5) [Figure 70-100-25], valve seat (34,0 mm)
washer (Item 6) [Figure 70-100-25] and the valve (Item
7) [Figure 70-100-25]. Installed Pressure 20-23 lbs.
(89-104 N)
Clean and inspect all components.
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Valve Depth Checking
Figure 70-100-27
3
1
2
B-5566A
The valve guides can be checked for wear with either of

N-00533 the operations listed in [Figure 70-100-28] or [Figure 70-
100-29].
Check the valve depth as shown in [Figure 70-100-27]. Use the following chart to check valve guides.
Inside Diameter:
The maximum depth is 0.073 inch (1,85 mm) for both
intake and exhaust valves. (Item 1) Figure 70-100-28 0.3744-0.3764 inch
(9,51-9,56 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 Outside Diameter:
valve seat insert must be installed.
(Item 2) Figure 70-100-28 0.6260-0.6264 inch
When the depth is less than 0.050-0.063 inch (1,27-1,60 (15,90-15,91 mm)
mm) the seat may be ground to lower the valve depth.
Interference fit of valve 0.0018-0.0027 inch
Valve Guides Checking guide to cylinder head: (0,047-0,007 mm)
Figure 70-100-28 Overall Length: (Item 3) Figure 70-100-28

Intake 2.281 inch
1 (57,94 mm)
Exhaust 2.406 inch
4 (61,10 mm)
Protrusion from bottom 0.585-0.596 inch

recess for valve spring: (14,85-15,15 mm)
3 Valve Guide Bore 0.6248-0.6256 inch
(15,87-15,89 mm)
To check the valve guides for wear using a valve.

2
Set up dial indicator gauge (Item 1) [Figure 70-100-29]
as shown.
B-5551
Lift the valve (Item 2) [Figure 70-100-29] 0.60 inches
(15,0 mm) and move the valve in and away from the
gauge (Item 1) [Figure 70-100-29]. Record this reading.
If the clearance exceeds 0.002-0.007 inches (0,25-0,069
mm) for intake or 0.004-0.008 inches (0,40-0,084 mm) for
exhaust (Item 3) [Figure 70-100-29] the valve guide
needs to be replaced.
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RECONDITIONING THE ENGINE (CONT’D) Valve Guide Installation
Valve Guide Removal Clean the guide bore in the head.
Figure 70-100-30 Figure 70-100-31
B-5549 B-5548
Install a valve guide removal/installation tool (Item 1) Lubricate the outer surface of the new guide (Item 1)
[Figure 70-100-30] on the valve guide (Item 2) [Figure [Figure 70-100-31] with engine oil.
70-100-30].
Put the guide in position on the valve guide removal/
Pull the guide (Item 2) [Figure 70-100-30] out of the installation tool (Item 2) [Figure 70-100-31].
cylinder head.
Pull the guide into the cylinder head.
When correctly positioned the top of the guide should

extend 0.594 inch (15,1 mm) above the valve spring seat.
(As Shown On Page 70-100-10 [Figure 70-100-31].)
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Valves Checking
Figure 70-100-32
3 N-00532N-
00532
1 Carefully turn the cutter in a clockwise direction using

B-5567 even downward pressure. Keep the valve seat as narrow
as possible [Figure 70-100-33].
NOTE: If the valves do not meet specifications they Remove any cutting debris.
need to be replaced. They cannot be ground.
Install the valve and lightly tap.
Use the following chart [Figure 70-100-32] to check the
valve dimensions: Check the valve depth to make sure that it is within limits.
(See Valve Depth Checking on Page 70-100-10.)
Ref . Valve Specifications
1. Intake 4.829-4.854 in. (122,66-123,30 mm) NOTE: If the valve seat is to worn or damaged, a new
Exhaust 4.829-4.854 in. (122,66-123,30 mm) valve seat insert can be installed.
2. Intake 0.3725-0.3536 in. (8,95-8,98 mm)
Exhaust 0.3519-0.3528 in. (8,93-8,96 mm) Valve Seat Assembly
3. Intake 1.688-1.698 in. (42,88-43,12 mm)
Exhaust 1.609-1.619 in. (40,88-41,12 mm) Figure 70-100-34
4. Int./Exh. 0.055-0.07 in. (1,40-1,70mm)
(Production)
Int./Exh. 0.077 in. (1,95 mm)
8 4 2
(Service 7
Max)
Intake/Exhaust Valve Face Angle 46°
Cutting A Valve Seat
Before any work is done the valve guides must meet

specifications or have been replaced. 6 3 1
8 5
Install the pilot in the valve guide.
P-8720
Select the correct size cutter.

Valve Seat Angle 46° Lubricate the valve stems (Item 1) [Figure 70-100-34]
with clean engine oil and install them in the respective
guides.
Install the spring seat washers (Item 2) [Figure 70-100-

34].
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Valve Seat Assembly (Cont’d)
Install new valve seals (Item 3) [Figure 70-100-34].
Install the inner and outer springs (Items 4 & 5) [Figure

70-100-34] on the washers with dampener coils (Item 6)
[Figure 70-100-34] toward the cylinder head.
Place the valve caps on the springs (Item 7) [Figure 70-

100-34].
Using a valve spring compressor compress the springs

and install the retainers (Item 8) [Figure 70-100-34].
N-00531
WARNING Install the valve spring compressor and adaptor [Figure

70-100-36].
Wear safety glasses to prevent eye injury when any Compress the valve springs and remove the retainers.
of the following conditions exist:
• When fluids are under pressure. NOTE: Do not rotate the crankshaft while the valve
• Flying debris or loose material is present. springs are removed.
• Engine is running.
• Tools are being used. Release the compressor and remove the valve spring(s).
W-2019-1285
Place the new valve springs in position.

Changing Valve Springs (With Cylinder Head
Installed) Compress the valve springs and install the retainers.
Remove the rocker cover.
Figure 70-100-35
B-5565
Rotate the crankshaft clockwise until the intake valve has

opened and the exhaust valve has not fully closed. In this
position the piston (Item 1) [Figure 70-100-35] will be at
approximately T.D.C.
Remove the rocker shaft assembly.
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Valve Clearance Adjustment
Adjust the valve clearance as follows:

Cylinder 1 2 3 4
Figure 70-100-37 Number
Valve 1 2 3 4 5 6 7 8
Number
Valve I E I E I E I E
I=Intake
E=Exhaust
2 1
Use the following sequence to set the valves [Figure 70-

100-38] & [Figure 70-100-39]:
3
B-5568 1. With the rocker arm rocking (valves 7 & 8) on No. 4
cylinder set clearance at No. 1 cylinder (valves 1 & 2).
Loosen the lock nut (Item 1) [Figure 70-100-37]. 2. With the rocker arm rocking (valves 3 & 4) on No. 2
Turn the adjustment screw (Item 2) [Figure 70-100-37]
until the correct clearance is obtained. 3. With the rocker arm rocking (valves 1 & 2) on No. 1
NOTE: The clearance is measured between the
rocker arm and valve stem tip (Item 3). 4. With the rocker arm rocking (valves 5 & 6) on No. 3
Adjust the valve clearance as follows:
0.008 inch (0,20 mm) Intake

0.018 inch (0,45 mm) Exhaust
Figure 70-100-38
1 2 3 4 5 6 7 8
B-5569
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Timing Case And Drive Assembly Description
The timing case and cover are made of aluminum and in 1

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 fuel injection pump
and to the water pump.
The camshaft and fuel injection pump run at half the

speed of the crankshaft.
Timing Cover Removal
Figure 70-100-40 P-8734
Remove the cover (Item 1) [Figure 70-100-42] and

1 gasket.
Timing Cover Installation

procedure:
MEL1537 - Timing Cover Centralizing Tool
To install the timing cover, the tool will be needed to

center the timing cover around the crankshaft.
P-8729
NOTE: If the cover is not centered correctly the
backlash between the injection pump gear
Remove the crankshaft pulley (Item 1) [Figure 70-100- and water pump gear will be affected. This can
40]. cause seizure of the injection pump.
Remove the water pump. (See Water Pump Removal on Clean the gasket mating surfaces.
Page 70-100-34.)
Place the gasket and timing cover on the engine.
Figure 70-100-41
Hold the timing cover in position and install two bolts that
are on opposite sides of the cover. Do not tighten the
1 bolts.
1
1
1 1
P-8732
Remove the timing cover bolts (Item 1) [Figure 70-100-

41].
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RECONDITIONING THE ENGINE (CONT’D) Front Oil Seal Removal
Timing Cover Installation (Cont’d) Remove the crankshaft pulley.
Figure 70-100-43 Remove the oil seal using a seal removal tool.
Do not damage the edge of the seal housing.
Front Oil Seal Installation

3
Clean the oil seal housing.
2 Lubricate and place the new seal in the housing. Make

sure the spring loaded lip faces toward the engine.
Figure 70-100-45
3
1
B-5557 1
Install the tool (Item 1) [Figure 70-100-43] in the oil seal

housing.
Using the special washer (Item 2) [Figure 70-100-43],

install the crankshaft pulley bolts (Item 3) [Figure 70-
100-43] and tighten evenly to center the cover.
Install the remainder of the cover bolts, tighten the bolts 2

to 16 ft.-lbs. (22 Nm) torque.
N-00711
Remove the tool.

Place the seal tool (Item 1) [Figure 70-100-45] against
Install the water pump. (See Water Pump Removal on the seal.
Page 70-100-34.)
Using the three hole washer (Item 2) [Figure 70-100-45],
Figure 70-100-44 install the crankshaft bolts and tighten evenly until the
face of the seal tool is against the face of the seal
housing.
NOTE: The standard seal is installed to a depth of

0.266/0.285 inch (6,75/7,25 mm) from the front
face of the oil seal housing. If there is wear on
the seal surface of the crankshaft pulley the
seal can be installed to a depth of 0.366 inch
2 (9,3 mm)
Clean and lubricate the seal surface of the crankshaft

pulley before installing.
1
P-8729
Install the crankshaft pulley (Item 1) [Figure 70-100-44].
Tighten the crankshaft pulley bolts (Item 2) [Figure 70-

100-44] to 85 ft.-lbs. (115 Nm) torque.
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Timing Case And Gear Removal

1
Remove the timing cover. (See Timing Cover Removal on
Page 70-100-15.)
Figure 70-100-46
1
3
1
4 P-8736
Remove the cam gear (Item 1) [Figure 70-100-47].

5 3 Figure 70-100-48
1
P-8735
Rotate the crank shaft until the timing marks (Item 1)

[Figure 70-100-46] are lined up.
Remove the fuel injection pump gear (Item 2) [Figure 70-

100-46].

the idler gear (Item 4) [Figure 70-100-46].
Remove the idler gear (Item 4) [Figure 70-100-46]. 1

1
P-8737
NOTE: Do not turn the crankshaft with the idler gear
removed.
Remove all the timing case bolts [Figure 70-100-48].
Remove the cam gear retaining bolt (Item 5) [Figure 70-
100-46]. Remove the two bolts (Item 1) [Figure 70-100-48] from
the front of the oil pan.
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Timing Case And Gear Removal (Cont'd) 1

Figure 70-100-49
4
3
P-8736
Install the cam gear (Item 1) [Figure 70-100-50].

1 P-8738
Figure 70-100-51
Remove the timing case (Item 1) [Figure 70-100-49] and

gasket (Item 2) [Figure 70-100-49] from the engine. Do 4
not allow the idler gear hub (Item 3) [Figure 70-100-49]
and camshaft thrust washer (Item 4) [Figure 70-100-49] 5
3
to fall. 5
Timing Case And Gear Installation

2
Clean the mating surfaces. If the oil pan was not removed
trim the oil gasket flush with the block.
Using the three idler gear bolts, position the idler hub 1 3
(Item 3) [Figure 70-100-49] with the lubrication hole on 5
top. Press the hub on by tightening the bolts evenly. P-8735
Install the camshaft thrust washer (Item 4) [Figure 70-

100-49]. Install the cam gear retaining bolt (Item 1) [Figure 70-
100-51]. Tighten to 58 ft.-lbs. (78 Nm) torque.
Install the case cover gasket (Item 2) [Figure 70-100-49]
and trim the bottom to fit. Apply sealant to the bottom Install the idler gear (Item 2) [Figure 70-100-51].
ends of the gasket.
Install the idler gear retaining bolts (Item 3) [Figure 70-
Place the timing case (Item 1) [Figure 70-100-49] in 100-51]. Tighten to 33 ft.-lbs. (44 Nm) torque.
position. Make sure it's positioned correctly against the
block. Place the fuel injection pump gear (Item 4) [Figure 70-
100-51] in the case.
Tighten the eight millimeter bolts to 16 ft.-lbs. (22 Nm)
torque. NOTE: Make sure all the timing marks (Item 5) [Figure
70-100-51] are in correct alignment.
Tighten the ten millimeter bolts to 33 ft.-lbs. (44 Nm)
torque. Install the timing case cover. (See Timing Cover
Tighten the two oil pan bolts (Item 1) [Figure 70-100-49]
to 16 ft.-lbs. (22 Nm) torque. Remove the timing case cover. (See Timing Cover
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Camshaft And Tappets Removal
Figure 70-100-52
P-8742
Carefully remove the camshaft (Item 1) [Figure 70-100-

P-8740 54].
Figure 70-100-55
Remove the fuel injection pump. (See Fuel Injection
Pump Removal And Installation on Page 70-70-1.)
Remove the timing case. (See Timing Case And Gear

Remove the rocker cover, rocker assembly and push

rods. (See Cylinder Head Removal on Page 70-100-4.)
Remove the fuel pump and gasket.

1
1
Turn the engine over and remove the oil pan mounting
bolts [Figure 70-100-52].
Remove the oil pan and gasket.
Installation: Tighten the oil pan mounting bolts to 16 ft.-

P-8743
.lbs. (22 Nm) torque.
Figure 70-100-53
Remove the tappets (Item1) [Figure 70-100-55] from the
block.
Camshaft And Tappets Installation
Clean and inspect the camshaft and tappets for

1
excessive wear and damage.
Inspect the camshaft bushing for excessive wear and

damage.
NOTE: Only the front camshaft journal bore has a

bushing.
Clearance between the camshaft journals, the bushing

P-8741
and camshaft bore is 0.0025-0.0055 inch (0,06-0,14
mm).
Remove the camshaft thrust washer (Item 1) [Figure 70-
100-53].
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Camshaft And Tappets Installation (Cont’d)
Figure 70-100-56
1
1
1
P-8741
Install the camshaft thrust washer (Item 1) [Figure 70-

P-8743 100-58]. Make sure that the dowel pin (Item 2) [Figure
70-100-58] lines up with the hole in the thrust washer.
Make sure all components are clean and lubricated with Install the timing case. (See Timing Case And Gear
clean engine oil. Installation on Page 70-100-18.)
Install the tappets (Item 1) [Figure 70-100-56]. Check camshaft end play. The end play for a new engine
is 0.004 - 0.016 inch (0,10 - 0,41 mm), service limits
Figure 70-100-57 0.021 inch (0,53 mm).
Figure 70-100-59
1 1
P-8742
P-8731
Carefully install the camshaft (Item 1) [Figure 70-100-
57].
Install the fuel pump and gasket. Tighten the bolts (Item
1) [Figure 70-100-59] to 16 ft.-lbs. (22 Nm) torque.
Install the timing gears. (See Timing Case And Gear

Install the injection pump. (See Fuel Injection Pump

Install the push rods and rocker assembly. (See Cylinder

Head Installation on Page 70-100-5.)
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Camshaft And Tappets Installation (Cont’d)

1 1
Install the timing cover. (See Timing Cover Installation on 1 1
Page 70-100-15.)
Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-100-40.)
Pistons And Connecting Rods Description
The pistons have a Quadram combustion chamber. They

have two compression rings and one oil control ring. The
top ring groove has a hard metal insert to reduce wear.
Full floating piston pins are used and are retained by
snap rings. P-8743
Controlled expansion pistons have a steel insert ring in

the piston skirt. The connecting rods are molybdenum Mark and remove the connecting rod caps (Item 1)
steel. The connecting rods on the turbocharged engines [Figure 70-100-61].
have wedge shaped small ends. The location of the
bearing caps to the connecting rods is made by
NOTE: Do not allow the connecting rods to hit the
serrations and the cap is retained by two bolts.
cooling jets.
The pistons used in the 1000 series engines have two
compression rings and one oil control ring. All the rings Figure 70-100-62
are above the piston pin. Each of the three piston rings
have different design features. Always use the engine 1
identification number to order new parts.
Pistons And Connecting Rods Removal
Figure 70-100-60
P-8745
Turn the connecting rods 90° to prevent contact with the

piston cooling jets (Item 1) [Figure 70-100-62]. Push the
1
piston and rod assemblies out the top of the cylinder.
P-8744
Remove the cylinder head. (See Cylinder Head Removal

on Page 70-100-4.)
Remove all the carbon from the top of the cylinder liners.
Remove the oil pan. (See Oil Pan Removal And

Remove the oil pick up screen and tube (Item 1) [Figure

70-100-60].
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Pistons And Connecting Rods Removal (Cont’d)

4
Figure 70-100-63
1 1
3
1 1
1 2
P13999
Remove the piston rings (Item 1) [Figure 70-100-65] with

P-8746 a ring expander.
Remove the snap rings (Item 2) [Figure 70-100-65]

Inspect the crankshaft journals (Item 1) [Figure 70-100- which retain the piston pin.
63] for wear or damage.
Push the piston pin (Item 3) [Figure 70-100-65] out by
NOTE: Keep all parts together so they can be hand. If the pin doesn't push out easily, heat the piston to
replaced in their original position. 100°-120° F (40°-50° C) for easier removal.
NOTE: Before installing the pistons check cylinder Remove the connecting rod (Item 4) [Figure 70-100-65].
bore for wear or damage. (See Cylinder Liner
Inspection on Page 70-100-45.)
Pistons And Connecting Rods Disassembly
Figure 70-100-64
1
1
4 4
B-5570
Mark the piston to indicate the cylinder number (Item 1)

[Figure 70-100-64] as shown on the connecting rod.
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Piston Ring End Gap
Figure 70-100-66
3
B-5575
Install the oil control ring over the spring (Item 1) [Figure
B-5571 70-100-68].
Make sure the ring gap is 180° from the latch pin.
Place the piston rings in the upper part of the cylinder to
check the end gap [Figure 70-100-66]. Install the cast iron ring with the tapered face (Item 2)
Top Ring End Gap 0.014-0.028 inch [Figure 70-100-68] in the second groove with the word
(0,35-0,70 mm) TOP or symbol facing the top of the piston.
Second Ring End Gap 0.012-0.030 inch
(0,30-0,76 mm) New second rings have a green identification mark,
which must be on the left of the ring gap after the ring is
Third Ring End Gap 0.010-0.031 inch
installed and the piston is upright.
(0,25-0,75 mm)
The second ring has an external step at the bottom of the
Piston Ring Installation tapered face.
Figure 70-100-67 Place the chromium ring (Item 3) [Figure 70-100-68] with
the symbol or word TOP up when installed on the piston.
The top ring (Item 3) [Figure 70-100-68] 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.
B-5572
Install the spring of the oil control ring in the bottom

groove with the latch pin inside both ends of the spring
[Figure 70-100-67].
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.
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RECONDITIONING THE ENGINE (CONT’D) Measure this 5.0 inch (127 mm) on each side of the
connecting rod axis on a test fixture.
Piston Ring Groove Clearance
With the piston pin bushing installed the limit is reduced
Figure 70-100-69 to ± 0.0025 inch (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.
Ream the bushing to get the proper clearance of 0.0008 -

0.0017 inch (0,02 - 0,043 mm) between the small end
B-5576 bushing and piston pin.
Piston And Connecting Rod Assembly

With the piston rings installed, check the groove
clearance [Figure 70-100-69]. Figure 70-100-71
Top Ring Wedge
Second Ring Side 0.003-0.004 inch
Third Ring Side 0.002-0.003 inch
Connecting Rod Inspection
Figure 70-100-70 2
1
3
P-13999
5” 5”
(127 mm) (127 mm)
Install the connecting rod (Item 1) [Figure 70-100-71],
0.010” 0.010”
(±0.25mm) piston pin (Item 2) [Figure 70-100-71] and two snap
(±0.25mm)
rings (Item 3) [Figure 70-100-71] in the piston.
B-5577
Checking the connecting rod for distortion [Figure 70-

100-70].
NOTE: The large and small end bores must be square

and parallel within the limits of ± 0.010 inch
(0,25 mm).
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Piston And Connecting Rod Installation
Apply a light coat of oil to the piston and piston rings.
NOTE: Make sure the piston ring end gaps are 120°
apart.
1 1
Figure 70-100-72
1
P-8745
Clean the bearing surfaces and crank pin. Lubricate the

crank pin (Item 1) [Figure 70-100-74] with clean engine
oil.
Figure 70-100-75
B-5578
Install the ring compressor over the piston rings [Figure 1

70-100-72].
Carefully place the connecting rod in the cylinder and

using a hammer handle, push the piston in the bore.
1
Figure 70-100-73
B-5580
Install the upper and lower bearing shells in position

making sure the locating tang (Item 1) [Figure 70-100-
75] is in the correct position.
FRONT 1
NOTE: New connecting rod nuts must be installed
each time the rod caps are removed.
B-5579
When the piston has cleared the cooling jet, rotate the
piston assembly so that the arrow or FRONT mark is
toward the front of the engine [Figure 70-100-73].
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RECONDITIONING THE ENGINE (CONT’D) Carefully move the dial gauge so that the plunger is on
top of the piston above the axis of the piston pin.
Piston And Connecting Rod Installation (Cont’d)
Rotate the crankshaft to bring the piston to it's highest
Figure 70-100-76
point. Record this gauge reading.
1 1 The quadram piston when install, the top surface of the

1 piston is slightly above the surface of the cylinder block.
1
For the Quadram piston engines, the height above the
surface of the block should be 0.005 to 0.014 inch (0,14
to 0,36 mm).
NOTE: Two Quadram piston heights can be used. In

the factory H - high or L - low. In service only
L pistons are supplied.
If a L piston is used in place of an H piston the

height may be up to 0.0075 inch (0,19 mm)
P-8743
below the bottom limit. The top of the piston
can not be machined.
Install the caps (Item 1) [Figure 70-100-76] and nuts.
Gradually tighten the nuts to 45 ft.-lbs. (61 Nm) torque. If the original piston is being reused, install the
Tighten to a final torque of 92 ft.-lbs. (125 Nm). piston with the original connecting rod in the
cylinder bore that it was removed from.
Rotate the crankshaft. The crankshaft must rotate
smoothly. Install the cylinder head. (See Cylinder Head Installation
on Page 70-100-5.)
Figure 70-100-77
Crankshaft And Bearings Description
The crankshaft is a chrome-moly forging which has five

main journals. End play is controlled by two half thrust
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
1 lip to the outside of the main lip.
Crankshaft And Bearings Removal

P-8744
Remove the water pump. (See Water Pump Removal on
Install the oil pick up tube and screen (Item 1) [Figure Page 70-100-34.)
70-100-77].
Remove timing case cover. (See Timing Cover Removal
Install the oil pan. (See Oil Pan Removal And Installation on Page 70-100-15.)
on Page 70-100-40.)
Checking Piston Height Pump Removal And Installation on Page 70-70-1.)
Rotate the crankshaft until the piston is approximately at Remove the timing gears and timing case. (See Timing
top dead center (T.D.C.). Case And Gear Removal on Page 70-100-17.)
Using a dial indication gauge, pre-load the plunger on the

top surface of the block and zero the gauge.
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Crankshaft And Bearings Removal (Cont’d)
Figure 70-100-78 1 1 1 1 1
P-8746
Mark the main bearing caps (Item 1) [Figure 70-100-80]

P-8748 for correct installation.
Remove the main bearing cap bolts.

Remove the flywheel. (See Flywheel Removal And
Installation on Page 70-90-1.) Figure 70-100-81
Remove the pistons and connecting rods (See Pistons

And Connecting Rods Removal on Page 70-100-21.),
keeping them in order.
Remove the rear oil seal housing (Item 1) [Figure 70-

100-78].
Figure 70-100-79
1 1 1 1 1
P-8750
1 1
Remove the main bearing caps (Item 1) [Figure 70-100-
81].
P-8749
Remove the two bolts (Item 1) [Figure 70-100-79]

retaining the bridge piece.
Remove the bridge piece.
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Crankshaft And Bearings Removal (Cont'd)
Figure 70-100-82
P-8752
Remove the crankshaft bearings from the engine block

P-8753 [Figure 70-100-84].
Keep the bearings with their respective caps for

Remove the thrust washers from the sides of the center installation.
main bearing bore [Figure 70-100-82].
Inspection Of Crankshaft And Bearings
Figure 70-100-83
Figure 70-100-85
P-8751
A-2763
Remove the crankshaft [Figure 70-100-83].

Check the crankshaft for wear [Figure 70-100-85]. The
maximum wear and out of round of the crank journals is
0.0016 inch (0,04 mm).
The main journals and the crank pins of standard size

can be machined 0.010 inch (0,25 mm) 0.020 inch (0,50
mm) or 0.030 inch (0,75 mm).
NOTE: (See Crankshaft on Page SPEC-20-4.) for more

crankshaft specifications.
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Inspection Of Crankshaft And Bearings (Cont’d)
Check the oil clearance of the bearings.
All Main Bearings

0.0022 - 0.0046 inch (0,057 - 0,117 mm)
Thrust Washer Thickness

Standard0.089 - 0.091 inch (2,26 - 2,31 mm)
Oversize0.096 - 0.098 inch (2,45 - 2,50 mm)
Crankshaft And Bearings Installation
Figure 70-100-86 P-8751
Make sure the main journals are clean and install the
crankshaft in the block [Figure 70-100-87].
Make sure the locating pins for the main caps are in
position.
Figure 70-100-88
P-8754
Clean the main bearing bores and install the upper

bearing shells in position. Lubricate the bearings with
clean engine oil [Figure 70-100-86].
NOTE: Only the upper half of the bearings has oil

lubrication holes and must be installed in the
cylinder block. P-8753
Clean and install the upper and lower thrust bearings on

each side of the center main bearing [Figure 70-100-88].
Clean the main caps and install the bearings.
Lubricate the bearings with clean engine oil.
Install the main cap bolts and torque in steps working

from the center outward.
Step 165 ft.-lbs. (88 Nm)

Clean the bridge piece and apply a bead of LOCTITE

#518 in the corners and around the thread holes on the
block.
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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 70-100-89 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

Figure 70-100-91
P-8755
Install the bridge piece, and using a straight edge, align

the bridge with the cylinder block [Figure 70-100-89].
Tighten the bridge retaining bolts to 12 ft.-lbs. (16 Nm) 1
torque.
2
Figure 70-100-90 B-5581

procedure;
MEL1532 - Rear Crankshaft Seal Installation Tool
1 The seal can be installed from flush with the housing face
(Item 1) [Figure 70-100-91] to 0.27 inch (6,86 mm) (Item
2) [Figure 70-100-91] back from the housing face. Install
seal so that the seal lip does not line up with any worn
areas on the crankshaft.
Figure 70-100-92
2
P-8756
Inject LOCTITE #518 into the groove (Item 1) [Figure 70-

100-90] at each end of the bridge piece. Continue to
inject sealant until it leaves the lower groove (Item 2)
[Figure 70-100-90] at the front and rear of the piece.
N-00550
Install the seal in the seal housing using the seal

installation tool. Seat the seal to the correct depth
[Figure 70-100-92].
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Rear Oil Seal Installation

1
Install the new seal in the housing.
Figure 70-100-93
4 3
P-8748
2
Tighten the bolts (Item 1) [Figure 70-100-94] to 16 ft.-lbs.

1 (22 Nm) torque.
B-5582 Checking Crankshaft End Play
The axial movement of the crankshaft is controlled by two

Make sure the dowels (Item 1) [Figure 70-100-93] are in half thrust washers placed on both sides of the center
the block correctly. main bearing.
Install the new gasket (Item 2) [Figure 70-100-93] on the Figure 70-100-95
housing (Item 3) [Figure 70-100-93].
Install the seal replacer tool (PD145-3) (Item 4) [Figure

70-100-93] on the crankshaft.
Lubricate the seal, tool, and crankshaft with clean engine

oil.
Carefully push the seal and housing (Item 3) [Figure 70-

100-93] over the tool and crankshaft and into position on
the dowels. Remove the tool.
P-8840
Install a dial indicator on the end of the crankshaft

[Figure 70-100-95].
Pry the crankshaft to the rear of the cylinder block and

set the dial indicator to zero.
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RECONDITIONING THE ENGINE (CONT’D) Cooling System Description
Checking Crankshaft End Play (Cont’d) Figure 70-100-98
Figure 70-100-96
P-10545
P-8841
Coolant from the radiator passes through the centrifugal
water pump (Item 1) [Figure 70-100-98], to assist the
Remove the pry bar and record the dial indicator reading flow of the coolant through the system.
[Figure 70-100-96].
The water pump is gear driven from the gear off the fuel
The end play specification is 0.0075 inch (0,019 mm) injection pump.
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 70-100-97 the cylinder block to the rear of the cylinder block.
Figure 70-100-99
B-5583 1
N-16420
The end play can also be checked using a feeler gauge
[Figure 70-100-97].
The oil cooler (Item 1) [Figure 70-100-99] is installed on
Pry the crankshaft to the rear of the cylinder block and the left side of the engine. Coolant from the by-pass
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.
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RECONDITIONING THE ENGINE (CONT’D) Installation: Make sure all gasket surfaces are clean.
Replace the gasket before installing the thermostat
Cooling System Description (Cont’d) housing.
Figure 70-100-100 Figure 70-100-102
N-16396 N-16395
The coolant then passes around the cylinders and in the Remove the housing and thermostat (Item 1) [Figure 70-
cylinder head. The coolant leaves the cylinder head at 100-102].
the front and passes into the thermostat housing (Item 1)
[Figure 70-100-100]. Figure 70-100-103
If the thermostat is closed, the coolant goes directly

through a by-pass to the inlet side of the water pump. If
the thermostat is open, the thermostat closes the by-pass
and the coolant passes to the radiator.
Thermostat Removal and Installation
Drain the engine coolant until it is below the thermostat

level.
Figure 70-100-101
1 1
N-16394
Remove the six mounting bolts at the coolant housing

(Item 1) [Figure 70-100-103].
1
N-16396
Remove the bolts (Item 1) [Figure 70-100-101] and

thermostat housing.
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RECONDITIONING THE ENGINE (CONT’D) Water Pump Removal
Thermostat Removal and Installation (Cont’d) Remove the coolant from the cooling system.
Figure 70-100-104 Figure 70-100-105
1 1
N-16393 P10543
Remove coolant housing (Item 1) [Figure 70-100-104] Remove the nuts (Item 1) [Figure 70-100-105].
from the engine block.
Figure 70-100-106
Thermostat Testing
1
Hang the thermostats in a suitable container filled with
coolant.
Heat the coolant gradually. Use a thermometer to check

the temperature when it starts to open and when it's fully 1
open. 1
If the thermostats do not operate correctly they must be

replaced.
1
NOTE: Identify thermostat temperature by the 1
stamping on the by-pass valve.
P-10545

from the water pump.
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RECONDITIONING THE ENGINE (CONT’D) Engine Oil Cooler Removal And Installation
Water Pump Removal (Cont’d) Figure 70-100-108
Figure 70-100-107
N-16420
1
N-16396
Remove the bolt and nut (Item 1) [Figure 70-100-108]
and hold the low-pressure fuel pipes to the top of the
Loosen the hose clamp (Item 1) [Figure 70-100-107]. cooler.
Remove the water pump. Figure 70-100-109
Water Pump Installation

1
Clean the gasket surfaces and replace the O-ring.
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.
Pipe thread sealant must be applies to the pump

mounting bolts before installation.
Install the water pump bolts (Item 1) [Figure 70-100-106]

and tighten to 16 ft.-lbs. (22 Nm) torque.
N-16405
Install the two nuts (Item 1) [Figure 70-100-105] and
tighten to 16 ft.-lbs. (22 Nm) torque.
Remove the support bracket (Item 1) [Figure 70-100-
Tighten the hose clamp (Item 1) [Figure 70-100-107]. 109] for the oil cooler.
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Engine OIl Cooler Removal And Installation (Cont’d)
Figure 70-100-110
1 2
1
N-16402
Remove the oil cooler from the engine block [Figure 70-
N-16406 100-112].
Installation: Install new O-rings for the inlet (Item 1)

Loosen the hose clamp (Item 1) [Figure 70-100-110] at [Figure 70-100-112] and outlet (Item 2) [Figure 70-100-
the front of the oil cooler. 112] connections. Replace the gasket for the oil pipe
flange.
Figure 70-100-111
Figure 70-100-113
2
2
N-16404
N-16403
Remove the front cooler mounting bolt (Item 1) [Figure

70-100-111]. Remove the hose and clamp (Item 1) [Figure 70-100-
113].
Remove the cooler mounting bolt (Item 2) [Figure 70-
100-111]. Check the hose for damage and replace as needed.
Installation: Tighten the mounting bolts to 16 ft.-lbs. (22 Installation: Put a small amount of oil on the hose (Item
Nm) torque. 1) [Figure 70-100-113] before installing the oil cooler.
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Engine Oil Cooler Disassembly And Assembly
Figure 70-100-114
1 1
1
1
N-16401
Remove the self-locking nuts (Item 1) [Figure 70-100-

N-16400 116] on the back of the oil cooler.
Assembly: Tighten the nuts to 42 ft.-lbs. (58 Nm) torque.

cover. Figure 70-100-117
Assembly: Tighten the bolts to 96 in.-lbs. (11 Nm)

torque.
2
Figure 70-100-115
1
N-16397
Remove the cooler element from the housing [Figure 70-

100-117].
N-16399
Assembly: Replace the O-rings (Item 1) [Figure 70-100-
117] on the flange of the element. Replace the O-rings
Remove the cover from the element [Figure 70-100- (Item 2) [Figure 70-100-117] on the studs of the element.
115].
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Engine Lubrication System Description
Figure 70-100-118
1 3
N-16391
The engine oil passes from the filter (Item 1) [Figure 70-
P-8834 100-120] 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 70-100-118] 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
strainer (Item 2) [Figure 70-100-118] and pipe to the Engine oil passes from the main bearings through
suction side of the pump. passages in the cylinder block to the journals of the
camshaft. Engine oil passes from the center journal of
The engine oil passes from the outlet side of the pump the camshaft through a passage in the cylinder block and
through a pipe to a relief valve (Item 3) [Figure 70-100- cylinder head to a restriction in the pedestal of the rocker
118], which is installed in the bottom left side of the shaft, at a reduced pressure, to feed the rocker bushing.
cylinder block. The relief valves opens if the oil pressure The oil passes through a passage in the rocker shaft to
is too high; this allows some of the engine oil to return to the bearings of the rocker levers. The valve stems, valve
the sump. springs and the tappets are lubricated by splash and oil
mist.
Figure 70-100-119
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.
N-16404
From the relief valve, engine oil passes to a plate type oil
cooler (Item 1) [Figure 70-100-119].
Oil flows through the oil tubes (Item 2) [Figure 70-100-

119] to the filter.
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Engine Lubrication System Description (Cont’d)
Figure 70-100-121
1
1
1
N-16391
Remove the four bolts (Item 1) [Figure 70-100-123] and

P-8745 the filter adapter (Item 2) [Figure 70-100-123].
Oil Filter Adapter Installation

Turbocharged engines have piston cooling jets (Item 1)
[Figure 70-100-121]. These jets are connected to the oil Figure 70-100-124
pressure rail and spray lubricating oil inside the pistons to
keep them cool.
Oil Filter Adapter Removal

2
Remove the oil filter. 1
Figure 70-100-122
N-16390
Clean the filter adapter (Item 1) [Figure 70-100-124] and

the block mounting surfaces (Item 2) [Figure 70-100-
124].
Using a new gasket, install the adapter (Item 1) [Figure

N-16392 70-100-124] on the block.
Connect the turbocharger oil supply line.

Remove the oil cooler pipes (Item 1) [Figure 70-100-122]
from the filter adapter. Disconnect the turbocharger oil Connect the oil cooler lines to the filter adapter.
supply line.
Install the oil filter.
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RECONDITIONING THE ENGINE (CONT’D) Remove the bolts (Item 3) [Figure 70-100-126] from the
pick-up tube flange.
Oil Pan Removal And Installation
Remove the pick-up tube (Item 4) [Figure 70-100-126]
Figure 70-100-125 and gasket.
Wash the assembly in solvent and dry with compressed

air.
Check the tube and strainer for cracks or other damage.

Replace as necessary.
Loosely assemble the bracket (Item 2) [Figure 70-100-

126] with the pick-up tube to the main bearing cap.
Install the pick up tube gasket and mounting bolts (Item

3) [Figure 70-100-126].
Tighten the mounting bolts to 16 ft.-lbs. (22 Nm) torque.

P-8740
Tighten the bolt (Item 1) for the pick-up tube bracket.
Remove the oil pan retaining bolts [Figure 70-100-125]. Tighten the bolt to 16 ft.-lbs. (22 Nm) torque.
Remove the pan and gasket. Oil Pump Removal
Clean the pan in solvent and dry with compressed air. NOTE: The oil pump has a channel in the body of the
pump. Oil from the front main bearing passes
Clean the block surface. down the channel of the pump to an oil hole in
the idler shaft for lubrication of the idler shaft
Installation: Place a new gasket on the oil pan. Place bushing.
two bolts on each side to position the oil pan correctly.
Install the remaining bolts. Tighten the bolts to 16 ft.-lbs. Remove the oil pan. (See Oil Pan Removal And
(22 Nm) torque [Figure 70-100-125]. Installation on Page 70-100-40.)
Oil Screen And Pick-up Tube Figure 70-100-127
Figure 70-100-126
1
4 2
1
3
P-8744
P-8834
Remove the oil pressure relief valve (Item 1) [Figure 70-
100-127].
Remove the bolt (Item 1) [Figure 70-100-126] that holds
the bracket (Item 2) [Figure 70-100-126] to the main Remove the oil screen and pick-up tube.
bearing cap.
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Oil Screen And Pick-up Tube (Cont’d)
Figure 70-100-128
2 2
P-8835
1
Lubricate with clean engine oil and install the washer,
P-8835 idler gear (Item 1) [Figure 70-100-129] and snap ring
(Item 2) [Figure 70-100-129].
The oil pump is installed on the number 1 main bearing Check the backlash between oil pump and idler gears.
cap.
There must be a minimum of 0.003 inch (0,076 mm).
NOTE: The pump can be removed with the main
bearing cap if a spanner wrench is available Figure 70-100-130
that will allow the torque to be applied directly
to the main cap bolts.
If there is no spanner wrench, the front timing case cover

must be removed. (See Timing Cover Removal on Page
70-100-15.)
Remove the snap ring (Item 1) [Figure 70-100-128], idler

gear (Item 2) [Figure 70-100-128], and washer.
Remove the bolts and oil pump.
Oil Pump Installation
Fill the pump with engine oil. B-5588
If the number one main cap was removed, reinstall and

tighten to 185 ft.-lbs. (250 Nm) torque. Check that there is a minimum of 0.003 inch (0,076 mm)
backlash between the idler gear and oil pump gear
Install the pump on the main cap and tighten to 16 ft.-lbs. [Figure 70-100-130].
(22 Nm) torque.
End play for the idler gear should be 0.0005/0.0253 inch
Check the idler gear and bushing for wear. (0,012/0,643 mm).
Install the oil screen and pick-up tube. (See Oil Screen
And Pick-up Tube on Page 70-100-40.)
Install the pressure relief valve.
Install the oil pan. (See Oil Pan Removal And Installation
on Page 70-100-40.)
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Oil Pump Disassembly And Assembly
Figure 70-100-131
B-5593
Check the rotor end play [Figure 70-100-133].

B-5591
Rotor end play must be 0.001-0.004 inch (0,03-0,10 mm).
NOTE: If any part is worn enough to effect Install the cover and tighten the bolts to 16 ft.-lbs. (22
performance replace the complete oil pump. Nm) torque.
Remove the cover of the oil pump.
Remove the outer rotor and thoroughly clean. Check for

cracks or other damage.
Install the outer rotor and check the outer rotor to body
clearance [Figure 70-100-131].
Clearance between the outer rotor and body must be

0.006-0.013 inch (0,15-0,34 mm).
Figure 70-100-132
B-5592
Check the inner rotor to outer rotor clearance [Figure 70-

100-132].
Clearance between the inner rotor and outer rotor must

be 0.0015 - 0.005 inch (0,04-0,13 mm).
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RECONDITIONING THE ENGINE (CONT’D) Engine Block Description
Oil Pressure Relief Valve Disassembly And Assembly The cylinder block is made of cast iron and provides full
length support for the dry liners.
Figure 70-100-134
Figure 70-100-135
5
4
1
3 1
B-5606
P-8837
Press the end plate (Item 1) [Figure 70-100-134] in the

valve body (Item 2) [Figure 70-100-134] and remove the The liners (Item 1) [Figure 70-100-135] are made of cast
snap ring (Item 3) [Figure 70-100-134]. iron. Production liners are a press fit and service liners
are a transion fit. Both types of liners are honed with
Remove the end plate (Item 1) [Figure 70-100-134], silicon carbide tools to a specially controlled finish to
spring (Item 4) [Figure 70-100-134], and plunger (Item 5) ensure long engine life and low oil consumption.
[Figure 70-100-134] from the body (Item 2) [Figure 70-
100-134]. Figure 70-100-136
Clean the parts in solvent and dry with compressed air.
Lubricate the bore of the valve body (Item 2) [Figure 70-

100-134], plunger (Item 5) [Figure 70-100-134] and the 1
end plate (Item 1) [Figure 70-100-134] with clean engine
oil before assembly.
P-8742
A bushing (Item 1) [Figure 70-100-136] is installed in the

cylinder block for the front camshaft journal while the
other camshaft journals run directly in the block.
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RECONDITIONING THE ENGINE (CONT’D) Piston Cooling Jet Removal
Engine Block Disassembly And Assembly Figure 70-100-137
Remove the water pump. (See Water Pump Removal on

Page 70-100-34.)

Pump Removal And Installation on Page 70-70-1.)
1 1
Remove the oil cooler. (See Removal And Installation on
Page 30-80-1.)
Remove the oil filter and oil pan. (See Oil Pan Removal

and Installation on Page 70-100-49.) P-8754
Remove the lift fuel pump. (See Removal And Installation

on Page 70-70-7.) Remove the piston cooling jet assembly (Item 1) [Figure
70-100-137] from the engine block.
Remove the starter. (See Removal And Installation on
Page 60-40-1.) Figure 70-100-138
Remove the cylinder head. (See Cylinder Head Removal

on Page 70-100-4.)
Remove the timing case and gears. (See Timing Case

And Gear Removal on Page 70-100-17.) 2
Remove the piston and connecting rod assemblies. (See

Pistons And Connecting Rods Removal on Page 70-100-
21.)
Remove the camshaft and tappets. (See Camshaft And

3
Tappets Removal on Page 70-100-19.)
1
Remove the engine mounting bracket and flywheel. (See P-8836
Mounting Brackets Removal And Installation on Page 70-
80-6 and See Flywheel Removal And Installation on
Page 70-90-1) Inspect the jet tube (Item 1) [Figure 70-100-138], mount
bolt (Item 2) [Figure 70-100-138] and alignment pin
Remove the rear oil seal and the crankshaft. (See Rear (Item 3) [Figure 70-100-138] for damage. Replace as
Oil Seal Removal on Page 70-100-30.) needed.
Piston Cooling Jet Installation
Clean all parts in solvent and dry with compressed air.
Install the cooling jet (Item 1) [Figure 70-100-138] being

sure it is seated correctly on the dowel (Item 3) [Figure
70-100-138] in the block.
Install the mounting bolt (Item 2) [Figure 70-100-138]

and tighten to 15 ft.-lbs. (20 Nm) torque.
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Piston Cooling Jet Alignment
Figure 70-100-139
1.3” P-8837
(33 MM)
0.8” Examine the liner surface (Item 1) [Figure 70-100-140]

(21 MM) N-00535 for cracks, deep scratches and polished areas where the
honed finish is worn away.
Insert a 0.067 inch (1,70 mm) diameter rod of suitable Figure 70-100-141
length, in the jet.
The tip of the rod must extend out the top of the cylinder
in an area 1.30 inch (33 mm) in height and 0.8 inch (21
mm) of width to provide proper cooling jet alignment to
cool the pistons [Figure 70-100-139].
Inspection
Clean all passages of coolant and oil.
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 B-4066
and piston height above the top face of the
cylinder block.
Check the cylinder liner bore for out of round or wear
Check the camshaft bushing for wear. If the bushing beyond service limits [Figure 70-100-141]. The inside
needs to be replaced, press out old one. Press a new diameter of the service liner should be 3.937-3.939 inch
one in, insuring that the oil holes line up. (100,00-100,06 mm).
Cylinder Liner Inspection A flex type hone may be used to clean up small scoring
or pitting.
The condition of a cylinder liner is decided by:
Damaged or worn liners must be replaced.
• The amount and location of polished areas.
• Wear.
• 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.
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RECONDITIONING THE ENGINE (CONT’D)
Cylinder Liner Removal
Figure 70-100-142
B-5556
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) [Figure 70-100-142] over the

center of the liner (Item 2) [Figure 70-100-142]. Make
sure the flat bearing race (Item 3) [Figure 70-100-142] is
against the bottom of the recess.
Install the rod (Item 4) [Figure 70-100-142] through the

handle (Item 5) [Figure 70-100-142].
Place the adapter (Item 6) [Figure 70-100-142] under

the cylinder liner. Tighten the nut and washer. Turn the
handle and pull out the old liner.
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RECONDITIONING THE ENGINE (CONT’D) Turn the handle and press the liner in the bore, stopping
when approximately 2 inch (50 mm) remain. Apply
Cylinder Liner Installation LOCTITE #603 to the outer surface below the flange and
to the flange recess.
Figure 70-100-143
Continue to press the liner into position. Remove the tool.
4 NOTE: Do Not hit the cylinder liners with a hammer.

They will be damaged.
5
Figure 70-100-144
3
1
2 2
1
B-5607
Check liner protrusion with a dial gauge [Figure 70-100-

144].
6 The liner may have 0.004 inch (0,10 mm) protrusion or
B-5555 recession from the block face.
Allow 15 minutes before measuring the bore. The liner

Clean the cylinder bore and the outside of the liner. will take six hours to reach full strength.
Lubricate the cylinder bore with engine oil. The inside diameter of the service liner should be 3.937-
3.939 in. (100,00- 100,06 mm).
Start the liner (Item 1) [Figure 70-100-143] in the bore.
Make sure it is started straight. New piston rings must be used when the cylinder liners
have been replaced.
With the adapter (Item 2) [Figure 70-100-143] on the top
of the liner, place the bearing (Item 3) [Figure 70-100- The measurement must be from the flange (Item 1)
143] in the recess at the top. [Figure 70-100-144] of the cylinder liner, not the top of
the flame ring (Item 2) [Figure 70-100-144].
Place the threaded rod (Item 4) [Figure 70-100-143]
through the handle (Item 5) [Figure 70-100-143] and
liner (Item 1) [Figure 70-100-143].
Adjust the rod until it is below the bottom of the block IMPORTANT
surface.
For the first five hours after the new liners have been
Install the adapter (Item 6) [Figure 70-100-143] on the installed:
rod. Center the adapter against the bottom of the block. • Do not operate at full load.
• Do not operate at high speed.
Tighten the nut and washer. • Do not allow engine to idle for extended periods.
I-2117-1196
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RECONDITIONING THE ENGINE (CONT’D)
Turbo Charger 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
Too Much Lubricating Oil At Turbine End 2, 7, 8, 17, 19, 20, 22, 28, 30, 31, 32
Too 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, 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. 19. Leakage from turbocharger seals.
2. Restricted crankcase breather. 20. Worn turbocharger bearings.
3. Air filter element missing, leaking, or not sealing 21. Excessive dirt in turbocharger housing.
correctly. Loose connection to turbo charger.
4. Internal distortion or restriction in pipe from air fil- 22. Excessive carbon behind turbine rotor.
ter to turbocharger.
5. Damaged/restricted crossover pipe, turbocharger 23. Engine speed raised too rapidly at initial start.
to induction manifold.
6. Restriction between air filter and turbocharge. 24. Insufficient engine idle period.
7. Restriction in exhaust system. 25. Faulty fuel injection pump.
8. Turbocharger loose or clamps/setscrews loose. 26. Worn or damaged fuel injectors.
9. Induction manifold cracked or loose, flanges dis- 27. Valves burned.
torted.
10. Exhaust manifold cracked or loose, flanges dis- 28. Worn piston rings.
torted.
11. Restricted exhaust system. 29. Lubricating oil leakage from supply pipe.
12. Delay of lubricating oil to turbocharger at engine 30. Excessive starting fluid (on initial engine start).
start.
13. Insufficient lubrication. 31. Excessive engine idle period.
14. Dirty lubricating oil. 32. Restriction in turbocharger bearing housing.
15. Incorrect lubricating oil. 33. Restriction in lubricating oil filter.
16. Restricted lubricating oil supply pipe. 34. Engine stopped too soon from high load.
17. Restricted lubricating oil drain pipe. 35. Insufficient lubricating oil.
18. Turbine housing damage or restricted. 36. Fuel leakage from fuelled starting aid.
37. Crack in back plate of compressor.
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RECONDITIONING THE ENGINE (CONT’D) Turbo Charger Removal and Installation
Turbo Charger Description Remove the three nuts (Item 2) [Figure 70-100-145] that
mount the extension tube to the turbo.
Figure 70-100-146
WARNING
Turbochargers, operate at high speed and high
temperatures. Keep fingers, tools and other objects
away from the inlet and outlet ports. Avoid contact
with hot surfaces.
W-2257-1196 1
Figure 70-100-145
N-21625
1
2 extension tube and muffler.
Remove the extension tube [Figure 70-100-146].
Figure 70-100-147
N-21602
The turbocharger (Item 1) [Figure 70-100-145] is placed

between the exhaust and intake manifolds. It is driven by
hot exhaust gases and supplies air at more than
atmospheric pressure to the intake. It is lubricated by oil
from the main gallery.
The oil flows from the filter adapter through the bearing 1
housing and returns to the engine block.
The turbocharger should only be serviced by an

authorized dealer or repair shop. N-15857
Disconnect the air cleaner hose (Item 1) [Figure 70-100-

147] from the turbocharger.
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Turbo Charger Removal and Installation (Cont'd)
Figure 70-100-148
N-16388
Remove the oil return line (Item 1) [Figure 70-100-150].

N-16386
Figure 70-100-151
Thoroughly clean the turbocharger.
Loosen the hose clamps at the compressor outlet hose

(Item 1) [Figure 70-100-148].
Figure 70-100-149
1
1
N-16387
1
Remove the four nuts (Item 1) [Figure 70-100-151] for
the turbocharger to exhaust manifold flange.
Installation: Apply anti-seize compound to the mounting

N-16389 studs. Tighten the nuts to 33 ft.-lbs. (44 Nm) torque.
Remove the turbocharger and gasket from the exhaust

Disconnect the oil supply tubeline (Item 1) [Figure 70- manifold.
100-149].
The turbocharger must only be serviced by an authorized
Installation: Fill the bearing housing with clean oil repair shop.
through the oil supply port.
Before starting the engine, disconnect the electrical stop
control. Crank the engine until oil pressure is obtained.
Stop cranking and reconnect the stop control.
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HEATING, VENTILATION, AIR CONDITIONING
AIR CONDITIONING SERVICE . . . . . . . . . . . . . . . . . . . . . . . 80-90-1

Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-90-1
SAFETY &
AIR CONDITIONING SYSTEM FLOW . . . . . . . . . . . . . . . . . . 80-10-2 MAINTENANCE
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-3
Principals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-10-2
BASIC TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1

Checking The Electrical System . . . . . . . . . . . . . . . . . . . . 80-50-4
Cleaning The A/C Evaporator Coil & Heater Coil . . . . . . . 80-50-1
Compressor Drive Belt Inspection: . . . . . . . . . . . . . . . . . . 80-50-4
Engine Coolant By-Passing The Heater Valve . . . . . . . . 80-50-12
Heater Valve Not Opening Or Closing . . . . . . . . . . . . . . . 80-50-12
Poor A/C Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-50-1
COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-20-1
COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
Compressor Clutch Disassembly. . . . . . . . . . . . . . . . . . . 80-110-1
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-110-1
CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-120-1
EVAPORATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-190-1
EVAPORATOR/HEATER UNIT . . . . . . . . . . . . . . . . . . . . . . . 80-160-1 HVAC

Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . 80-160-2
EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-180-1

GENERAL AIR CONDITIONING SERVICE GUIDELINES . . . 80-60-1

Component Replacement And Refrigeration Leaks. . . . . . 80-60-2
Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
Compressor Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-60-1
HEATER COIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-200-1

Removal And Installation With A/C . . . . . . . . . . . . . . . . . 80-200-1
Removal And Installation Without A/C . . . . . . . . . . . . . . . 80-200-2
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HEATING, VENTILATION, AIR CONDITIONING (CONT’D)
HEATER/AC FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-210-1


Wire Connector Removal and Installation . . . . . . . . . . . . 80-210-4
HEATER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . 80-220-1
PRESSURE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 80-140-1

PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-150-1

RECEIVER/DRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-130-1
REGULAR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-1

Cleaning The Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . 80-40-3
Compressor Drive Belt Inspection . . . . . . . . . . . . . . . . . . . 80-40-2
Filter Elements Removal And Installation . . . . . . . . . . . . . 80-40-1
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
Safety Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-30-1
SYSTEM CHARGING AND RECLAMATION . . . . . . . . . . . . 80-100-1

Charging Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-4
Charging Procedure With A Manifold Gauge Set . . . . . . 80-100-3
Reclamation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 80-100-1
SYSTEM TROUBLESHOOTING CHART . . . . . . . . . . . . . . . . 80-70-1

Gauge Pressure Related Troubleshooting. . . . . . . . . . . . . 80-70-2
TEMPERATURE/PRESSURE. . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-80-1
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-170-1
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AIR CONDITIONING SYSTEM FLOW
Principals
In an air conditioning system the refrigerant is circulated under pressure through five major components in a closed circuit.
At these five points in the system the refrigerant goes through pressure and temperature changes.
The compressor (Item 1) (See Chart on Page 80-10-3.) takes in heated, low pressure refrigerant gas through the suction
valve (low pressure side) and as the name indicates, pressurizes the heated refrigerant and forces it through the discharge
valve (high pressure side) on the condenser (Item 2) (See Chart on Page 80-10-3.).
Ambient air passing through the condenser removes the heat from refrigerant resulting in physical state change in the
refrigerant from a gas to a liquid.
The liquid refrigerant moves on to the receiver/drier (Item 3) (See Chart on Page 80-10-3.) where impurities such as
moisture and dirt are filtered out. The receiver/drier also serves as the storage tank for the liquid refrigerant. The liquid
refrigerant (still under high pressure) flows to the expansion valve (Item 4) (See Chart on Page 80-10-3.).
The expansion valve meters the amount of refrigerant into the evaporator coil (Item 5) (See Chart on Page 80-10-3.). As
the refrigerant passes through the expansion valve, it again changes its physical state. It becomes a low temperature, low-
pressure liquid and saturated vapor. The low pressure liquid immediately starts to boil and vaporize as it enters the
evaporator. The hot humid air of the machine's cab is drawn through or blown into the evaporator by the evaporator fan
(Item 6) (See Chart on Page 80-10-3.). Since the refrigerant is colder than the air, it absorbs the heat from the air and
produces cooled air, which is pushed into the cab by the fan. The moisture in the air condenses on the evaporator coil and
drips into the drain pan, which directs the water out of the cab.
The refrigerant cycle is completed when the heated low pressure gas is again drawn into the compressor.
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AIR CONDITIONING SYSTEM FLOW (CONT’D)
Chart
Thermostat
Cold Air
Evaporator
5
Evaporator
4
Expansion Valve
Blower
6
1 Compressor
2 Condenser
Pressure
Switch
Sight
Glass
Fan
Dessicant
3 Receiver Drier
Status Of R134a_______________________________________________
High Pressure Gas Low Pressure Liquid
High Pressure Liquid Low Pressure Gas

b-16691
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COMPONENTS Figure 80-20-3
Identification
Figure 80-20-1
1 1
P-21900
Receiver/Drier: The receiver/drier (Item 1) [Figure 80-20-

P-21898 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
minutes weekly throughout the year to
lubricate the internal components. 1
Figure 80-20-2
N-22206
1
Pressure Relief Valve: The pressure relief valve (Item 2)

[Figure 80-20-3] is located on the receiver drier
assembly. This small brass valve (Item 1) [Figure 80-20-
4] is a safety feature that is designed to open and release
the A/C charge if the pressure reaches 535 PSI.
P-21899
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.
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COMPONENTS (CONT’D) Figure 80-20-7
Identification (Cont'd)
Figure 80-20-5
3
1
2
1
N-22087
Evaporator Coil: The evaporator coil (Item 1) [Figure 80-

P-21901 20-7] cools and dehumidifies the air before it enters the
cab.
Heater/Evaporator Unit: The heater/evaporator unit (Item Thermostat: The thermostat (Item 2) [Figure 80-20-7]
1) [Figure 80-20-5] is located behind the loader cab. The controls the temperature of the evaporator coil.
unit delivers the cold air for the A/C and warm air for heat
into the cab. The unit contains the blower, heat & A/C Heater Coil: The heater coil (Item 3) [Figure 80-20-7]
coils, thermostat and expansion valve. supplies the warm air into the cab by passing air through
the coil.
Figure 80-20-6
Figure 80-20-8
P-21902
N-22100
Expansion Valve: The expansion valve (Item 1) [Figure

80-20-6] controls the amount of refrigerant entering the Heater/Evaporator Blower: The blower (Item 1) [Figure
evaporator coil. 80-20-8] is used to push air through the heater and
evaporator coils and into the cab.
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COMPONENTS (CONT’D) Figure 80-20-11
Identification (Cont'd)
Figure 80-20-9
2 4 P-21900
3
Pressure Switch: The pressure switch (Item 1) [Figure

N-22261 80-20-11] will disengage the compressor clutch at high
pressure readings over 384 PSI. (2647 kPa) on the high
side, or at very low pressure of 28 PSI (193 kPa) or less
Control Panel: The panel (Item 1) [Figure 80-20-9] has on the high side, which indicates loss of refrigerant.
three separate components.
Fan Switch: This is a four position rotary switch (Item 2)

[Figure 80-20-9]. When the fan switch is in the off
position the A/C will not engage, but the heat valve will
operate, as it is controlled by the ignition power.
A/C Switch: The rocker switch (Item 3) [Figure 80-20-9]

will be illuminated when the A/C is engaged.
Potentiometer: The potentiometer (Item 4) [Figure 80-

20-9] controls the Heat Valve from fully Off to fully On.
This can be used in conjunction with the A/C for defrost
of the windows and temperature control.
Figure 80-20-10
P-21903
Heater Valve: The heater valve (Item 1) [Figure 80-20-

10] is used to control the amount of engine coolant that
flows to the heater coil.
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SAFETY
Safety Equipment
WARNING
HFC 134A refrigerant can be dangerous if not
WARNING properly handled. Liquid 134A may cause blindness
if it contacts the eyes and may cause serious
frostbite if it contacts the skin.
In the event of a leakage, wear safety goggles. • Gaseous 134A becomes lethal (phosgene) gas
Escaping refrigerant can cause severe injuries to when it contacts open flame or very hot
eyes. In contact with a flame, R134a refrigerant gives substances.
a toxic gas. • NEVER SMOKE when there is the possibility of
W-2371-0500 even small amounts of 134A in the air.
Any servicing work that involves release or addition
Figure 80-30-1 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
Figure 80-30-2
P-16398
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.
P-16399
In addition to exercising caution in your work, DO WEAR

SAFETY GLASSES OR A FACE SHIELD [Figure 80- R-134a inside a canister or in an A/C system is a liquid
30-1] when you are using R-134a or a leak detector, under pressure. When it escapes or releases into the air,
adjusting service valves or the manifold gage set ITS TEMPERATURE DROPS TO 21.6 F DEGREES
connectors. Safety glasses or a transparent face shield "INSTANTLY". If it spills on your skin or in your eyes you
are practical safety items and one or the other is should flood the area with cool water and SEEK
absolutely required. MEDICAL ATTENTION FAST! It is a good idea to wear
gloves [Figure 80-30-2] to prevent frost bite if you should
get refrigerant on your hands.
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REGULAR MAINTENANCE Figure 80-40-3
Filter Elements Removal And Installation
Figure 80-40-1
1
1
P-21906
Remove the filter (Item 1) [Figure 80-40-3] from the

P-21904 cover.
The fresh air filter must be cleaned sometimes as often

Remove the two mount bolts (Item 1) [Figure 80-40-1] as twice a day, depending on the operating environment.
from the fresh air filter cover at the rear of the loader cab. The filter can be cleaned by removing and shaking it. A
small amount of air pressure can be used to clean the
Figure 80-40-2 filter. However the fresh air filter should be changed at
least 2-4 times per year in normal conditions. In
extremely dusty conditions the fresh air filter may need to
be changed weekly.
1 Figure 80-40-4
P-21905 2
1
Remove the filter cover and filter (Item 1) [Figure 80-40-
2] from the loader.
N-22153
Remove the two retaining knobs (Item 1) [Figure 80-40-

4] from the recirculating air filter cover, at the back of the
cab.
Remove the retaining cover (Item 2) [Figure 80-40-4]

from the loader cab.
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REGULAR MAINTENANCE (CONT’D) Compressor Drive Belt Inspection
Filter Elements Removal And Installation (Cont'd) It is a good rule to regularly inspect (weekly) the
compressor drive belt for tension and wear.
Figure 80-40-5
Open the rear door.
1 Figure 80-40-7
P-21907
Remove the recirculating air filter (Item 1) [Figure 80-40-

P-21908
5] from the rear of the cab.
Figure 80-40-6 Check the tension on the compressor belt (Item 1)

[Figure 80-40-7].
The belt has a self tensioner, if the belt becomes loose

check the tensioner to see that it functions properly.
N-22274
The recirculating air filter [Figure 80-40-6] is made of

open cell foam and should be cleaned with water. A mild
detergent may also be used. It does not require cleaning
as frequently as the fresh air intake filter.
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REGULAR MAINTENANCE (CONT’D) Figure 80-40-10
Cleaning The Condenser
Open the rear door.

2
Raise the rear grill on the loader. 3
Figure 80-40-8
1 1
P-21910
With water or air, the radiator (Item 1) [Figure 80-40-10]

the oil cooler (Item 2) [Figure 80-40-10], and the
condenser (Item 3) [Figure 80-40-10] can be cleaned.
P-21899
Check the condenser (Item 1) [Figure 80-40-8] for mud

or dirt.
Lift the condenser.
Figure 80-40-9
P-21909
The condenser and oil cooler are both mounted on a

hinge. Lift and support on the outside corners of the
condenser (Item 1) [Figure 80-40-9].
With the condenser lifted and supported, the oil cooler

can also be lifted.
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BASIC TROUBLESHOOTING Check the belt tension on the A/C compressor. (See
Compressor Drive Belt Inspection: on Page 80-50-4.)
Poor A/C Performance
Check the A/C condenser for dirt or mud, and clean if
Figure 80-50-1 necessary. (See Contents, Page 80-01.)
Check the A/C evaporator coil for dirt or mud, and clean if
necessary. (See Cleaning The A/C Evaporator Coil &
Heater Coil on Page 80-50-1.)
Inspect the sight glass located on the receiver/drier for air

bubbles. (See RECEIVER/DRIER on Page 80-130-1.)
Check the engine coolant to see if it is bypassing the

1
heater valve. (See Engine Coolant By-Passing The
Heater Valve on Page 80-50-12.)
Cleaning The A/C Evaporator Coil & Heater Coil
N-22273 Raise the lift arms and install an approved lift arm
Figure 80-50-2
on Page 10-70-1.)
Figure 80-50-3
N-22411
Start the loader, engage the parking brake. Engage the

A/C system with the blower fan on high. Run the loader at
N-22122
full RPM for approximately 15 minutes, with the loader
cab door closed.
At the rear of the cab, disconnect the thermostat wiring
Check the temperature at the louvers (Item 1) [Figure connector (Item 1) [Figure 80-50-3].
80-50-1] with a thermometer [Figure 80-50-2].
The louver temperature should be between 36-53° F.

(2,2-11,6° C) depending on the amount of humidity in the
air.
If louver temperature is too high, (See SYSTEM

TROUBLESHOOTING CHART on Page 80-70-1.)
Check the blower fan for proper operation or noise, and

replace if necessary. (See Removal And Installation on
Page 80-210-1.)
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BASIC TROUBLESHOOTING (CONT’D) Figure 80-50-6

(Cont'd)
Figure 80-50-4
N-22119
1
Remove the two mounting nuts (Item 1) [Figure 80-50-
6].
N-22130
Figure 80-50-7

the left side cab access cover.
Remove the access cover (Item 2) [Figure 80-50-4] from

the loader.
1
Figure 80-50-5
N-22120
1
7].
N-22129
Disconnect the blower fan wiring connector (Item 1)

[Figure 80-50-5] from the loader wiring harness.
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(Cont'd)
Figure 80-50-8
1
2
N-22125
1
Remove the three mount bolts (Item 1) [Figure 80-50-10]

and the one center mount bolt (Item 2) [Figure 80-50-10]
N-22123 from the Evaporator/Heater Unit rear cover.
Remove the rear cover from the unit.

Remove the Evaporator/Heater Unit from the rear of the
cab. Place it on the fenders of the loader supported with Figure 80-50-11
2x4's (blocking) [Figure 80-50-8].
Remove the two mount bolts (Item 1) [Figure 80-50-8] 1

from the Evaporator/Heater Unit rear cover.
Figure 80-50-9
2
N-22127
With air or water, clean the heater coil (Item 1) [Figure

1 80-50-11] and evaporator coil (Item 2) [Figure 80-50-11].
N-22124

from the Evaporator/Heater Unit rear cover.
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BASIC TROUBLESHOOTING (CONT’D) Push the A/C switch (Item 1) [Figure 80-50-13] to the
ON position. Turn the blower fan switch (Item 2) [Figure
Compressor Drive Belt Inspection: 80-50-13] to the first On position.
Figure 80-50-12 The compressor clutch should make a click sound, which
indicates the clutch is engaging.
Figure 80-50-14
P-21908
Regularly inspect (weekly) the compressor drive belt

P-21912
(Item 1) [Figure 80-50-12] for wear.
Open the rear door. If the compressor clutch does not engage, check the
loader fuse (Item 1) [Figure 80-50-14] located on the
The compressor belt has a self tensioner. control panel in the loader cab.
Check to see that the tensioner works properly. Replace the fuse if burned out.
Checking The Electrical System NOTE: The decal inside the fuse cover, refers to the
fuse as HEATER. This fuse controls the power
Check to see if the compressor clutch is engaging. for both the Heater and the A/C systems.
With an operator in the loader seat and the cab door Raise the lift arms and install an approved lift arm
open, turn the loader key switch to RUN (Standard Panel) support device. (See Engaging The Lift Arm Support
OR press the RUN/ENTER Button (Deluxe Panel), Device on Page 10-50-1.)
without starting the loader.
Figure 80-50-13 on Page 10-70-1.)
2
1
N-22284
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Checking The Electrical System (Cont'd)
Figure 80-50-15
1
P-21943
With a multimeter, check the voltage to the compressor

P-16554 clutch at the loader harness (Item 1) [Figure 80-50-17].
The voltage reading should be around 12 volts.

Disconnect the loader harness (Item 1) [Figure 80-50-
15] from the compressor clutch wire. If there is no power at the clutch, check the wiring
harness for broken wires.
Figure 80-50-16
If there is power at the clutch, reconnect the wiring
harness to the compressor clutch.
Figure 80-50-18
2
1
P-21943
With a multimeter, check the resistance to the

compressor clutch (Item 1) [Figure 80-50-16].
P-21914
If there is no resistance value, replace the compressor

clutch. Compressor Clutch Disassembly80-110-1 Disconnect the loader harness (Item 1) [Figure 80-50-
18] from the pressure switch (Item 2) [Figure 80-50-18].
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Figure 80-50-19
N-22258
Disconnect the thermostat wiring connector (Item 1)

P-21915 [Figure 80-50-21] from the loader wiring harness.
Figure 80-50-22
Using a multimeter check the loader wiring harness (Item
1) [Figure 80-50-19] for voltage.
The voltage should be around 12 volts.
If there is no voltage at the wiring harness, check the

Figure 80-50-20
N-22259
Check the loader harness (Item 1) [Figure 80-50-22] for

voltage. The voltage should be 12 volts.
1
P-21915
If there is voltage at the harness, check the resistance at

the pressure switch (Item 1) [Figure 80-50-20].
If there is no resistance value, check for low refrigerant

level. (See BASIC TROUBLESHOOTING on Page 80-
50-1.)
If a resistance value is observed, the pressure switch is

good.
Reconnect the loader harness to the pressure switch.
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Figure 80-50-23
N-22129

N-22259 [Figure 80-50-25] from the loader wiring harness.
Figure 80-50-26
If there is voltage at the wiring harness, check the
thermostat (Item 1) [Figure 80-50-23] for resistance.
The resistance value of the thermostat should be 10

Ohms at 68° F (20° C).
If there is no resistance value, replace the thermostat.

1
If there is a resistance value, check the blower fan.
Figure 80-50-24
N-22260
2

N-22130

Remove the access cover (Item 2) [Figure 80-50-24]

from the loader.
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Figure 80-50-27
1
N-22262
Remove the control panel and wiring harness from the

N-22260 cab [Figure 80-50-29].
Figure 80-50-30
resistance to the blower fan at the blower fan wiring
If there is no resistance value replace the blower fan.

1
If there is a resistance value check the climate controls at
the control panel inside the loader cab.
Figure 80-50-28
N-22265
1 Disconnect the loader wiring harness (Item 1) [Figure

80-50-30] from the blower switch.
Check the loader harness for voltage. The voltage should

be 12 volts.
1 If there is no voltage at the wiring harness, check the

N-22261

from the cab control panel.
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Figure 80-50-31
H 1
C
B
M
L
N-22264
At the loader cab, disconnect the loader harness (Item 1)

N-22288 [Figure 80-50-32] from the A/C switch.
Check the harness for voltage. The voltage should be 12

If there is voltage at the wiring harness, check the blower volts.
switch [Figure 80-50-31] for resistance.
With the switch in the OFF position, there should be zero harness for broken wires.
resistance between all terminals.
Figure 80-50-33
With the switch in the 1 position, there should be
resistance between C terminal and the B terminal. And
also between the C terminal and the L terminal frame
[Figure 80-50-31].
With the switch in the 2 position, there should be 1

also between the C terminal and the M terminal frame 2
[Figure 80-50-31].
With the switch in the 3 position, there should be

also between the C terminal and the H terminal frame
[Figure 80-50-31].
N-22289
If any of the above resistance tests fail, replace the
blower switch.
If there is voltage at the wiring harness, check the A/C
If the above resistance tests are good, check the A/C switch [Figure 80-50-33] for resistance.
switch.
With the switch in the OFF position there should be no
resistance between any of the three terminals on the A/C
switch.
With the switch in the ON position there should be

resistance between terminal (Item 1) [Figure 80-50-33]
and terminal (Item 2) [Figure 80-50-33].
If no resistance value is found, replace the A/C switch.
If a resistance value is found, check the potentiometer.

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Figure 80-50-34
A C
1 B
N-22290

N-22262 potentiometer [Figure 80-50-36] for resistance.
The resistance should be 10 K Ohm's between wire

The potentiometer will effect the A/C system and also terminal A and wire terminal C frame [Figure 80-50-36].
effect the operation of the heater.
If no resistance is found replace the potentiometer.
If heater valve does not open, or close, or the A/C does
not work, check the potentiometer. Figure 80-50-37
At the loader cab, disconnect the loader harness (Item 1)

[Figure 80-50-34] from the potentiometer.
Figure 80-50-35
N-22201
The white wire B, (Item 1) [Figure 80-50-37], on the

potentiometer, is a resister wire.
N-22263


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Figure 80-50-38
N-22175
N-22175
1
To check the resistance of the white wire, turn the

N-22175 potentiometer control (Item 1) [Figure 80-50-40] to the
full Heater position.
To check the resistance of the white wire, turn the Figure 80-50-41
potentiometer control (Item 1) [Figure 80-50-38] to the
full A/C position [Figure 80-50-38].
Figure 80-50-39
A C
A C
B
N-22290
B
Check the resistance between the wire terminal A and
N-22290 wire terminal B frame [Figure 80-50-41] should be
approximately 39 K Ohm's.
The resistance between the wire terminal A and wire Check the resistance between the wire terminal C and
terminal B frame [Figure 80-50-39] should be wire terminal B frame [Figure 80-50-41] should be
approximately 49 K Ohm's. approximately 49 K Ohm's.
Check the resistance between the wire terminal C and If the resistance is not found replace the potentiometer.
wire terminal B frame [Figure 80-50-39] should be
approximately 39 K Ohm's.
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BASIC TROUBLESHOOTING (CONT’D) If the hose is hot, the heater valve is leaking by, and
needs to be replaced.
Engine Coolant By-Passing The Heater Valve
Heater Valve Not Opening Or Closing
Figure 80-50-42 Device on Page 10-50-1.)
Figure 80-50-44
2 3
1
2 3
1
N-22284
N-22284
Push the A/C switch (Item 1) [Figure 80-50-42] to the
OFF position. Turn the fan switch (Item 2) [Figure 80-50-
42] to the High Speed position. Turn the temperature Push the A/C switch (Item 1) [Figure 80-50-44] to the
control (Item 3) [Figure 80-50-42] to the High A/C OFF position. Turn the fan switch (Item 2) [Figure 80-50-
position, with the loader ignition switch OFF. 44] to position 1. Turn the temperature control (Item 3)
[Figure 80-50-44] to the High A/C position, with the
Raise the operator cab. (See Raising The Operator Cab loader ignition switch OFF.
on Page 10-70-1.)
Connect the remote start tool to the loader. (See on Page 10-70-1.)
Start the loader and run at high idle, for ten minutes. REMOTE START on Page 10-90-1.)
Figure 80-50-43
P-21916
Check the heater hose (Item 1) [Figure 80-50-43] for

temperature.
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BASIC TROUBLESHOOTING (CONT’D)
Heater Valve Not Opening Or Closing (Cont’d)
Figure 80-50-45
P-21916
Place the remote start tool on the left fender of the

loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-50-45], as the key of
the remote start tool is turned to the ON position without
starting the loader. The heater valve should rotate. Place
a mark on the loader shaft.
Turn the key of the remote start tool to the OFF position
and remove the remote start tool from fender.
Lower operator cab.
Turn the temperature control (Item 3) [Figure 80-50-44]

to the High Heater position, with the loader ignition switch
OFF.
Raise the operator cab.
Place the remote start tool on the left fender of the

loader, so the heater valve can be clearly seen. Watch
the valve shaft (Item 1) [Figure 80-50-45], as the key of
the remote start is turned to the ON position without
starting the loader. The heater valve should rotate.
If it does not rotate, check the potentiometer for proper

function. (See Checking The Electrical System on Page
80-50-4.)
Replace the heater valve. (See Removal and Installation

on Page 80-220-1.)
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963 Bobcat Loader
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GENERAL AIR CONDITIONING SERVICE refrigerant in the system. Therefore, when checking the
GUIDELINES amount of oil in the system or replacing any system
component, the compressor must be run in advance to
Compressor Oil
insure return of oil to the compressor.
Figure 80-60-1
If the amount of refrigerant in the system has decreased,
charge the system. (See Charging Procedure With A
Manifold Gauge Set on Page 80-100-3 or See Charging
Procedure on Page 80-100-4)
1
Open the cab door and windows.
Run the blower at maximum speed.
Run the compressor for at least 20 minutes at 800-1200

RPM.
Remove the compressor from the loader. (See Removal

N-22243 Figure 80-60-2
The compressor (Item 1) [Figure 80-60-1] is factory filled

with 150-170 cc's of PAG oil (Poly Alkelene Glycol).
Unlike engine oil, it is not necessary to frequently check

or change the compressor oil.
It is necessary to check, replenish or replace the

compressor oil in the following cases: 1
1. When the evaporator, condenser or receiver-drier is
replaced.
2. When refrigerant has leaked from the system.

N-22245
3. When refrigerant is suddenly released from the
cooling cycle.
Figure 80-60-3
4. When any oil related problems occur in the cooling
cycle.
When one of the components (the evaporator, condenser

or receiver-drier) is replaced, one ounce (30 cc) of PAG
oil should be added for each component replaced.
If the A/C compressor is changed, no oil should be added

to the system, because the compressor comes factory
filled with oil.
NOTE: Only PAG oil should be used. Never mix R-12

and R-134a Oils.
Compressor Oil Check

P-16534A
The compressor oil should be checked as follows when

oil is being added to an in service loader. Remove the oil drain plug (Item 1) [Figure 80-60-2] and
drain the oil through the connectors and the oil drain hole
There is a close affinity between oil and refrigerant.
[Figure 80-60-3].
During normal operation, part of the oil circulates with the
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GENERAL AIR CONDITIONING SERVICE Figure 80-60-5
GUIDELINES (CONT’D)
Compressor Oil Check (Cont'd)

1
Figure 80-60-4
N-22245
1
Add new compressor oil through the suction side
N-22246
Installation: Add 150 -170 cc's of PAG oil.
Installation: Tighten the oil drain plug to 9.4-10.8 ft.-lbs. NOTE: The suction port on the compressor is marked
(13-15 Nm) torque. with an S and is the larger port on the
compressor.
NOTE: After draining the oil through the drain hole
and the connectors, extract the remaining oil Component Replacement And Refrigeration Leaks
through the discharge-side connector by
rotating the drive pulley (Item 1) [Figure 80-60- Figure 80-60-6
4] several times by hand.
Measure the drained oil in a measuring cylinder.
Check the oil for contamination, dirt, metal shavings, or

varnish color, discard the oil if contaminated.
NOTE: If metal shavings are found in the compressor

oil, replace the complete compressor
assembly.
1
P-21900
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.
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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 Check the fan motor ground and connectors. Repair the wiring or connec-
bad connection. tor.
3. Fan motor malfunc- Check the lead wires from the motor with a circuit tester. Replace Motor.
tion.
4. Resistor malfunc- Check resistor using a circuit tester. Replace resistor.
tion.
5. Fan motor switch Check power into and out of the fan switch. Replace Fan Switch.
malfunction.
Blower motor operates normally, but air flow is insufficient.

1. Evaporator inlet Check evaporator for plugging. Remove obstruction and
obstruction. clean evaporator fins with air
or water.
2. Air leak. Check to make sure air hoses are properly hooked to Louvers, and Repair or adjust.
air ducts.
3. Defective thermo- Check thermostat using a circuit tester. Replace thermostat.
stat. switch (frozen
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 in Repair any leaks and
refrigerant sight glass on receiver drier. recharge the refrigerant to the
correct level.
2. Excessive refriger- The high pressure side pressure will be high. Use refrigerant recovery
ant. equipment to capture excess
refrigerant. Charge to the cor-
rect refrigerant level.
The compressor does not operate at all, or operates improperly.

1. Loose drive belt. The belt is vibrating or oscillating. Adjust tension.
2. Internal compres- The compressor is locked up and the belt slips. Replace compressor.
sor malfunction.
Magnetic clutch related
3. Low battery volt- Clutch slips. Recharge the battery.
age.
4. Faulty coil. Clutch slips. Replace the magnetic clutch.
5. Oil on the clutch Clutch slips. Replace or clean the clutch
surface. surface.
6. Open oil. 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 Clutch will not engage. Inspect the ground and connections. Repair.
poor ground.
8. Wiring harness Test the conductance of the pressure switch, thermostat, relay, etc. Check operation.
components.
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SYSTEM TROUBLESHOOTING CHART (CONT'D)
Gauge Pressure Related Troubleshooting
Normal compressor suction (low side) and discharge (high side) pressure at ambient temperatures of 86-96 degrees F
(30-38 degrees C) and compressor speed of approximately 2000 RPM are:
High pressure side pressure: 210-265 PSI
Low pressure side pressure:15-33 PSI
As a rule of thumb the high side pressure will be around eight times greater then the low side pressure.

Low pressure side The low pressure side pressure normally becomes too high when
Too high. the high pressure side pressure is too high. As this is explained
below, the following inspection is only used when the low pressure
side is too high.
1. Expansion valve Frost is present on the suction hose. Replace expansion valve.
opens too far.
2. Defective compres- The high and low pressure side gauge pressures equalize when Replace compressor.
sor. the magnetic clutch is disengaged.
Low pressure side
Too low.
1. Low refrigerant The high side pressure will be low and bubbles may be present in Repair any leaks and
charge. sight glass on receiver drier. recharge the refrigerant to the
correct level.
2. Clogged or closed The expansion valve’s inlet side is frosted. Moisture or other con- Clean or replace the expan-
expansion valve. taminants can be the cause. sion valve.
3. Restriction Frost on the line between drier and expansion valve. A negative low Flush system or replace hose.
between drier and pressure reading may be shown.
expansion valve.
4. Thermostat The evaporator is frozen. Adjust thermostat’s temp. set-
malfunction. ting or probe placement or
replace thermostat.
High pressure side
Too high.
1. Poor condenser Dirty or clogged condenser fins. Condenser fans not operating. Clean fins, and/or repair the
performance. fan.
2. Excessive The high pressure side pressure will be high. Use refrigerant recovery
refrigerant. equipment to capture excess
refrigerant. Charge to the cor-
rect refrigerant level.
3. Excessive oil The high pressure side will be high. Evacuate system. Remove oil
charge from condenser and compres-
sor. Measure oil from com-
pressor 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 be low. Evacuate and flush system
condenser or high replacing defective parts.
pressure line.
High pressure side
Too low.
1. Low refrigerant The high side pressure will be low and bubbles may be present in Repair any leaks and
charge. sight glass on receiver drier. recharge the refrigerant to the
correct level.
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SYSTEM TROUBLESHOOTING CHART (CONT’D)
Gauge Pressure Related Troubleshooting (Cont'd)

System pressures
Equal.
1. Clutch not operat- See magnetic clutch related topics above.
ing.
2. Compressor not Equal high and low pressures. Replace compressor.
pumping.
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TEMPERATURE/PRESSURE
Chart
NORMAL EVAPORATOR RANGE NORMAL CONDENSER RANGE

TEMP F. PSIG TEMP F. PSIG
16 15.69 93 110.20
18 17.04 94 112.10
20 18.43 95 114.10
22 19.87 100 124.30
24 21.35 102 128.50
26 22.88 104 132.90
28 24.47 106 137.30
30 26.10 108 141.90
32 27.79 110 146.50
34 29.52 112 151.30
36 31.32 114 156.10
38 33.17 116 161.10
40 35.07 118 166.10
42 37.03 120 171.30
44 39.05 122 176.60
45 40.09 124 182.00
50 45.48 126 187.50
55 51.27 128 193.10
60 57.47 130 198.90
65 64.10 135 213.70
70 71.19 140 229.40
75 78.75 145 245.80
80 86.80 150 263.00
85 95.40 155 281.10
90 104.40 160 300.10
91 106.30 165 320.10
92 108.20 170 340.80
Evaporator
Pressures represent gas temperatures inside the coil, not the coil surface. For an estimate of the temperature of the air
coming off the coil add 8-10 degrees F. to the temperature on the chart.
Condenser
Temperatures are not ambient temperatures but condensing temperatures. Add 40 degrees F. to the ambient temperature
to get the condensing temperature and then refer to the pressure chart to see appropriate pressure for ambient
temperature.
Example: Ambient Temperature=90 degrees F.

90 degrees F.
+40 degrees F.
130 degrees F. condenser temperature=200 psig
Conditions and pressures will vary from system to system.
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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:
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SYSTEM CHARGING AND RECLAMATION
Reclamation Procedure
WARNING
Figure 80-100-1
In the event of a leakage, wear safety goggles.
Escaping refrigerant can cause severe injuries to
1 eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
NOTE: This test is run with the loader engine OFF,

and the A/C switch in the OFF position.
Figure 80-100-3
N-23024
NOTE: Before reclaiming a refrigeration system, it is

recommended to identify the type of
refrigerant that is in the A/C system and if it is
pure enough to use. The tool MEL 1592,
Refrigerant Identifier (Item 1) [Figure 80-100-1]
will determine, the kind of refrigerant and any
possible harmful or dangerous substances
that may be present in the system. Thus
P-21917
preventing mixing of dangerous material with
your reclaimed R-134a in your reclaimer, and
further contamination to other A/C systems Connect the Refrigerant Identifier to the low pressure
that are reclaimed and charged from your hose [Figure 80-100-3].
MEL 1581 Recovery/Recycling/Recharging
Machine. Connect the Refrigerant Identifier to its power source.
Figure 80-100-2 Follow the steps displayed on the refrigerant identifier

screen.
Allow two minutes for the refrigerant identifier to display

the type of refrigerant and air content. An alarm will
sound if potentially flammable hydrocarbons are present
and will also indicate on the visual display.
1 Disconnect the refrigerant identifier from the loader A/C.
If the refrigerant is dangerous or flammable, it must be

evacuated from the A/C system into a separate container
and properly and safely disposed of.
If R134a is found, evacuate the system.

P-21900
Remove the protective cap (Item 1) [Figure 80-100-2]

from the low pressure hose.
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SYSTEM CHARGING AND RECLAMATION (CONT’D) Figure 80-100-5
Reclamation Procedure (Cont'd)

1
IMPORTANT: Only A/C trained technicians should
2
perform the reclaiming and recharging
procedure.
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
P-21918
frostbite if it contacts the skin.
• Gaseous 134A becomes lethal (phosgene) gas
when it contacts open flame or very hot Connect the Red hose (Item 1) [Figure 80-100-5] to the
substances. high pressure port and open the valve.
• NEVER SMOKE when there is the possibility of
even small amounts of 134A in the air. Connect the Blue hose (Item 2) [Figure 80-100-5] to the
Any servicing work that involves release or addition low pressure port and open the valve.
of 134A to the system must be done by a competent
refrigeration dealer who has the proper equipment, Figure 80-100-6
knowledge, and experience to service refrigeration
equipment.
W-2373-0500
Figure 80-100-4
N-22292
Turn the reclaimer unit [Figure 80-100-6] to the ON

position and follow the on screen instructions.
N-22291
Use an approved recovery/charging unit [Figure 80-100-

4] to evacuate the system.
Connect the reclaimer to the loader A/C charge ports.
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Reclamation Procedure (Cont'd)
Figure 80-100-7
1
P-21953
Check to see that the hand valves (Item 1) [Figure 80-

N-22381 100-8] are closed on the manifold gauge set.
If there is any refrigerant in the A/C system, it must be

NOTE: The reclaimer unit, has a complete step by recovered by an approved A/C reclamation procedure.
step set of instructions [Figure 80-100-7] to (See Reclamation Procedure on Page 80-100-1.)
follow for reclamation and recharging of the
A/C system. A trained technician should Connect the gauges to the loader A/C charge ports.
follow these instructions as they may very
slightly depending on the model and brand of Figure 80-100-9
reclaimer used.
Charging Procedure With A Manifold Gauge Set
Raise the loader lift arms and install an approved lift arm
Raise the operator cab. (See Raising The Operator Cab 2

on Page 10-70-1.)
1
WARNING P-21954

Escaping refrigerant can cause severe injuries to Connect the Red hose (Item 1) [Figure 80-100-9] to the
eyes. In contact with a flame, R134a refrigerant gives high pressure port and open the valve.
a toxic gas.
W-2371-0500
Connect the Blue hose (Item 2) [Figure 80-100-9] to the
low pressure port and open the valve.
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SYSTEM CHARGING AND RECLAMATION (CONT’D) Charging Procedure
Charging Procedure With A Manifold Gauge Set Figure 80-100-12

(Cont’d)
Figure 80-100-10
1
1
P-21954
P-21955 Note vacuum pressure indicated on the low pressure

(Blue) gauge (Item 1) [Figure 80-100-12]. Let stand for
5-10 min. and recheck the pressure for changes.
Connect the Yellow hose (Item 1) [Figure 80-100-10] to
the vacuum pump. If the pressure drops, this may be an indication of a leak
in the A/C system.
Figure 80-100-11
Determine the problem with the A/C system and repair it.
Figure 80-100-13
P-21956
1
Start the vacuum pump and open ISO-valve (Item 1)

P-21957
[Figure 80-100-11] on the vacuum pump.
Run the vacuum pump for at least 5-10 minutes to insure A thermistor vacuum gauge (Item 1) [Figure 80-100-13]
that a vacuum has been pulled on the system. can be used to determine the critical vacuum level during
evacuation. It is a solid state instrument that constantly
Close the ISO-valve (Item 1) [Figure 80-100-11] (which monitors and visually indicates the vacuum level.
isolates the vacuum pump from the A/C system) and turn
OFF the vacuum pump. The thermistor vacuum gauge is used with the vacuum
pump [Figure 80-100-13].
Start the vacuum pump and open ISO-valve on the

vacuum pump.
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Charging Procedure (Cont’d)
Figure 80-100-14
2
1
1
P-21959
2
Open the valve on the refrigerant container (Item 1)

P-21958 [Figure 80-100-15] and open the low pressure hand
valve (Blue) (Item 2) [Figure 80-100-15] on the manifold
gauge set. Allow the vacuum to pull in the refrigerant until
Be sure that both hand valves, and both charge port the pressure stabilizes.
valves are open.
Run the vacuum pump for at least 45 minutes to insure

that all the moisture is boiled out of the system.
Stop the vacuum pump and close the ISO-valve on the

vacuum pump.
Close both hand valves on the manifold gauge set and

remove the yellow hose from the vacuum pump that goes
to the manifold gauge set.
Remove the vacuum pump and thermistor vacuum

gauge.
Place a refrigerant container with R134a (Item 1) [Figure

80-100-14] on a charging scale (Item 2) [Figure 80-100-
14] and zero out the scale.
Connect the yellow hose (Item 3) [Figure 80-100-14]

from the manifold gauge set to the valve on the
refrigerant tank.
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SYSTEM CHARGING AND RECLAMATION (CONT’D)
Charging Procedure (Cont'd)
Figure 80-100-16
2 1
N-22284

Press the A/C switch (Item 1) [Figure 80-100-16] to ON

position.
Turn fan switch (Item 2) [Figure 80-100-16] to HIGH

position.

on Page 10-70-1.)
Start loader engine, with the remote start switch, and run
at medium speed.
Watch the scale and run system until the predetermined

amount of refrigerant is added to the A/C system.
The A/C system holds 2.75 lbs. (1,24 kg) of

refrigerant.
Turn OFF the valve on the refrigerant container, and hand

valves on the manifold gauge set.
Turn OFF the engine, and remove the A/C charging

equipment from the loader.
Lower the operator cab. (See Lowering The Operator

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COMPRESSOR Figure 80-110-2
WARNING
Escaping refrigerant can cause severe injuries to 1
eyes. In contact with a flame, R134a refrigerant gives
a toxic gas.
W-2371-0500
Figure 1 P-21961
2 Remove the compressor mount bolt (Item 1) [Figure 80-

110-2].
1 Remove the compressor from the loader.
Compressor Clutch Disassembly
Figure 80-110-3
P-21960
1
on Page 10-70-1.)
Evacuate the A/C system. (See SYSTEM CHARGING

AND RECLAMATION on Page 80-100-1.) N-22244
Remove the compressor adjustment bolt (Item 1) [Figure

1]. Remove the center armature bolt (Item 1) [Figure 80-
110-3].
Installation: Tighten the compressor adjustment bolt to
34 ft.-lbs. (46 Nm) torque. Installation: Tighten the armature bolt to 8-10 ft.-lbs.
(12-14 Nm) torque.
Remove the compressor belt.
Mark the compressor hoses for proper installation.
Remove the compressor hoses (Item 2) [Figure 1] from

the compressor.
Installation: Tighten the compressor hoses to 22 ft.-lbs.

(29,8 Nm) torque.
Cap and plug the compressor hoses and the fittings with
with the proper A/C caps and plugs.
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COMPRESSOR (CONT’D) Figure 80-110-6
Compressor Clutch Disassembly (Cont'd)
Figure 80-110-4
N-22278
Turn the bolts into the three 8 mm holes (Item 2) [Figure

N-22277 80-110-4] on the armature plate as shown in Fig. [Figure
80-110-6].
To remove the armature plate (Item 1) [Figure 80-110-4] Figure 80-110-7

from the clutch face, you must make an armature plate
puller.
Figure 80-110-5
1.32”
1
1.32”
1.32”
N-22279
1 2
Attach a slide hammer puller (Item 1) [Figure 80-110-7]
N-22275 to the armature puller disk.
Remove the armature plate from the compressor clutch.

The armature plate puller, (Item 1) [Figure 80-110-5] can
be constructed by drilling three 10 mm holes in a flat
circular plate, located 1.32 inches apart [Figure 80-110-
5].
Attach the puller to the armature plate using three 8 mm

bolts (Item 2) [Figure 80-110-5].
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Figure 80-110-8
N-22369
Install the pulley puller tool MEL 1595 on the compressor

N-22280 pulley [Figure 80-110-10].
Figure 80-110-11
Remove the shims (Item 1) [Figure 80-110-8] from either
the armature shaft or armature plate.
Installation: Insure that the clutch has the correct

clearance by adding the shims (Item 1) [Figure 80-110-
8].
The specified clearance for the clutch is 0.01-0.02 in.

(0.3-0.6 mm). Adjusting shims are available in the
following thicknesses:
0.0039 in. (0,1 mm)
0.0118 in. (0,3 mm)
0.0197 in. (0,5 mm)
Figure 80-110-9 N-22370
Remove the pulley from the compressor [Figure 80-110-

11].
1
N-22283

the pulley assembly.
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Figure 80-110-12
N-22374
Remove the coil lead wire (Item 1) [Figure 80-110-14]

N-22371 from the wire holder on the compressor.
Figure 80-110-15
The pulley assembly and bearing [Figure 80-110-12]
must be replaced as a complete unit.
Figure 80-110-13
N-22372
Remove the three coil mount bolts (Item 1) [Figure 80-

N-22373 110-15] from the compressor.
Installation: Tighten the mount bolts to 2.9-4.3 ft.-lbs. (4-

Slide the wire grommet (Item 1) [Figure 80-110-13] from 6 Nm) torque.
the wire holder.
Remove the coil from the compressor.
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COMPRESSOR (CONT’D)
Figure 80-110-16
N-22375
The compressor [Figure 80-110-16] must be replaced as

a complete unit.
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CONDENSER Figure 80-120-2
WARNING
In the event of a leakage, wear safety goggles. 1
a toxic gas.
W-2371-0500
Figure 80-120-1 P-21899
Mark the two A/C hoses (Item 1) [Figure 80-120-2] for

proper installation.
1
Disconnect the two hoses from the condenser.
Cap and plug the hoses and the condenser fittings with
the proper A/C caps and plugs.
Figure 80-120-3
N-22708
Remove the refrigerant from the A/C system. (See 2

SYSTEM CHARGING AND RECLAMATION on Page 80-
100-1.)
Open the rear door of the loader. 1
Open the rear grill on the loader.
Remove the retaining clip (Item 1) [Figure 80-120-1] P-21962

from the condenser mount bracket.
Lift the rear of the condenser, and pull toward the left
upright of the loader til the mounting pin (Item 1) [Figure
80-120-3] slides out of bracket (Item 2) [Figure 80-120-
3].
Remove the condenser from the loader.
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CONDENSER (CONT’D)
Figure 80-120-4
N-22708
Installation: When installing the condenser, be sure to

start with the left side first, sliding the condenser back
toward the right rear upright, compressing the spring far
enough to insert the retaining clip (Item 1) [Figure 80-
120-4] through the hole in the pin.
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RECEIVER/DRIER Figure 80-130-2
WARNING 1

a toxic gas.
W-2371-0500 3
Figure 80-130-1 P-21963
Note the flow direction on the drier (Item 1) [Figure 80-

130-2] for proper installation.
Remove the two A/C hoses (Item 2) [Figure 80-130-2]

from the receiver/drier.
Cap and plug the hoses and the receiver/drier fittings

1
Loosen the hose clamp (Item 3) [Figure 80-130-2] that
holds the receiver/drier to the mount.
P-21900 Remove the receiver/drier from the loader.
NOTE: When replacing a receiver/drier in an A/C

Raise the loader lift arms and install an approved lift arm system 1 fl. oz. (30 cc) of PAG oil must be
support device. (See Engaging The Lift Arm Support added to the system when recharging.
Figure 80-130-3
on Page 10-70-1.)
1
Remove the refrigerant from the A/C system. (See
SYSTEM CHARGING AND RECLAMATION on Page
80-100-1.)
Mark the A/C hoses (Item 1) [Figure 80-130-1] for proper

installation.
Both fittings on the drier are the same size, so the hoses
can be hooked up incorrectly.
N-22687

from the receiver/drier mount bracket.
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PRESSURE RELIEF VALVE
Figure 80-140-1
N-22205
The pressure relief valve (Item 1) [Figure 80-140-1] is

located on the receiver drier assembly.
Figure 80-140-2
N-22206
The pressure relief valve [Figure 80-140-2] is designed

to open and release the A/C charge if the pressure
reaches 535 PSI (3689 kPa)
This will cause the A/C system to shut down, saving the
compressor.
The Pressure Relief Valve is a secondary protection

device in the A/C system, with the Pressure Switch
shutting down the system at 384 PSI (2648 kPa).
NOTE: If a Pressure Relief Valve is found open, check

the A/C system for problems. Replace the
complete receiver/drier unit.
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PRESSURE SWITCH Figure 80-150-2
WARNING
eyes. In contact with a flame, R134a refrigerant gives 1
a toxic gas.
W-2371-0500
Figure 80-150-1 P-21900
Remove the pressure switch (Item 1) [Figure 80-150-2]

from the A/C high pressure hose.
Remove the pressure switch from the loader.
Shreader Valve Removal And Installation
1
Figure 80-150-3
P-21914
1

on Page 10-70-1.) N-22166
Disconnect the loader wire harness (Item 1) [Figure 80-

The shreader valve (Item 1) [Figure 80-150-3] is located
150-1] from the pressure switch wire harness.
in the A/C high pressure hose and is located under the
pressure switch.
NOTE: The pressure switch can be changed without
evacuating the A/C system. Raise the loader lift arms and install an approved lift arm
on Page 10-70-1.)
Remove the refrigerant from the A/C system. (See
SYSTEM CHARGING AND RECLAMATION on Page
80-100-1.)
Remove the pressure switch.
With a tire valve core removal tool, remove the valve core
from the hose.
Replace with a new core.
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EVAPORATOR/HEATER UNIT Figure 80-160-3
Figure 80-160-1
N-22129

N-22122 [Figure 80-160-3] from the loader wiring harness.
Figure 80-160-4

on Page 10-70-1.)

AND RECLAMATION on Page 80-100-1.)
1
At the rear of the cab, disconnect the thermostat wiring
Figure 80-160-2
N-22119

2 4].
WARNING
1 In the event of a leakage, wear safety goggles.
a toxic gas.
N-22130
W-2371-0500

Remove the access cover (Item 2) [Figure 80-160-2]

from the loader.
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EVAPORATOR/HEATER UNIT (CONT’D) Figure 80-160-7
Figure 80-160-5
1
1
N-22128
Remove the heater hoses (Item 1) [Figure 80-160-7]

N-22120 from the heater coil.
Installation: Tighten the Heater hoses to 22 ft.-lbs. (29,8

Remove the two mounting nuts (Item 1) [Figure 80-160- Nm) torque.
5].
Remove the evaporator/heater unit from the loader
Figure 80-160-6
Figure 80-160-8
1 1
1
1
N-22126
Remove the Evaporator/Heater Unit from the rear of the

N-22065
cab. Place it on the fenders of the loader supported by
blocking [Figure 80-160-6].
Remove the eight mount bolts (Item 1) [Figure 80-160-8]
Remove the two A/C hoses (Item 1) [Figure 80-160-6] from the Evaporator/Heater Unit rear cover.
from the expansion valve.
Remove the rear cover from the unit.
Installation: Tighten the A/C hoses to 22 ft.-lbs. (29,8
Nm) torque.
Cap and plug the hoses and the expansion valve fittings
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THERMOSTAT Figure 80-170-3
Figure 80-170-1
1
N-22072
Remove the thermostat from the unit [Figure 80-170-3].

N-22069
Figure 80-170-4
NOTE: The thermostat can be changed without

evacuating the A/C system, or removing the A
evaporator/heater unit from the loader.
Remove the rear cover from the evaporator/heater unit. B

C
Remove the two thermostat mount bolts (Item 1) [Figure
80-170-1], and remove the wiring harness and grommet
(Item 2) [Figure 80-170-1] from the evaporator/heater 1
housing.
Figure 80-170-2
N-22072
The wire connector (Item 1) [Figure 80-170-4] can be

changed. The wiring position and color in the connector is:
A Blue
B White
1 C Black
N-22071
Remove the thermostat probe (Item 1) [Figure 80-170-2]

from the A/C evaporator coil.
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EXPANSION VALVE Figure 80-180-2
WARNING
a toxic gas. 2
W-2371-0500
Figure 80-180-1 N-22073A
Remove the two evaporator fittings (Item 1) [Figure 80-

180-2] from the expansion valve.
Installation: Tighten the two evaporator fittings to 22 ft.-

lbs. (29,8 Nm) torque.
1
Remove the two mount bolts (Item 2) [Figure 80-180-2].
Remove the expansion valve from the loader.
Figure 80-180-3
N-22150
NOTE: The expansion valve can be changed without

removing the evaporator/heater unit from the
loader. 1


on Page 10-70-1.)
N-22074A
Cap and plug the evaporator tubelines (Item 1) [Figure
Remove the two A/C hoses (Item 1) [Figure 80-180-1] 80-180-3] and the expansion valve fittings with the proper
from the expansion valve. A/C caps and plugs.
Installation: Tighten the two A/C hose fittings to 22 ft.-

Cap and plug the hoses and the expansion valve fittings
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EXPANSION VALVE (CONT’D)
Figure 80-180-4
1
1
N-22074A

from the expansion valve mount.
Remove the expansion valve mount from the unit.
Figure 80-180-5
N-22085
The expansion valve [Figure 80-180-5] is replaced as a

complete unit.
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EVAPORATOR Figure 80-190-3
Figure 80-190-1
N-22075
1 Remove the two mount bolts (Item 1) [Figure 80-190-3]

N-22073 from the mount plate (Item 2) [Figure 80-190-3].
Remove the mount plate from the unit.

support device. (See Engaging The Lift Arm Support Figure 80-190-4

on Page 10-70-1.)

Remove the evaporator/heater unit from the back of the

cab. ((See Removal And Installation on Page 80-160-1.)
1
Remove the expansion valve (Item 1) [Figure 80-190-1]
from the unit. (See Removal And Installation on Page 80-
180-1.)
N-22076
Figure 80-190-2
Remove the two retaining clips (Item 1) [Figure 80-190-

4] that connect the evaporator coil, to the heater coil.
Remove the evaporator coil from the unit.
N-22074
Remove the expansion valve mount bracket (Item 1)

[Figure 80-190-2] from the unit.
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EVAPORATOR (CONT’D)
Figure 80-190-5
N-22078
Inspect the evaporator coil [Figure 80-190-5] for leaks,

and replace as needed.
Clean with low water or air pressure.
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HEATER COIL Figure 80-200-2
Removal And Installation With A/C

1
Figure 80-200-1
N-22086

N-22128 from the heater coil at the expansion valve end of the
unit.
Raise the lift arms and install an approved lift arm Figure 80-200-3

on Page 10-70-1.)

cab. (See Removal And Installation on Page 80-160-1.)
Mark the heater hoses (Item 1) [Figure 80-200-1] for

proper installation. 1
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil with hydraulic caps N-22087
and plugs to prevent oil loss from the system.
Installation: Tighten the two heater hose fittings to 22 ft.- Remove the two retaining clips (Item 1) [Figure 80-200-
lbs. (29,8 Nm) torque. 3] that connect the evaporator coil, to the heater coil.
Remove the rear cover from the evaporator/heater unit.

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HEATER COIL (CONT’D) Removal And Installation Without A/C
Removal And Installation With A/C (Cont'd) Figure 80-200-6
Figure 80-200-4
1 1 1
2
N-22128
N-22089
Remove the three mount bolts (Item 1) [Figure 80-200-4] Device on Page 10-50-1.)
and remove the mount plate from the end of the unit.
Remove the two mount bolts (Item 2) [Figure 80-200-4] on Page 10-70-1.)
that support the heater coil tubelines to the unit.
Remove the heater unit from the back of the cab. (See
Remove the heater coil from the unit. Removal And Installation on Page 80-160-1.)
Figure 80-200-5 Mark the heater hoses (Item 1) [Figure 80-200-6] for
proper installation.
Remove the two heater hoses from the heater coil.
Cap the hoses and the heater coil with hydraulic caps
Installation: Tighten the two heater hose fittings to 22 ft.-

Remove the rear cover from the evaporator/heater unit.

N-22090
The heater coil [Figure 80-200-5] can be cleaned with

low air or water pressure.
If the heater coil needs replacement it must be replaced

as complete unit.
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HEATER COIL (CONT’D)
Removal And Installation Without A/C (Cont’d)
Figure 80-200-7
N-22093

and remove the mount plate from the end of the unit.

that support the heater coil tubelines to the unit.
Figure 80-200-8
N-22094

from the heater coil.
Remove the heater coil from the unit.
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HEATER/AC FAN Figure 80-210-2
Figure 80-210-1
1
1
N-22097
NOTE: On some early evaporator/heater units the

N-22096 metal was not cut out, so the blower wiring
harness (Item 1) [Figure 80-210-2] could not
be removed without removing the wiring
Raise the lift arms and install an approved lift arm connector.
Device on Page 10-50-1.) Figure 80-210-3

on Page 10-70-1.)

cab. (See Removal And Installation on Page 80-160-1.) 1
NOTE: The heater/AC fan assembly can be removed

from the evaporator/heater unit without
disconnecting the heater or A/C plumbing.
The unit is removed here for photo clarity.
Remove the grommet (Item 1) [Figure 80-210-1] from

the side of the evaporator/heater unit.
N-22098
If the metal is not cut out on the housing, mark the area
(Item 1) [Figure 80-210-3] and remove it with a metal
shears.
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HEATER/AC FAN (CONT’D) Disassembly And Assembly
Figure 80-210-4
2
1
1 1
2 N-22102
N-22099
Remove the eight mount bolts (Item 1) [Figure 80-210-6]
from the blower wheel cover.
Remove the blower fan wiring harness and grommet
(Item 1) [Figure 80-210-4] from the unit. Remove the blower wheel cover from the fan housings.
Figure 80-210-5 Remove the four mount bolts (Item 2) [Figure 80-210-6]
from the fan motor mount.
1 Remove the fan motor mount.
Remove the fan motor assembly from the housing.
Figure 80-210-7
N-22100

from the blower fan housing. 1
2
Remove the blower fan housing from the evaporator/
heater unit.
N-22107
Check the blower housing (Item 1) [Figure 80-210-7] and

fan motor mount (Item 2) [Figure 80-210-7] for wear and
replace as needed.
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HEATER/AC FAN (CONT’D) Figure 80-210-10
Figure 80-210-8
1
1
N-22110
2
Figure 80-210-11
N-22108
Remove the outside rings (Item 1) [Figure 80-210-8] and

fan wheel covers (Item 2) [Figure 80-210-8] from the fan
motor and blower wheels.
Figure 80-210-9
N-22112
Remove the outside blower wheel clamp (Item 1) [Figure

80-210-10] & [Figure 80-210-11] from the blower wheel.
Figure 80-210-12
N-22109
Inspect the end rings and fan wheel covers for wear and
replace as needed [Figure 80-210-9].
N-22111
Remove the inside blower wheel clamp (Item 1) [Figure

80-210-12] from the blower wheel.
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HEATER/AC FAN (CONT’D) Figure 80-210-15
Figure 80-210-13
1 1
2
N-22104
Remove the plastic wedge (Item 1) [Figure 80-210-14] &

N-22116 [Figure 80-210-15] from the center of the blower fan
motor wiring connector.
Remove the blower wheel (Item 1) [Figure 80-210-13] Figure 80-210-16

and inside ring (Item 2) [Figure 80-210-13] from the
blower fan motor shaft.
Repeat the procedure for the other blower wheel. 1

Wire Connector Removal and Installation
Figure 80-210-14
1 1
1
1 N-22105
With a pointed screw driver lightly press in on the tabs

(Item 1) [Figure 80-210-16] and remove the individual
wires from the connector.
N-22103
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HEATER/AC FAN (CONT’D)
Wire Connector Removal and Installation (Cont'd)
Figure 80-210-17
N-22106
The wiring code for the blower fan connector [Figure 80-
210-17] is:
Number on Connector Wire Color

1 Orange
2 Red
3 Yellow
4 Black
5 Open
6 Open
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HEATER VALVE Figure 80-220-3
Removal and Installation
Figure 80-220-1
1
1
P-21966
Disconnect the loader wiring harness (Item 1) [Figure

P-21965 80-220-3] from the heater valve.

220-1] from the heater valve. Figure 80-220-4
Cap the hoses and the heater valve with hydraulic caps
Figure 80-220-2
1
1
N-22155

from the heater valve actuator.
P-21964

from the heater valve mount bracket.
Remove the heater valve and mount bracket from the

loader.
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HEATER VALVE (CONT’D) Figure 80-220-7
Figure 80-220-5
2 1
N-22158
Remove the mount plate (Item 1) [Figure 80-220-7] from

N-22156 the heater valve bracket.
Figure 80-220-8
Remove the actuator (Item 1) [Figure 80-220-5] and the
three mounting spacers (Item 2) [Figure 80-220-5] from
the heater valve mount plate.
Figure 80-220-6
N-22159
1

8] from the heater valve.
N-22157
Remove the three mounting bolts (Item 1) [Figure 80-

220-6] from the heater valve mount plate.
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HEATER VALVE (CONT’D)
Figure 80-220-9
N-22160
Remove the heater valve mount bracket (Item 1) [Figure

80-220-9] from the heater valve.
Replace the parts as needed.
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963 Bobcat Loader
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SPECIFICATIONS
CONVERSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-70-1-1
Decimal And Millimeters Equivalents. . . . . . . . . . . . . SPEC-70-1-1
U.S. To Metric Conversion . . . . . . . . . . . . . . . . . . . . . SPEC-70-1-1 SAFETY &
MAINTENANCE
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-1
Camshaft And Thrust Washer . . . . . . . . . . . . . . . . . . SPEC-20-1-6
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-4
Crankshaft Re-Grind Data . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-5
Connecting Rods And Bearings. . . . . . . . . . . . . . . . . SPEC-20-1-3
Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-6
Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-1 DRIVE
Cylinder Liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-6 SYSTEM
Engine Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-10
Exhaust Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-1
Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-8
Fuel Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-7
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-7
Fuel Lift Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-1 ELECTRICAL
Intake Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-2 SYSTEM &
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-6 ANALYSIS
Oil Pump, Gear And Relief Valve. . . . . . . . . . . . . . . . SPEC-20-1-8
Pistons And Piston Rings. . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-3
Rocker Shaft, Rockers And Bushings . . . . . . . . . . . . SPEC-20-1-2 ENGINE
Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-6 SERVICE
Timing Case And Timing Gears . . . . . . . . . . . . . . . . . SPEC-20-1-7
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-8
Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-1
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1-2 SPECIFICATIO
Water Pump And Thermostat. . . . . . . . . . . . . . . . . . . SPEC-20-1-9
HYDRAULIC CONNECTION SPECIFICATIONS . . . . . . SPEC-50-1-1

Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1-2 SPECIFICATIONS
O-ring Flare Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1-3
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . SPEC-50-1-1
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1-5
Straight Thread O-ring Fitting . . . . . . . . . . . . . . . . . . SPEC-50-1-1
Tubelines And Hoses. . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1-1
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONSSPEC-60-1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-60-1-1
963 Bobcat Loader

SPEC-01 Service Manual
607 of 640
SPECIFICATIONS (CONT’D)
LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1-1

Loader Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1-1
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1-4
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1-2
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1-3
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1-4
LOADER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1-1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1-1
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . SPEC-40-1-1

Torque For General Metric Bolts . . . . . . . . . . . . . . . . SPEC-40-1-2
Torque For General SAE Bolts. . . . . . . . . . . . . . . . . . SPEC-40-1-1
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SPEC-02 Service Manual
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LOADER SPECIFICATIONS
Loader Dimensions
• Dimensions are given for loader equipped with standard tires and dirt bucket and may vary with other bucket types.
All dimensions are shown in inches. Respective metric dimensions are given in millimeters inclosed by parentheses.
• Where applicable, specification conform to SAE or ISO standards and are subject to change without notice.
B-16363
Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the
loader parts.
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SPEC-10-1 Service Manual
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LOADER SPECIFICATIONS (CONT’D)
Performance
963
Rated Operating Capacity (SAE) 3000 lbs. (1361 kg)
Tipping Load (SAE) 6000 lbs. (2722 kg)
Operating Weight (SAE) 9900 lbs. (4491 kg)
SAE Breakout Force-Lift 6050 lbf. (26910 N)
-Tilt 6300 lbf. (28022 N)
Axle Torque 9200 ft.-lbs. (12475 Nm)
Travel Speed (Low) 5.2 MPH (8.3 km/hr.)
(High) 9.0 MPH (14.5 km/hr.)
Controls
Vehicle Steering Direction and speed controlled by two hand levers.

Loader Hydraulics
Lift and Tilt Controlled by separate foot pedals or Opt. Advanced Hand Controls.
Front Auxiliary Controlled by electrical switch on RH steering lever.
Rear Auxiliary (Option) Controlled by electrical switch on LH steering lever.
Engine Hand lever throttle: Key-type starter switch and shutdown.
Starting Aid Optional ether start aid - Automatically activated.
Service Brake Two independent hydrostatic systems controlled by two hand operated steering
levers.
Parking Brake Hydraulic Disc, foot operated pedal.
Engine
Make/Model Perkins/1004.40 t Turbo-Charged

Fuel/Cooling Diesel/Liquid
Horsepower (ISO) Gross: 105 (78,3 kW)
Maximum Governed RPM 2200 RPM
Torque @ 1600 RPM (ISO) Gross: 308 lbf.-ft. (418Nm)
Number of Cylinders 4
Displacement 243 cu. in. (3,99 L)
Bore/Stroke 3.94/5.00 (100/127)
Lubrication Pressure System W/Filter
Crankcase Ventilation Open System
Air Cleaner Dry replaceable cartridge with safety element
Ignition Compression
Low Idle 950-1000 RPM
High Idle 2335-2400 RPM
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Hydraulic System
963
Pump Type Engine driven, Gear type
Pump Capacity 26.2 GPM (99,2 L/min.) @3300RPM
Lift & Tilt Relief Settings 3000 PSI (207 Bar)
System Relief at Quick Couplers 3350 PSI (231 Bar)
Hydraulic Filter Replaceable #3 micron element
Hydraulic Cylinders Double-acting
Tilt cylinder has cushioning feature on dump & roll back
Bore Diameter: Lift Cylinder (2) 3.00 (76,2)
Tilt Cylinder (2) 3.00 (76,2)
Rod Diameter: Lift Cylinder (2) 1.75 (44,5)
Tilt Cylinder (2) 1.50 (38,1)
Stroke: Lift Cylinder (2) 31.81 (808,0)
Tilt Cylinder (2) 21.11 (536,2)
Control Valve 3-Spool, open center type w/float detent on lift and hydraulic bucket positioning.
Electronically controlled auxiliary spool.
Fluid Type Bobcat Fluid (P/N 6563328). If fluid is not available, use 10W-30/10W-40 Class
SE motor oil for temperatures above 0°F (-18°C) or 5W-30 motor oil for
temperatures below 0°F (-18°C).
Fluid Lines SAE standard tubelines, hoses and fittings.
Hydraulic Function Time:
Raise Lift Arms 4.4 Seconds
Lower Lift Arms 3.0 Seconds
Bucket Dump 2.8 Seconds
Bucket Rollback 2.2 Seconds
Electrical
Alternator 50 amp open frame with integral regulator.

Battery 12 volt; 1000 cold cranking amps @ 0°F (-18°C); 180 minute reserve capacity at
25 amps.
Starter 12 volt; Gear Reduction Type
Instrumentation (Standard) Gauges: Hourmeter, Fuel, Engine Coolant Temperature.
Warning lights: Fuel level, Glow Plugs, System Voltage, Seat Belt, Engine
Coolant Temperature, Engine Oil Pressure, Hydrostatic Charge Pressure,
Hydraulic Oil Temperature, Engine Air Filter & Hydraulic Filter.
Other: Audible Alarm BICS Function, Lights, Opt./Accessory Switches.
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Drive System
963
Main Drive Hydraulic 4 wheel drive.
Transmission Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing
hydrostatic motors. Separate gear type charge pump.
Final Drive Double gear reduction & #120 HS endless roller chain & sprockets in sealed
chaincase with oil lubrication.
Total Engine to Wheel Reduction N/A
Axle Size 2.95 (75)
Wheel Bolts (10) 3/4 inch
Capacities
Cooling System 20 qts. (18,9 L)

Fuel Tank 32.5 gals. (123,0 L)
Engine Oil W/Filter 8 qts. (7,6 L)
Hydraulic Reservoir 7 gals. (26,5 L)
Hydraulic/Hydrostatic System 14.9 gals. (56,4 L)
Chaincase Reservoir 20.5 gals. (77,6 L)
Tires
Standard 14-17.5, 12 ply rating

Super Flotation 38 x 20-16, 8 ply rating
Solid 9.00 - 16
Recommended Pressure Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT
mix brands of tires used on the same loader.
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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 3.937 (100)
Stroke 5.000 (127)
Compression Ratio 17.25:1
Displacement 243 C.I. (4 liters)
Firing Order 1-3-4-2
Cylinder Head
Head Thickness 4.047-4.078 (102,8-103,6)
Head Thickness After Machining (Minimum) 4.035 (102,5)
Valve Seat Angle 46°
Leak Test Pressure 29 PSI (200kPa)
Valve Guides
Inside Diameter 0.3744-0.3764 (9,51-9,56)
Outside Diameter 0.6260-0.6264 (15,90-15,91)
Valve Guide Bore 0.6248-0.6256 (15,87-15,89)
Valve Guide Clearance in the Cylinder Head (Interference) 0.0018-0.0027 (0,047-0,007
Overall Length:
Intake 2.281 (57,94)
Exhaust 2.406 (61,10)
Protrusion From Bottom 0.585-0.596 (14,85-15,15)
Exhaust Valves
Valve Stem Diameter 0.3515-0.3528 (8,93-8-96)
Valve Guide Clearance 0.0016-0.0033 (0,040-0,84)
Maximum 0.0041 (0,104)
Valve Head Diameter 1.609-1.619 (40,88-41,12)
Valve Face Angle 45°
Overall Length 4.829-4.854 (122,66-123,30)
Seal Type Positive
Valve Clearance 0.018 (0,45)
Exhaust Depth (Production) 0.055-0.067 (1,40-1,70)
Exhaust Depth (Service) 0.077 (1,95)
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ENGINE SPECIFICATIONS (CONT’D)
Intake Valves
Valve Stem Diameter 0.3525-0.3535 (8,95-8,98)
Valve Guide Clearance 0.0010-0.0027 (0,025-0,069)
Maximum 0.005 (0,13)
Valve Head Diameter 1.688-1.698 (42,88-43,12)
Valve Face Angle 45°
Overall Length 4.829-4.854 (122,66-123,30)
Seal Type Positive
Valve Clearance 0.008 (0,20)
Exhaust Depth (Production) 0.050-0.068 (1,27-1,60)
Exhaust Depth (Service) 0.077 (1,85)
Valve Springs
Double Valve Springs (Outer)
Installed Height 1.41 (35,8)
Installed Height Pressure 39.5-43.7 lbs. (176-195 N)
Double Valve Springs (Inner)
Installed Height 1.34 (34,0)
Installed Height Pressure 20-23 lbs. (89-104 N)
Rocker Shaft, Rockers And Bushings

Shaft Outside Diameter 0.748-0.750 (19,01-19,04)
Rocker Arm Bushing Bore Diameter 0.875-0.876 (22,23-22,26)
Outside Diameter of the Bushing 0.877-0.8783 (22,28-22,31)
Rocker Arm Bushing Clearance 0.0008-0.0035 (0,020-0,089)
Inside Diameter of Reamed Rocker Bushing 0.750-0.752 (19,06-19,10)
Clearance Between Rocker Arm Bushing and Shaft 0.001-0.0035 (0,03-0,09)
Maximum 0.005 (0,13)
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Pistons And Piston Rings

Type Fastram combustion bowl inserted top ring groove, graphite skirt
Piston Pin Bore Diameter 1.5001-1.5004 (38,103-38,109)
Piston Projection Above the Block Deck 0.006-0.014 (0,14-0,36)
Top Ring Groove Width Tapered
Second Ring Groove Width 0.1008-0.1016 (2,56-2,58)
Third Ring Groove Width 0.1591-0.1598 (4,04-4,06)
Top Ring Barrel Face, Molybdenum insert, Wedge
Second Ring Taper Face, Cast Iron, Outside Bottom Step
Oil Control Ring Coil Spring Loaded, Chromium Face
Top Ring Width Tapered
Second Ring Width 0.097-0.098 (2,48-2,49)
Third Ring Width 0.1366-0.1374 (3,47-3,49)
Top Ring Side Clearance Wedge
Second Ring Side Clearance 0.003-0.004 (0,07-0,10)
Third Ring Side Clearance 0.002-0.003 (0,05-0,07)
Top Ring End Gap 0.011-0.025 (0,28-0,63)
Top Ring End Gap (With Internal Step) 0.014-0.028 (0,35-0,70)
Second Ring End Gap 0.012-0.030 (0,30-0,76)
Second Ring End Gap (With External Step) 0.016-0.034 (0,40-0,85)
Third Ring End Gap 0.010-0.031 (0,25-0,75)
Piston Pin Type Full Floating
Piston Pin Outside Diameter 1.5628-1.5630 (39,694-39,700)
Piston Boss Clearance 0.0001-0.0006 (0,003-0,015)
Bushing Type Steel Back, Lead Bronze Tin Bearing Material
Bushing Outside Diameter 1.6972-1.6988 (43,11-43,15)
Bushing Inside Diameter (Reamed) 1.5638-1.5645 (39,723-39,738)
Piston Pin Bushing Clearance 0.0009-0.0017 (0,023-0,044
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)
Piston Pin End 1.656-1.657 (42,07-42,09)
Length Between Centers 8.624-8.626 (219,05-219,10)
Bearing Type Steel Back, Lead Bronze Bearing Material with Lead Finish
Bearing Width 1.242-1.255 (31,55-31,88)
Bearing Thickness at the Center 0.0723-0.0726 (1,835-1,844)
Bearing Clearance 0.0012-0.0032 (0,03-0,081)
Bearing Undersize Available -0.010 (-0,25), -0.020 (-0,51), -0.030 (-0,76)
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Crankshaft
Main Journals 2.998-2.999 (76,16-76,18)
Maximum Wear and Out of Round of the Journals and Crank Pins 0.0016 (0,04)
Width of Front Journal 1.454-1.484 (36,93-37,69)
Width of Center Journal 1.738-1.741 (44,15-44,22)
Width of Other Journals 1.545-1.549 (39,24-39,35)
Crank Pin Diameters 2.499-2.500 (63,47-63,49)
Width of Crank Pins 1.589-1.591 (40,35-40,42)
Crankshaft End Play 0.00075 (0,019)
Thrust Washer Thickness: Std. 0.090-0.091 (2,26-2,31)
Oversize 0.096-0.098 (2,24-2,50)
Main Bearing Oil Clearance 0.0022-0.0046 (0,057-0,117)
Undersize Journals and Crank Pins 0.010 (0,25) 0.020 (0,51) 0.030 (0,76)
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 0.003 (0,08)
Journal #3 0.006 (0,15)
Journal #4 0.003 (0,08)
Journal #5 Mounting
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Crankshaft Re-Grind Data
6 6 6 6
0.189
(4,8)
9 9 9 9
9 2 2
1 1 1 1 1 7
9 9
2 2
9 9
4 3 5 3 3 8
B-5594A
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 2.9784-2.9792 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 1.554 (39,47) maximum — —
4 1.489 (37,82) maximum — —
5 1.759 (44,68) maximum — —
6 1.596 (40,55) maximum — —
7 5.243 (133,17) maximum — —
8 Do not machine this diameter — —
9 0.145-0.156 (3,68-3,96) — —
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.
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Main Bearings
Type Steel Back, 20% Tin Aluminium
Center Bearing Width 1.430-1.445 (36,32-36,70)
All Others 1.245-1.255 (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)
Thrust Washers
Type Steel Back, Lead Bronze
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 1.997-1.998 (50,71-50,74)
Clearance On All Journals 0.0024-0.0055 (0,6-0,14)
Cam Lift (Intake) 0.2999-0.3027 (7,62-7,69)
Cam Lift (Exhaust) 0.3035-0.3066 (7,71-7,79)
Maximum Wear And Out Of Round 0.002 (0,05)
Camshaft End Play 0.004-0.016 (0,10-0,41)
Service Limits 0.021 (0,53)
Thrust Washer Type 360°
Thrust Washer Thickness 0.216-0.218 (5,49-5,54)
Thrust Washer Recess Depth 0.215-0.218 (5,46-5,54)
Bore #1 2.187-2.189 (55,56-55,59)
Bore #2 1.990-1.992 (50,55-50,60)
Bore #3 1.970-1.972 (50,04-50,09)
Cylinder Block
Cylinder Bore Diameter 4.103-4.104 (104,20-104,23)
Cylinder Liner Flange Recess 0.150-0.154 (3,81-3,91)
Cylinder Liner Flange Recess Diameter 4.245-4.250 (107,82-107,95)
Main Bearing Bore Diameter 3.166-3.167 (80,416-80,442)
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 (Installed) 3.937-3.961 (100,0-100,63)
Maximum 0.010 (0,25)
Flange Thickness 0.150-0.152 (3,81-3,86)
Liner Projection From Desk Surface 0.004 (0,10) Above or 0.004 (0,10) Below
Hose Angle 30/35°
Piston Cooling Jets 20 ft. lbs. (27 Nm)
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Fuel Injection Pump

Type Stanadyne DB4, Pin Timed
Number 1 Cylinder Outlet 8 O’clock Position Viewed from the Rear
Rotation From Drive End Clockwise
Fuel System Self Vent
Fuel Injectors
Working Pressure 4263 PSI (29393 kPa)
Fuel Lift Pump

Type A.C. Delco, Type XD
Method of Drive Camshaft
Standard Pressure 6-10 PSI (42-70 kPa)
Minimum Pressure 3.75 PSI (25 kPa)
Timing Case And Timing Gears

Camshaft Gear Number Of Teeth 56
Camshaft Gear Bore Diameter 1.375-1.376 (34,93-34,95)
Camshaft Hub Outside Diameter 1.374-1.375 (34,90-34,92)
Camshaft Gear Hub Gear Clearance 0.0003-0.0019 (0,008-0,048)
Fuel Pump Gear Number Of Teeth 56
Fuel Pump Gear Bore 1.417-1.420 (36,00-36,06)
Crankshaft Gear Number Of Teeth 28
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- +0.0010 (-0,020- +0,048
Idler Gear Number Of Teeth 63
Idler Gear Bore Diameter 2.250-2.251 (57,14-57,18)
(With Needle Bearings) 2.717-2.718 (69,01-69,03)
Width Of Idler Gear And Bushing Assembly 1.186-1.187 (30,14-30,16)
Flanged Bushing Inside Diameter 1.999-2.000 (50,78-50,80)
Idler Gear Hub Outside Diameter 1.996-1.998 (50,70-50,74)
Idler Gear Hub Bushing Clearance 0.0016-0.0039 (0,04-0,10)
Gear End Play 0.004-0.008 (0,10-0,20)
Service Limit 0.015 (0,38)
Backlash For All Gears 0.003 (0,08) Minimum
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Oil Pump, Gear And Relief Valve

Type Of Oil Pump Gear Driven, Differential Rotor
Number Of Lobes Inner 6, Outer 7
Clearance Of Outer Rotor To Body 0.006-0.013 (0,15-0,34)
Inner To Outer Rotor Clearance 0.0015-0.0050 (0,04-0,13)
End Play 0.001-0.004 (0,03-0,10)
Oil Pump Idler Gear Bushing I.D. 0.875-0.876 (22,23-22,26)
Idler Shaft O.D. 0.873-0.874 (22,19-22,21)
Idler Gear Shaft Bushing Clearance 0.0008-0.0026 (0,020-0,066)
Oil Pump Idler Gear End Play 0.0005-0.0253 (0,012-0,643)
Relief Valve Plunger Bore Diameter 0.718-0.719 (18,24-18,27)
Relief Valve Plunger Outside Diameter 0.715-0.716 (18,16-18,18)
Clearance 0.002-0.004 (0,06-0,11)
Length Of The Spring (Installed) 2.35 (59,8)
Load On The Spring (Installed) 3.6-5.2 PSI (15,9-23,1 Nm)
Pressure To Open Pressure Relief Valve 60-68 PSI (415-470 kPa)
Oil Filter Type Full Flow Screw-on Type Canister
Pressure To Open By-pass Valve In Oil Filter 8-12 PSI (55-83 kPa)
Pressure To Open By-pass Valve In Oil Cooler 25 PSI (172 kPa)
Minimum Engine Oil Pressure At Maximum Speed 40 PSI (280 kPa)
Oil Pump Gear and Idler Gear Backlash 0.003 (0,076)
Turbocharger
Type Garrett T20
Flywheel
Run-Out Less than 0.012(0,30)
Misalignment 0.008 (0,203) @ 8 (203)
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Water Pump And Thermostat

Type Centrifugal, Gear Drive
Shaft Outside Diameter 0.746-0.747 (18,95-18,96)
Drive Gear Bore Diameter 0.744-0.750 (18,90-18,92)
Drive Gear Shaft Clearance 0.0012-0.0024 (0,03-0,06)
Impeller Bore Diameter 0.625-0.626 (15,87-15,89)
Impeller Shaft Outside Diameter 0.626-0.627 (15,91-15,92)
Impeller Clearance On Shaft 0.0007-0.002 (0,02-0,05)
Bearing Bore Diameter 1.498-1.499 (38,06-38,08)
Bearing Diameter 1.499-1.500 (38,09-38,10)
Bearing Clearance In Pump Body 0.0004-0.0016 (0,01-0,04)
Thermostat Type Wax Pellet, By-pass Blanking
Nominal temperature Start to open Fully open Minimum valve

stamped on thermostat temperature temperature lift, fully open
by-pass valve
180° F 170°/185°F 198°/208° F 0.35
(82° C) (77°/85° C) (92°/98° C) (9,0)
160° F 153°/167° F 185°/190° F 0.35
(71° C) (67°/75° C) (85°/88° C) (9,0)
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Engine Torque
Component Ft.-Lbs. Nm
Bridge Piece To Block 12 16
Camshaft Gear Bolt 58 78
Camshaft Gear Bolts (45 mm long) 74 100
Connecting Rod Nuts
Step 1 45 61
Final 92 125
Crank Pulley Bolts 85 115
Cylinder Head Bolt
Step One 80 108
Step Two - Short Bolts 150°
Step Two - Medium Bolts 180°
Step Two - Large Bolts 210°
Engine Lift Bracket Bolts 33 44
Exhaust Manifold Nuts 37 50
Flywheel Housing To Cylinder Block 52 70
Flywheel To Crankshaft Bolts 77 105
Fuel Injector Nut 23 30
Fuel Injection Pump Gear Mounting Bolts 20 28
Fuel Injection Pump Gear Nut 59 80
Fuel Injection Pump Flange Nuts 16 22
Fuel Lift Pump Bolts 16 22
High Pressure Fuel Lines Fittings 16 22
Idler Gear Hub Bolts 33 44
Intake Manifold Bolts 33 44
Main Bearing Bolts
Step 1 65 88
Step 2 125 170
Step 3 185 250
Oil Cooler Cover Bolts 96in-lbs. 11 Nm
Oil Cooler Mounting Bolts 16 22
Oil Cooler To Back Plate 42 58
Oil Pan Bolts 16 22
Oil Pan Plug 25 34
Oil Pump Cover 21 28
Oil Pump To Front Main Cap 16 22
Oil Transfer Plate Bolts 22 30
Piston Cooling Jets 15 20
Rear Oil Seal Housing Bolts 16 22
Rear Oil Seal Housing Bolts (Torx) 16 22
Rear Oil Seal Housing To Bridge Piece (Torx also) 13 18
Rear Oil Seal Housing To Bridge Piece (Thread Size M6) 10 13
Rocker Cover Nuts (With Shim Washer) 22 30
Rocker Cover Nuts 15 20
Rocker Shaft Bracket Nuts 55 75
Timing Case To Block (M8 Bolts) 16 22
Timing Case To Block (M10 Bolts) 33 44
Timing Case Cover To Timing Case Bolts 16 22
Timing Case Cover To Timing Case Nuts 16 22
Turbocharger To Manifold Nuts 33 44
Water Pump To Timing Case Bolts & Nuts 16 22
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LOADER TORQUE
Specifications
Component Ft.-Lbs. Nm
Axel Hub End Plate Bolts 210-230 (285-311)
Axel Sprocket End Plate Bolts 210-230 285-311
Bob-Tach Lever Mounting Nut 25-28 34-38

Bob-Tach Pivot Pin Bolt (Tilt Cylinder Rod End) 125-140 170-190
Bob-Tach Pivot Pin Retainer Bolt 16-20 21-27
Bucket Position Valve Mounting Bolts 15 20
Control Pedal Linkage Bolt and Nut 21-25 28-43
Hydraulic Control Valve Mounting Bolts 25 34

Hydraulic/Hydrostatic Filter Housing Mounting Bolts 25 34
Hydraulic Pump Mounting Bolts 30 40
Hydraulic Pump Mounting Bracket Nuts 70 95
Hydrostatic Motor Cover Mounting Bolts 220-245 298-332
Hydrostatic Motor Mounting Bolts 65-70 88-95
Hydrostatic Pump Mounting Bolts 65-70 88-95
Hydrostatic Pump Pulley Nut 175-200 237-271
Lift Arm Pivot Pin Retainer Bolt 16-20 21-27

Lift Cylinder Pivot Pin Retainer Bolt 16-20 21-27
Operator Cab Pivot Bolt and Nut 25-35 34-47
Parking Brake Mounting Bolts 70 95

Pedal Interlock Mounting Nuts 84-95 in.-lbs. 9,5-10,8
Pedal Interlock Linkage Shield Mounting Nuts 25-28 34-38
Rear Door Latch Nut 65-70 88-95

Reduction Gearcase Mounting Bolts 220-245 298-332
Steering Cross Shaft Mounting Bolts 15-17 21-23
Tilt Cylinder Base End Pivot Pin Bolt 220-245 298-332
Wheel Nuts 320-350 434-475
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TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts purchased from
Melroe that have zinc phosphate coating are specified by the letter H following the part number.
THREAD SIZE SAE GRADE 5 SAE GRADE 8

INCH. .250 80-90 110-120
LBS. (9,0-10,2 (12,4-13,6)
(Nm) .3125 180-200 215-240
(20,3-22,6) (24,2-27,1)
.375 25-28 35-40
(34-38) (47-54)
.4375 40-45 60-65
(54-61) (81-88)
.500 65-70 90-100
(88-95) (122-136)
.5625 90-100 125-140
(122-136) (170-190)
.625 125-140 175-190
(170-190) (240-260)
.750 220-245 300-330
FOOT (300-330) (410-450)
LBS. .875 330-360 475-525
(Nm) (450-490) (645-710)
1.000 475-525 725-800
(645-710) (985-1085)
1.125 650-720 1050-1175
(880-975) (1425-1600)
1.250 900-1000 1475-1625
(1200-1360) (2000-2200)
1.375 1200-1350 2000-2200
(1630-1830) (2720-2980)
1.500 1500-1650 2600-2850
(2040-2240) (3530-3870)
1.625 2000-2800 3450-3800
(2720-2980) (4680-5150)
1.750 2500-2750 4300-4800
(3390-3730) (5830-6500)
1.875 3150-3500 5500-6100
(4270-4750) (5830-6500)
2.000 3800-4200 6500-7200
(5150-5700) (8800-9800)
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TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
Thread Size Material

(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0.8 3-4 ft.-lbs.
(4-5 Nm)
M 6 x 1.0 6-7 ft.-lbs. 6-9 ft.-lbs.
(8-9 Nm) (8-12 Nm)
M 8 x 1.25 6-9 ft.-lbs. 11-16 ft.-lbs. 18-25 ft.-lbs.
(8-12 Nm) (15-22 Nm) (24-34 Nm)
(8-12 Nm) (30-41 Nm) (49-68 Nm)
(30-41 Nm) (54-73 Nm) (94-118 Nm)
(49-68 Nm) (79-108 Nm) (157-186 Nm)
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HYDRAULIC CONNECTION SPECIFICATIONS Straight Thread O-ring Fitting
O-ring Face Seal Connection Figure SPEC 50-02
IMPORTANT
Nut Nut
clean the work area before disassembly and keep all Washer
parts clean. Always use caps and plugs on hoses, Washer
tubelines and ports to keep dirt out. Dirt can quickly O-ring
damage the system. O-ring
I-2003-0888
Figure SPEC 50-01

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-
02].
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat.
B-7575 Replace hoses which show signs of wear, damage or

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 50-01].
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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 50-03].
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 50-03]. If the fitting leaks after
tightening, disconnect it and inspect the seat area for
Figure SPEC 50-03 damage.
TS-1619
Flare Fitting Tightening Torque

Tubeline TORQUE NEW RE-ASSEMBLY
Wrench Size Outside Thread Size Ft.-Lbs. Rotate No. ROTATE NO.
Diameter (Nm) of Hex Flats of 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” 1-5/6”-12 118 (160) 3/4 3/4
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HYDRAULIC CONNECTION SPECIFICATIONS Use the following procedure to tighten the O-ring flare
(CONT'D) fitting.
O-ring Flare Fitting Figure SPEC 50-05
Figure SPEC 50-04 Hex Flat Tightening Method
Primary O-ring Flare

Seal 1
Secondary TS-1619
Seal
P13009
Tighten the nut until it contacts with the seat. Make a
mark across the flats of both the male and female parts
The flare is the primary seal, the O-ring is the secondary of the connection (Item 1) [Figure SPEC 50-05].
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC 50-04]. Use the chart below to find the correct tightness needed
(Item 2) [Figure SPEC 50-05]. 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
TORQUE NEW RE-ASSEMBLY
Wrench Size Outside Thread Size
Ft.-Lbs. Rotate No. ROTATE NO.
Diameter
(Nm) of Hex Flats of 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” 1-5/6”-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.
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HYDRAULIC CONNECTION SPECIFICATIONS Figure SPEC 50-07
(CONT'D)
O-ring Flare Fitting (Cont'd)
NOTE: O-ring flare fittings are not recommended in 2

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 50-06 1
P13573
Copper Bonnet Orifice Always remove the O-ring (item 1) [Figure SPEC 50-
07] from the flare face as shown.
An O-ring (Item 2) [Figure SPEC 50-07] is added to the

flat boss of the fitting to seal the connection in this
application.
P13572
Use a standard flare fitting (Item 1) [Figure SPEC 50-06]

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.
963 Bobcat Loader

630 of 640
HYDRAULIC CONNECTION SPECIFICATIONS
(CONT'D)
PORT SEAL AND O-RING BOSS
Port Seal Fitting TIGHTENING TORQUE
Torque
Figure SPEC 50-08 Fitting Nut
Thread Size Ft.-lbs.
Wrench Size
(Nm)
11/16” 9/16”-18 22 (30)
15/16” 3/4”-16 40 (54)
1-1/8” 7/8”-14 60 (81)
1-1/4” 1-1/16”-12 84 (114)
1-1/2” 1-5/6”-12 118 (160)
NOTE: If a torque wrench cannot be used, use the

hex flat tightening method as an approximate
guideline.
NOTE: Port seal fittings are not recommended in all

Nut Seals
to Fitting applications. Use O-ring boss fittings in these
applications.
Figure SPEC 50-09

Nut Seals
to Port
Secondary O-ring Seal
P-13008
1
The nut is the primary seal, the O-ring is the secondary
seal and helps absorb vibration and pressure pulses at
the connection [Figure SPEC 50-08]. P-13571
The hex portion of the nut does not contact the surface of
the component when the nut is tight. Do not use port seal fittings when a thread in orifice (Item
1) [Figure SPEC 50-09] is used in the port. The orifice
Use the following procedure to tighten the port seal may interfere with the fitting and prevent it from sealing.
fitting:
Use an O-ring boss fitting (Item 1) [Figure SPEC 50-
Port seal and nut, washer and O-ring (O-ring Boss)
fittings use the same tightening torque valve chart. 09] as shown.
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.
Do not over tighten the port seal fitting.
963 Bobcat Loader

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963 Bobcat Loader
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HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS When temperatures below zero degree F (-18°C) are
common, the loader must be kept in a warm building.
Specifications Extra warm-up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will
Use Bobcat hydraulic transmission fluid (P/N 6563328). If not flow easily and it makes action on the hydraulic
this fluid is not available, use 10W-30 or 10W-40 SAE function slower. Loss of fluid flow to the hydrostatic
Motor Oil (5W-30 for 0°F [-18°C] and Below). transmission pump (indicated by TRANS light ON) can
cause transmission damage in less than 60 seconds.
DO NOT use automatic transmission fluids in the loader
or permanent damage to the transmission will result.
WARNING
WARNING During cold weather (32°F [0°C] and below), do not
operate machine until the engine has run for at least
Diesel fuel or hydraulic fluid under pressure can five minutes at less than half throttle. This warm-up
penetrate skin or eyes, causing serious injury or period is necessary for foot pedal operation and safe
death. Fluid leaks under pressure may not be visible. stopping. Do not operate controls during warm-up
Use a piece of cardboard or wood to find leaks. Do period.
enters skin or eyes, get immediate medical attention When temperatures are below -20°F (-30°C), the
from a physician familiar with this injury. hydrostatic oil must be heated or kept warm. The
W-2072-0496 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
963 Bobcat Loader

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963 Bobcat Loader
634 of 640
CONVERSIONS
Decimal And Millimeters Equivalents
U.S. To Metric Conversion
963 Bobcat Loader

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963 Bobcat Loader
636 of 640
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Above Listed Manual For Future Reference.
Revision No: 963-1

Date: 2 April 2001
Product: Bobcat Loader
Model: 963
Manual No: 6900988 (2-00)
The following pages are a revision to the above Service Manual.
Take out existing pages and put in the new pages as listed below:
TAKE OUT PUT IN REVISION DECRIPTION

Cover Cover Logo Changes
Cartoon Cartoon Text Changed
Alphabetical Index Alphabetical Index Text Changed
i, ii i, ii Text Added
50-70-1 thru 50-70-2 50-70-1 thru 50-70-2 Text and Photo Change
ELECTRICAL SYSTEM ELECTRICAL SYSTEM
INFORMATION PAGE INFORMATION PAGE
963 963
(Printed February 2000) (Printed April 2001)
ALL ALL Adding ACS

963 WIRING SCHEMATICS 963 WIRING SCHEMATICS
(Printed February 2000) (Printed April 2001)
60-140-1 thru 60-140-2 60-140-1 thru 60-140-2 Text and Photo Change
Section 80 Section 80 Added Heating, Ventilation, Air Conditioning Section
Section SPEC Revised Page Numbering
Printed in U.S.A.
637 of 640
638 of 640
ROUTE TO
ATTENTION
PARTS MANAGER
SERVICE MANUAL SERVICE MANAGER X
REVISION SALES MANAGER
NOTICE Insert This Sheet With The Below Listed Manual For Future Reference.
Revision No: 963-2

Date: 23 March 2006
Product: Bobcat Loader
Model: 963
Manual No: 6900988 (2-00)
963 Service Manual (P/N 6900988) Dated (3-06) contains updated service information which replaces the previous
963 Service Manual (P/N 6900988) Dated (2-00).
Printed in U.S.A.
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2 of 640

CORRECT CORRECT CORRECT

B-10731a B-15590 B-15591

WRONG WRONG WRONG

B-15592 B-15593 B-15599

B-15600 B-15601 B-6589

AHC SYSTEM....................................................................60-01 HYDROSTATIC MOTOR................................................... 30-01

BASIC TROUBLESHOOTING ...........................................80-01 LIFT ARMS ....................................................................... 50-01

DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX HYDROSTATIC

SAFETY & MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 DRIVE

HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01

MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL

963 Bobcat Loader

2. Check that ROPS mounting 10. Enclosure door latches must

3. The seat belt must be 11. Bob-Tach wedges and

6. Machine signs must be 14. Check hydraulic fluid level,

7. Steering levers and foot 15. Inspect for fuel, oil or

8. Check for correct function of 16. Lubricate the loader.

963 Bobcat Loader

21. Inspect for loose or broken

963 Bobcat Loader

• The Skid-Steer Loader Operator Training Course is

• Service Safety Training Courses are available from

• The Skid-Steer Loader Safety Video is available from

963 Bobcat Loader

The dealer and owner/operator review the recommended

Call Before You Dig

963 Bobcat Loader

Flammable debris (leaves, straw, etc.) must be removed

The spark arrestor muffler is designed to control the

• Do not use the machine where exhaust, arcs, sparks

• The operator cab, engine compartment, and engine

• Check all electrical wiring and connections for

• Check fuel and hydraulic tubes, hoses and fittings for

• Do not use ether or starting fluids on any engine

• Always clean the machine, disconnect the battery,

• Stop the engine and let it cool before adding fuel. NO

963 Bobcat Loader

Always use the serial number of the loader when Figure 3

Loader Serial Number

The serial number is on the engine block just above the

The loader serial number plate is located on the inside of

Explanation of loader Serial Number:

Module 1.- Model/Engine

1. The four digit Model/Engine Combination Module

963 Bobcat Loader

† BUCKET AUXILIARY HYDRAULIC

963 Bobcat Loader

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-130-1

HAND-LEVER BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1

HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1

LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-1

LUBRICATING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170-1

Continued On Next Page

963 Bobcat Loader

OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1

POWER BOB-TACH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-61-1

REMOTE START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90-1

SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) 10-81-1